Proven ways to keep your equipment running longer, smoother, safer.
Preventative Maintenance Programs are
designed to eliminate costly EMERGENCY Breakdowns, improving reliability
and lowering maintenance costs. Reliability Programs are pre-scheduled,
routine maintenance. The needed maintenance work is accomplished
during normal equipment down time (weekends, holidays, swing shifts,
etc.)
Stuart M. Davis, Inc. can immediately start your Preventative Maintenance
Program, plus with an “in-house”, staff Tribologist,
your lubricants can be quickly and accurately analyzed.
Get started NOW! Call or email us now. (Click here for our contact
page).
The following 3, 6, 12, 18 and 24 month Preventative Maintenance
Program is specifically designed for critical hydraulic systems,
however the overall objective can be achieved with electrical and
pneumatically powered equipment also.
THREE (3) MONTH INTERVAL
1. Fluid Sampling
1.1. Install fluid sampling valve in the return line, upstream
of the return line filter.
1.2. Fluid sampling: (link to Oil Analysis Page) use a trending
analysis approach (link here to the Fluid Analysis Page)
1.2.1. Take a sample of new, clean oil
1.2.2. Use this report as your oil “baseline”
1.2.2.1. Select your “go – no go” levels
of:
Silica
Water
T.A.N (acid)
Additives
Metals
I.S.O. Cleanliness Levels
1.3. Check filter placement and sizing. (link to Filtration Page)
Filters should provide a minimum of 800 hours operation under normal
conditions. This is assuming the system was flushed prior to start-up,
Beta 3 > 200 inline filter elements have been used, and an effective
Beta 1 > 200 air breather is used. Once the oil is clean, except
for maintenance, contamination levels should remain consistent.
2. Clean the equipment, put it into full service and check for leaks.
2.1. Look for such things as broken fittings, loose connections,
blocked oil passages in motors, and broken gauges. Repair as needed.
2.2. List location of leaks, damaged or broken parts and the
general operating condition of the equipment.
2.3. Check the condition and settings of the pressure and temperature
gauges. This is important for troubleshooting, to insure the hydraulic
system is operating properly.
2.4. Check the cooling fan assemblies in the electric motor
2.5. Check the control valves for leaks at the sealing joints,
including subplates and end caps where control shafts connect to
valve bodies.
2.6. Note anything unusual, listen for strange noises and locate
their source.
2.7. In general, see if the equipment is operating at its design
specifications.
3. Hose, Tubing and Fittings.
3.1. Look for cracking or signs of aging like brittleness. This
is a sign that the hose has been in service too long or the area
near the hose is too hot. If the operating temperatures of the
equipment / environment is too high, an upgraded class of hoses
should be considered.
3.2. Check the hose fittings for damage and leaks
3.3. In case of metal tubing, look for crimping or other mechanical
damage.
3.4. Make sure that the tubing and hose runs follow standard installation
practices.
3.5. For hoses, tubing and fittings, make sure that they have
enough clearance to prevent chaffing on other parts.
3.6. For repairing or replacing the damaged hoses, tubing and
fittings, check if they can be protected by rerouting or moving
out of the way.
3.6.1. Many leaks occur because clearance problems allow them
to hit or rub against something else.
SIX (6) MONTH INTERVALS (in addition to the 3-month interval inspection
above):
1. Motors, pumps, coupling condition and alignment:
1.1. Make alignment and electrical checks. Observe coupling condition
and measure alignment per manufacturers recommendations.
1.2. Check the hold-down bolts and the feet of the motor to make
certain they are in good condition and free of cracks.
1.2.1. The bolts should be in place and properly torqued.
TWELVE (12) MONTH INTERVALS (in addition to the 3 & 6-month
interval inspections above):
1. Reservoir Maintenance:
1.1. Completely clean fluid, wipe out with lint free rags.
1.2. Inspect internal baffles and repair if needed.
1.3. Inspect, clean, and repair or replace everything inside the
tanks before reinstalling the tank lids.
1.4. Clean the sealing surfaces and replace the seals or gaskets
around the lids.
1.5. Avoid reintroducing new dirt into the reservoir before closing
it up.
1.6. Drain and clean connecting equipment, hoses, lines and fittings.
1.7. Perform a pressure and flow test on the water-cooled heat
exchanger to check for tube fouling.
1.7.1. Send out for repairs if needed
1.7.2. Air / Oil Cooler? Back blow all baffles as needed.
Get started NOW! Call or email us now. (Click here for our contact
page).
TWENTY FOUR (24) MONTH INTERVALS (in addition to the 3, 6 & 12
month interval inspections above):
1. Major component maintenance:
1.1. Pump maintenance
- Check the pump(s) for leaks, broken and / or damaged fittings.
- The pump rotating group can be rebuilt in place and may of
the seals can be replaced without removing the unit from its
mounting.
- However, the 24-month overhaul is best completed upon a bench,
with a complete new seal kit.
1.2. Valve maintenance
- Dirty oil is the most common cause of valve failure.
- After disassembling the valve, clean and inspect it.
- Replace wear parts, which include springs, seals and those
parts recommended by the manufacturer.
1.3. Actuator maintenance
- Look for leaks, broken or damaged fittings, damaged body parts,
misalignment and chaffing.
- Leaks usually occur at shaft seals and sealing surfaces.
- Many seal leaks are caused by dried out seals or seals damaged
by a dirty work environment.
1.4. Electric Motor maintenance
- Checking should include visual inspection, vibration analysis,
current measurement and temperature monitoring on the frame and
bearings.
- Since the majority of electrical failures are mechanical,
it is important that the fits of the bearing journals and housing
should be measured.
- The frame and shaft should be free of cracks or areas weakened
by corrosion.
- The straightness of the shaft and balance of the rotor also
affect performance.
- Electrical tests should be carried out by an electrical apparatus
service center.
- Tests should include winding inspection, ground inspection,
condition of winding coils, and squirrel cage rotor inspection.
- The current in an AC motor increases with load, but the no-load
point varies from 20 to 70% of full load current in different
motor designs; slow speed and low HP motors have higher no-load
current.
- It is important to obtain the manufacturer’s values
before attempting measurements.
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