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Volume 11 ● June 2009
Volume 28 • November 2010
What Is Predictive Maintenance And How Does It Benefit
Overall Operating Costs?
P
redictive maintenance is the process of
using a detailed maintenance approach
and identifying component failure or
efficiency risks on equipment before they cause
unplanned downtime or loss of performance.
Maintenance methods may vary from highly
preventive to extremely reactive and some are
in between. However, a maintenance schedule
that bases activity on predictive performance
helps save valuable time and reduces overall
operating cost. The U.S. Department of Energy
publishes that...
“In many applications, fan maintenance is
reactive rather than proactive. For example,
bearing lubrication is performed in response
to audible bearing noises. Fan cleaning is
performed to correct an indication of poor fan
performance or vibration because of dust buildup. Unfortunately, many fan system problems
remain unaddressed until they become a
nuisance, by which time they may have resulted
in significantly higher operating costs”.
(U.S. Department Of Energy - DOE/GO-102003-1294)
“...Unfortunately, many fan system
problems remain unaddressed until
they become a nuisance, by which time
they may have resulted in significantly
higher operating costs”.
Basic Maintenance Recommendations For Belts and Bearings
(Recommendation excerpts (DOE/GO-102003-1294) Published by the U.S. Department Of Energy)
1. Belt inspection is particularly important
to the operation of large fans because of the
size of the power losses. For example, in a
200-horsepower (hp) fan, a 5 percent decrease
in power transmission efficiency results in a
10-hp loss, translating to $3,270 annually for a
continuously operating system.
Although belt inspection and tightening is
usually a routine task for any mechanic, increased
awareness of the costs associated with poorly
adjusted belts can improve the attention devoted
to this maintenance effort. In multiple-belt
arrangements, whenever one belt degrades to
the point of requiring replacement, all the belts
should be replaced at the same time.
Volume 28 • November 2010
As belts wear and age, they exhibit different
properties; consequently, replacing only one
or two belts in a multiple-belt arrangement
creates a risk of overloading one or more of
the belts. Exposing all the belts to roughly
the same operating time minimizes the risk
of uneven loading. Establishing proper belt
tightness is essential to minimizing the energy
losses associated with belt drives. However,
care should be taken to prevent
over-tightening the belts. This leads to high
radial bearing loads, accelerated wear, and
shorter bearing replacement intervals.
2. Worn bearings can create unsatisfactory
noise levels and risk seizure. Bearings should
be monitored frequently. Bearing lubrication
should be performed in accordance with the
manufacturer’s instructions. For example,
for high-speed fans in severe environments,
lubrication intervals can be necessary weekly
or more often.
• For grease-lubricated bearings, check
the grease quality and, if necessary, repack
the bearings. Be careful not to over-grease
bearings as this interferes with ball or roller
motion and may cause overheating.
• Ensure the bearings are adequately
protected from contamination.
Predictive Maintenance Recommendations For Belts and Bearings
To minimize overall operating cost it is vital to
include preventive maintenance inspections
that formally document current component
condition and the relative change since the
last inspection. By documenting and viewing
the data trends can quickly be identified and
it allows the technician to troubleshoot the
root cause before it erodes energy efficiency or
results in a breakdown situation.
Predictive Maintenance Best Practices
1. Identify all manufacturer
recommendations for maintenance and
product replacement (includes proper
installation, maintenance intervals, lubrication,
belt tension etc.)
2. Conduct and document a baseline audit
of existing product condition and installation
methods
3. Perform and document any required
maintenance or replacement actions required
to meet manufacturers recommendations
4. Establish inspection and scheduled
maintenance frequency
5. Store inspection data for future
comparison
6. Maintenance ongoing per manufacturer
recommendations
Volume 28 • November 2010
Summary
By adopting a predictive maintenance program maintenance technicians have a greater awareness of
optimal performance, correct product installation and required maintenance. This awareness and related
service action has a direct financial impact to equipment owners as reliability increases and their operating
costs decrease.
Note: In the March 2011 Belt Drive Monthly we will take an in-depth look into total cost savings examples and Overall
Equipment Effectiveness (OEE), which is used in extensively in LEAN/Six Sigma programs.
More Recommendations & Maintenance Information...
The following paths will lead you to additional information
helpful in facility audits and maintenance
• U.S. Department Of Energy – DOE/GO-102003-1294
and DOE/GO-102005-2060 www.eere.energy.gov
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• Bearing Myths – Don’t Believe Costly Misconceptions
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Thepowertransmission channel or Browning Save The Green
• Belt Efficiency Calculator - IPhone* App downloadable at the App Store*
for IPhone, IPod Touch*, and IPAD*.
• On Line - Belt Efficiency Calculator. Available at www.emerson-ept.com
– allows user to quickly calculate the savings benefit of converting from
wrapped style v-belts to cogged or “notched” style v-belts.
• Belt drive maintenance and installation video.
Available at www.emerson-ept.com or on CD by request.
• Sheave Wear Technical Bulletin (#1007) – offers explanation of groove
gauge usage and sheave wear dynamics. Available from Application Engineering.
• Belt Drive & Bearing Reference Guide (Form #8932) – offers basic product information,
installation information, preventive maintenance, and troubleshooting tips in a pocket size format
Browning, Emerson, Emerson. Consider It Solved., Emerson Industrial Automation and Save the Green are trademarks of Emerson Electric Co. or one of its affiliated companies.
* The following are believed to be the trademarks and/or trade names of their respective owners, and are not owned or controlled by Emerson Power Transmission. App Store,
iPhone and iPod Touch: Apple, Inc.; Facebook: Google, Inc.; IPAD: IP Application Development, LLC; Linkedin: Linkedin Corp.
©2010 Emerson Power Transmission, All Rights Reserved. MCO10053• Form 9392 • Printed in USA
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