In peak condition01 August 2006
Today's maintenance engineer is a far cry from that of a spanner-wielding repairman called in when something has broken down. The role of the modern maintenance department is very much about preventing the equipment failing in the first place. Predictive and preventative maintenance strategies, for example, have moved the engineer's focus away from the repair shop and on to the day-to-day operation of machinery, with the aim of uncovering potential problems before they can take hold.
Underlying this change in emphasis are the increasingly sophisticated condition monitoring procedures now available for most types of plant equipment. Even at the basic level, there are kits available that include a range of portable instruments to enable a multi-parameter approach to monitoring. The collection and correlation of data on parameters such as vibration, oil condition, temperature, speed, etc, helps to ensure an accurate and reliable assessment of a machine's condition.
On a wider level, this approach can be extended to networked monitoring systems that provide online information. These allow maintenance personnel to focus on diagnosing and correcting equipment problems, rather than spending their time on collecting the condition monitoring data.
In many cases, however, equipment problems - such as premature bearing failure, for example - are not the result of the normal wear and tear associated with plant operation. Far too often, they can be directly attributed to a combination of poor installation and maintenance procedures. Misaligned shafts, for example, are estimated by SKF to be responsible for up to a half of all costs related to rotating machinery breakdowns. Poorly specified lubrication also contributes to a situation in which it is estimated that 36% of all bearing failures are due to incorrect specification and inadequate application of the lubricant.
Getting these basics right from the start - in terms of plant design and construction, and in setting up the correct maintenance procedures - leads to extended machinery operating life and improved plant reliability. And it is easy to do, using the appropriate tools.
Accurate shaft alignment was once a highly skilled operation best left to experienced engineers with their dial indicators and other specialist equipment. That experience is thin on the ground these days, but the latest generation of laser alignment tools can offer quicker and more accurate results than the traditional methods. SKF's shaft alignment TMEA series of instruments, for instance, are easy to set up and use. They consist of two self-contained units, mounted opposite each other on the two shafts to be checked. Laser beams are transmitted from one to the other, with a hand-held LCD display unit showing the actual alignment status. As adjustments are made, normally by inserting shims under the machinery feet, the display counts down to zero, indicating the correct alignment.
The process is a simple three-stage operation ? measuring, aligning and documenting. The latter is particularly important in today's plant environment, where records of a machine's condition over its working life are of great benefit to the maintenance engineer.
Key to best practice
? Establish the appropriate condition monitoring procedures.
? Employ equipment to collect and correlate data on vibration, oil condition, temperature, speed, etc
? Ensure your maintenance personnel are focused on diagnosing and correcting equipment problems, rather than collecting condition monitoring data
Phil Burge is marketing manager for SKF UK. For further information, visit www.skf.co.uk
SOE
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