1998 Maintenance Tips Of The Year

03/01/1999


Our readers have spoken! Winners in Plant Engineering magazine's tenth annual "Tips & Tricks" contest have been determined! Ralph Dewey, Solvay Polymers, Deer Park, TX, submitted the top vote getter among the entries presented in the September 1998 issue. His "Maintenance Tip of the Year" explained and illustrated how to repair a stuck-open valve on a tank, without losing the contents. Mr. Dewey received $1000 for submitting the winning entry. Runners-up were Philip J. Soliday, Knox, IN; and Gary Bulgrien, Patriot Sensors, Peck, MI. Mr. Soliday showed how to remove a broken dowel pin, and Mr. Bulgrien provided a simple answer to locating which breaker is serving an outlet. The runners-up each received $250 for their suggestions.

Keep thinking

"Tips & Tricks" is an ongoing editorial project that relies on the input of readers for its success. If you come up with a maintenance idea that meets the time-conserving, money-saving, aggravation-avoiding criteria, send it along immediately, while the thought and intent to share information are still fresh. Remember that drawings or photographs of the maintenance tip add a great deal to the understanding of the suggestion.

New ideas submitted, along with all other suggestions received for the 1998 contest, but not making it to the finals, will be considered for the 1999 edition of "Tips & Tricks" or "Simple Solutions" articles. The 1999 "Tips & Tricks" article will be published in the September issue.

Please send your tips to Gary Weidner, Senior Editor, Plant Engineering magazine, 2000 Clearwater Dr., Oak Brook, IL 60523; 630-320-7143; gweidner@cahners.com.

Tip Of The Year

Inflating plug

Problem: When a valve on an open tank doesn't shut-off, the entire inventory must be dumped to repair the problem. Can this expense be saved?

Solution: Install an inflatable pipe plug. Select a piece of pipe just slightly smaller than the section to be plugged. Weld the end shut and drill a 1/4-in. hole in the side. Cut a piece of tire inner tube to fit over the outside pipe. Use wire to seal the ends of the rubber inner tube. From the top of the tank, insert the plug into the pipe opening. Apply about 5 psig of air to inflate the plug. The valve can be replaced without losing the contents.

Contributor: Ralph Dewey, Solvay Polymers, Deer Park, TX; 713-307-3784

Runner-Up

Pulling pins

Problem: Removing a dowel pin broken below the surface in a blind hole can be a real chore (1). Is there an easy way to pull it out?

Solution: Just 10 min. can do the job. Use a hand grinder to put a small center in the broken pin (2). Drill through the center of the dowel until you break into the area behind the pin (3). Take some of your kid's Silly Putty and push it in the hole with a slip fit pin (4). Hammer in more putty, and as you do the pocket fills and starts to slide the broken dowel out (5).

Contributor: Philip J. Soliday, Knox, IN

Runner-Up

Locating feeds

Problem: How can I locate which breaker is feeding a 120-V outlet?

Solution: Plug a troublelite with a flasher button installed in the socket. Check the current at the breakers. The sought circuit has a fluctuating current.

Contributor:

Gary Bulgrien, Patriot Sensors, Peck, MI





Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
July/Aug
GAMS preview, 2018 Mid-Year Report, EAM and Safety
June 2018
2018 Lubrication Guide, Motor and maintenance management, Control system migration
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, programming cavity pumps
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
August 2018
Choosing an automation controller, Lean manufacturing
February 2018
Setting internal automation standards

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Material Handling
This digital report explains how everything from conveyors and robots to automatic picking systems and digital orders have evolved to keep pace with the speed of change in the supply chain.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me