Industrial Maintenance Solutions

Submersible pumps are commonly used in various industries such as construction, mining, wastewater treatment, agriculture, and general manufacturing. Typically, these pumps consist of a vertical electric drive motor that is directly connected to the impeller, and they are designed to operate for long periods with minimal maintenance. BEARING ARRANGEMENT The bottom bearing, also known as the locating bearing, usually consists of a double-row angular contact ball bearing or a pair of angular contact bearings, which are responsible for supporting the axial and radial loads generated by the pumped fluid. Since the bearing is subjected to heavy loads, it is important to select the appropriate bearing to achieve the desired service life. On the other hand, the top free bearing is generally a deep groove ball bearing that takes a light radial load. Typically, C3 clearance is used to compensate for the reduction in clearance caused by the heat generated by the electric motor. CREEP PHENOME...

By NTS Pump shaft failure can lead to significant downtime and repair costs in industrial plants. One of the most common locations for pump shaft failure is at the keyway area. In this article, we will explore the reasons why pump shafts often break at the keyway and what can be done to prevent such failures. The keyway is a high-stress point (weakest point)  on the shaft, where a key is inserted to transmit torque between the shaft and the pump impeller or coupling. During operation, the keyway experiences cyclic loading that creates a bending moment in the shaft, which is concentrated in the keyway area. Over time, this cyclic loading can cause fatigue failure in the shaft material, leading to a fracture at the keyway. In addition to cyclic loading, other factors can contribute to shaft failure at the keyway. Improper keyway design or installation can lead to stress concentrations or inadequate clearance between the key and keyway . Misalignment or overloading can also cause ex...

By NTS Pump shaft breakage is a common issue that can cause costly downtime and repairs in various industries. In this article, we will explore several case studies of pump shaft breakage and the solutions implemented to prevent future failures. Case Study 1: Chemical Processing Plant A chemical processing plant experienced repeated pump shaft breakages in their cooling water pumps. Investigation revealed that the pumps were not properly aligned with the motor and had excessive vibration due to the misalignment. This caused the pump shaft to fatigue and break over time. The problem was resolved by realigning the pumps and installing vibration monitoring equipment to detect any future misalignment or excessive vibration. Case Study 2: Wastewater Treatment Plant A wastewater treatment plant had issues with pump shaft breakage in their sludge pumps. The pumps were designed with a straight shaft and lacked a flexible coupling, causing excessive stress and vibration on the pump sha...

Machinery that operates at speeds below 600 rpm falls under the category of low-speed machines. These machines are typically large and possess high rotating inertias, making them crucial components of the production line. Although these machines are less prone to breakdowns, they are considered critical, and their failure can result in enormous production losses, significant downtime, and substantial replacement costs. Historically, there has been limited interest in the condition monitoring of these machines due to their infrequent failures. The parts of these machines that necessitate condition monitoring are primarily the bearings and gears in motion. This article will cover modern and innovative techniques for monitoring the condition of low-speed machinery, with a particular emphasis on monitoring the condition of rolling element bearings. Monitoring low-speed bearings present unique challenges. In the case of high-speed bearings, vibration analysis, thermography, and wear deb...

By NTS. Pump shafts are essential in many industrial and commercial applications, providing the necessary mechanical force to move fluids through pipelines and process systems. However, when a pump shaft breaks, it can cause significant downtime, production losses, and safety risks. In this article, we will explore the common causes of pump shaft breakage and how to prevent it from occurring. 1. Excessive Load  The most common cause of pump shaft breakage is excessive load. When a pump is overloaded, it places a significant amount of stress on the shaft, causing it to bend, warp, or break. Overloading can be caused by a variety of factors such as a clogged discharge line, worn impeller, or damaged bearings. Proper maintenance, regular inspections, and monitoring of the pump's performance can help prevent overloading. 2. Misalignment  If the pump and motor are not properly aligned, it can cause stress on the pump shaft and lead to breakage. Misalignment can occur due ...

Electric motors are the workhorses of modern industry, powering everything from pumps and fans to conveyor belts and heavy machinery. But these vital components are not immune to wear and tear, and one common problem that can lead to premature motor failure is bearing damage caused by shaft current. Shaft current is a type of electrical discharge that occurs when there is a voltage potential between the motor shaft and the bearing, resulting in the flow of electrical current through the bearing. This current can cause a range of problems, including pitting and fluting of the bearing surfaces, which can lead to premature wear and failure. Shaft current Motor shaft current can have several harmful effects on bearings, including: 1.      Bearing pitting and fluting: Electrical discharges can cause tiny pits and flutes to form on the bearing surfaces, leading to premature wear and failure. 2.       Bearing noise and vibration: Shaft current can cause ...

This article provides an overview of the nine main types of maintenance, ranging from preventive to corrective maintenance and everything in between. Although specific terminology may vary, it's important to ensure that everyone is talking about the same thing and that the underlying principles are clear. Whether you refer to it as condition-based maintenance or predictive maintenance, what matters most is that we can have a meaningful conversation about when and how to use it. As such, this article also explores the appropriate applications of condition-based maintenance. Many people have questions about the different types of maintenance, so this quick overview provides a helpful starting point: There are nine distinct types of maintenance, which can be classified into two main categories: Preventive Maintenance and Corrective Maintenance.   Preventive Maintenance is performed proactively before any equipment failure occurs. This category encompasses: Time-Based Maintenance (TBM)...

The Maintenance Worker Skills Gap: An Ongoing Challenge  It's a well-known issue that has been around for a decade - the shortage of skilled maintenance workers. With fewer young people receiving proper training and experienced workers retiring, the pool of qualified workers is shrinking. To address this problem, many companies are relying on technology to support their maintenance efforts. However, the question remains - can digital solutions and vibration sensors truly fill the skills gap? The answer is not straightforward. While technology can certainly aid in maintenance efforts, it cannot replace the expertise and experience of human workers. Keeping a realistic perspective is crucial in understanding the limitations and capabilities of technology in the maintenance field. "Bridging the Maintenance Skills Gap with Technology: Moving Towards Predictive Maintenance"    As the skills gap in the maintenance industry persists, plants are turning to technology for support....