Reliability programs are proven to dramatically increase the productivity, reliability and safety of industrial machinery. With effective monitoring of

• Critical temperatures,
• Oil and lubrication levels,
• Amp loads,
• Vibration and
• Proper Maintenance Procedures,
• Industrial machines continue to run as designed.

Critical Temperatures:

Monitoring critical equipment temperatures of electrical motors, hydraulic oil, cooling towers, Operations and Management can proactively schedule needed maintenance prior to equipment failure.

Manufacturer’s recommendations need to be followed for minimium and maximum temperatures allowable for reliable operation. Coolers and / or heaters need to be installed to maintain tempeatures within manufacturer’s recommendations.

Digital and analog temperature sensors can be installed to continually monitor critical temperatures. Visual and / or Audible alamrs are also installed, alerting Operations of an out-of-normal condition. This pre-failure warning allows Operations and Management to schedule the needed downtime to repair the problem.

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Oil Levels:

Slow oil and / or lubricant leaks can lead to a dangerous condition within the hydraulic or lubrication system called Cavitation.

Cavitation results when the lubrication or hydraulic pump cannot suck enough oil, effectively sucking air, vs. oil. As the air / oil mixture in introduced into the system’s lubrication / hydraulic pump, the air bubbles, under pressure, literally implode within the cavitites of the pump. These implosions literally break off pieces of metal, putting them into the system, plus detoriating the effectiveness of the pump, until failure. Pieces / chunks of metal flowing downstream lodge and destroy valves and bearings. Catastrophic equipment failure is imminant.

Low-Oil and Low-Low-Oil Level gauges can be installed within critical lubrication and hydraulic reservoirs. The Low-Oil level indicator triggers an audible and / or visual warning to Operations. This gives Operations / Maintenance time to schedule the needed refilling of the reservoir to the proper levels.

The Low-Low-Oil Level indicator literally triggers an automatic elelctric motor shut-down process. This gauge is isntalled to protect the system if the oriignal / 1st warning had been ignored, or the leak is substantial that continual operation at these levels will cause catstrophic failure to the systems.

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Amp Loads:

Monitoring relative amp loading of all electric motors allows Opeations to effectively watch and respond to any over / under amp readings. High or low amp loads give indiations of under or over torque requirements being placed upon the specific electic motor. These torque levels need to be determined during initital and “normal’ operation mode. Recognizing a high or low torque (amp level) indicates failing / seizing bearings within the system, and / or overheated windings within the electric motor. Additional investigation must be completed to determine the actual failure area.

Vibration:

Vibration Anaylsis includes vibration sensors, trend monitors and expert readings of trend graphs. This highly specialized field installs either permanent or temporary vibration sensors at each critical bearing point. The vibration equipment actually graphs the vibration “curve” of the specific bearing being monitored. That graph is then compard to manufactuer’s existing “normal’ graphs, seeking to find an “out-of-balance condition. Vibratrion anaylsis is used primarly within the Paper, Steel and Power Generation Industries, which use extremly large (and expensive) roller bearings.

Proper Maintenance procedures:

A story.
A very large power plant had a recent turbine rebuild. Turbines utilize aproximately seven (7) large babitt style bearings (30.0” wide x 7.0 Feet ID) to support the main turbine as it turns at 1800 rpm. The start-up procedure of a turbine includes low and medium speed shaft rotation, prior to full-speed rotation being authorized. Turbine rebuilds typically last 2-4 months in length, and are complexly coordinated between many different vendors.

While in medium speed start-up, Operations, Maintenance and Management were all monitoring the seven main bearing temperatures, noting that one (1) bearing was ‘a little high”; not in warning mode, just a little high. As the turbine was turning (1200 rpm), and as all were watching the temeprature readout, temperature immediately shot past redline, the turbine shaft seized in it’s bore, and the entire turbine literally rotated 90 degrees, ripping all systems and connections from the turbine. A fire started, yet no one was hurt. All this in under 7 seconds!

The cause of the bearing failure? A mechanic’s rag had been left within the main lubrication plumbing, lodging itself at the bearing oil inlet port, starving the bearing of lubricant.

Cost of the repair exceeded $4.5 million dollars. A very expensive rag!

Proper Maintenance Procedures help to prevent any additional problems happening to the machine. Each machine has it’s own uniqueness and as such needs to be thoroughly reviewed for proper maintenance procedures. Site-Specific Training is avaialble to your mechanical staff (link to training Page) Generically though, the following procedures should be adhereed to in all cases.

1. The Operator of the machine should be consulted for any reports of trouble, or uniqueness to this specific machine.
2. All electrical, hydraulic and / or pneuamtic power to the machine needs to be formally locked-out.
3. Safety glass, resperators, safety shoes, gloves and hard-hats are all considered normal safety equipment for all maintenance personal.
4. Any enclosed space requires site, specific and OSHA approvede training.
5. All pressure, electrical loads and power sources must be completely ‘bled’ off prior to any work being started.
6. Each component to be repalced needs to be confimred as matchng PRIOR to removal of the old equipment. If the new component is different in size, shape and function, Management should be consulted PRIOR to any old equipment being removed.
7. Digital photos of all ‘to-be-removed” equipment should be taken, plus all incoming / outgoing connections tagged and identified.
8. All pipe, hose and tube connections need to be properly plugged / capped after removal from the machine. This keeps contaminant from entering the system. Each plug / cap needs to be easily visible, removeable and identifiable. This makes certain they are all removed prior to reinstallation.
9. All fittings should be wire brushed, and air blown PRIOR to removal or loosening. This keeps all dirt and crud around the fittng from entering the system.
10. Once the new component is reinstalled, all fitting plugs / caps need to be removed. All connections need to be loosely installed, tightening them all up only after all have been aligned and properly put in place.
11. If any component failure resulted in metal / contaminant being released into the system, the sytem’s oil must be drained, the reservoir cleaned out, all lines blown clean, the oil filtered with Beta 1 > 1000 rated filters. (link to filtration page)
12. All manufacturer’s start-up procedures must be followed.
13. All lock-outs are removed and system tested.

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