Trends to Reduce Rotating Equipment Downtime

Introduction:

Many industrial manufacturing businesses utilize rotating equipment such as vacuum pumps, blowers, compressors, fans, turbines, and related lubrication systems in their production and manufacturing processes. In most cases, this equipment is essential to maintaining high productivity levels for the manufacturing operation. Unscheduled downtime caused by equipment failure is a concern for operators at manufacturing sites. Results from a recent ARC Advisory Group Survey estimated that the cost of unscheduled shutdowns due to equipment failure and other related issues is equivalent to about 5 percent of the total output for process industries. That translates to significant cost savings opportunities when equipment can be kept up and running.

Today’s rotating equipment is designed to provide efficiency, reliability, and safety over extended time periods. However, over time equipment components such as shafts, rotors, blades, and vanes can start to wear out due to friction and contaminant build-up in the lubricating oils. This will reduce the performance and efficiency of the rotating equipment, eventually causing production issues and driving energy consumption and maintenance costs upwards. In severe cases, wear and tear can cause major mechanical issues and create potentially dangerous working environments.

While wear and tear are inevitable in all manufacturing and industrial equipment, there are proactive measures that can help extend the useful life of a piece of equipment.

Here are some tips from our experts.

Establish a Maintenance Routine

Setting a regular maintenance schedule for all industrial rotating equipment is critical to sustaining optimal performance. Although many operators have a “fix it when it breaks” methodology, It is generally less costly for the business to take a proactive approach which includes regularly inspecting and correcting small issues rather than waiting for things to take a turn for the worst.

Most rotating equipment uses consumable items such as air filters, oil filters, gaskets, and lubricating oils that maintenance personnel can easily replace with minimal time and effort . Using high quality consumables and servicing them regularly goes a long way towards protecting the equipment’s internal working components. When the internal working components are damaged, a costly repair or rebuild is required which can take days or weeks to complete and may require assistance from an outside firm.

Performance Indicator Monitoring

Emerging technology such as IoT (Internet of Things), machine learning, and AI are transforming the manufacturing industry right now. In addition to improving efficiency and output, they can also predict trouble before it occurs.

To prevent issues from occurring, performance indicators must be monitored and reviewed frequently. Examples of what to monitor include oil consumption rates, pump-down time, pressure/vacuum levels achieved, operating temperatures, vibration levels, and energy consumption levels to name a few. Gradual trends or any sudden changes could be a sign of impending equipment issues. Data analytics tools now often come standard with new equipment – but they may need to be installed for older systems.

Keep the Equipment and Facility Clean with Filters

A main purpose for a filter is to keep things clean. During many manufacturing processes, dust, oil, and other particles will escape into the air and surrounding work environment where it can be ingested by the rotating equipment. When this occurs, the particles cause damage to internal components or the sealing surfaces of the equipment. If enough particulate builds up, the equipment must work harder and the additional stress and strain eventually results in equipment failure and costly repairs. The lubrication oil can also become contaminated and breakdown when exposed to contaminants.

The optimal and simplest solution here is to install industrial filters to safely collect and remove particulate before it can build up in the equipment and cause damage. Filter media can be specially designed to capture even the smallest particles such as dust, smoke, and oil. Additionally, custom industrial filtration systems can be created to meet specific standards or to fit into tight spaces.

Some oil sealed rotating equipment will discharge its lubricating oil into the environment during operation. When the discharged oil mixes with other contaminants, the mix can be harmful to any equipment that ingests the mixture. Gearbox breathers, oil mist exhaust filters for vacuum pumps, lubrication skid breathers, and crankcase ventilation systems all help keep the facility free from airborne oil mist contamination.

Furthermore, related equipment parts (the floor, air vents, and surrounding areas) should be regularly cleaned to cut down on dust. For excessively dirty manufacturing environments, equipment can be placed in separate rooms to isolate it from the dirty environment.

Monitor Parts Needing Lubrication

You need to ensure that rotating equipment parts are sealed and lubricated correctly for optimized performance. Lubrication is essential for the operation of rotating equipment and overall performance. Lubrication reduces friction between gears, shafts, bearings, and other moving parts. It also prevents corrosion, and helps equipment run cooler.

Unfortunately, many manufacturing companies completely overlook this step in preventative maintenance. The latest research states that 57% of manufacturing businesses do not regularly schedule lubrication deliveries. Ninety-one percent did not even have a lubrication requirement sheet for their equipment.

In addition to regularly scheduling and completing lubrication, employees should learn the warning signs of lubrication issues on rotating equipment. Generally, the machines will start to vibrate or emit unusual sounds when lubricant levels are low. Equipment may start to overheat and energy consumption can spike, along with scrap and process waste amounts.

Have a Backup Plan

Even the most well executed maintenance programs aren’t perfect and rotating equipment can break without warning. When possible, having backup equipment on hand can shorten the length of downtime when an unforeseen equipment failure occurs.

Conclusion

Improving efficiency and output is a top goal in manufacturing industries and the best way to do that is to protect and regularly service all equipment. Downtime and repair costs can be greatly reduced through preventative measures and using top-quality filtration parts and other consumable components. If you have any further questions regarding industrial filtration systems for your rotating equipment, please contact us at Solberg. Our team of industry experts is happy to help answer any questions about our industrial equipment and find a filtration solution that meets your system’s needs.