Belt Drive Monthly
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.
“...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
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
build-up. 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)
(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.
Belt Drive Monthly
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
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.
Belt Drive Monthly
Volume 28 • November 2010
More Recommendations & Maintenance Information...
The following paths will lead you to additional information
helpful in facility audits and maintenance
1 V-Belt
Savi
• U.S. Department Of Energy – DOE/GO-102003-1294
and DOE/GO-102005-2060 www.eere.energy.gov
• Bearing Myths – Don’t Believe Costly Misconceptions
http://www.regalpts.com/eptroot/public/news/
pressreleases/pdfpressreleases/ianrubin_bearing_myths.pdf
just
hnician
This tec save his
helped to ,422 per
$1
customer afternoon
e
year in onStep #1 on page 2
* See
cient
UP TO
98% Effi
95%
Based on
t
Efficien
ndent test
indepe
2
ps
Easy Ste
In Three d belts
ponsibility
notche
Energy Res e from wrapped to
Upgrad
UP TO
Wear
iency.
1 and improve effic w belt slip. Inspect 1/32”
allo
than
Prop
er
Tens ly
io
Belts n
Ex
ample
of
glaze
d
due to belt
tensio under
worn ning and
shea
ve
s.
ter
aves
APPL
ICAT
Worn she wear. Wear grea
The prop
ION CON
re.
issue orermo
selec SIDE
5%
envir s will vary tion and RATIONS
2 sheaves for e efficiency requ
onm
appli
appr
catio
irem ents and eciably depe
n of powe
reas
ents.
liabil
cond
ity
Any technitions, nding
r
can dec
lubric upon transmissi
belts.For a copyfor the advic
on prod
e givenical advic ation requthe use
, or resule or revie
irem and appli ucts and
y tension
of liabil
of our
comp
ity apply
ts obta w furni ents, loadi cation
Stand
shed
ined,
ng supp of such onents,
3 Properl
to any ard Term
by
results
• Belt Efficiency Calculator - IPhone* App downloadable at the App
Store* for IPhone, IPod Touch*, and IPAD*.
• On Line - Belt Efficiency Calculator. Available at www.RegalPTS.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.regalpts.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 #8932E) – offers basic product information,
installation information, preventive maintenance, and troubleshooting tips in a pocket size format
Future article ideas or questions can be
Submitted to Don.Sullivan@regalbeloit.com
www.RegalPTS.com
Browning is a trademark of Regal Beloit Corporation or one of its affiliated companies.
©2016 Regal Beloit Corporation, All Rights Reserved. MCO16002E • Form 9392E • Printed in USA
Repl
ac
Shea e Worn
ve
• Groo
s
ve we
than
ar gr
1/3
eater
replac 2” ind
emen icates
• Belt
t is ne
sh
eded
botto ould neve
m of
groo r ride in
• Ins
ve
pect
for br
eaks
on fla
nge
all such
Rega
Brow
s and
perso
orts, products including
ning
advic l Beloit
and othe and
n who Cond
the
and
e and
ition
Ame
©200
may
r facto comp related
s of
rica,
revie
buy,
8 Rega Regal are
w being Inc. and rs can onents. area of prod
acqu Sale, Discl
trade
l Beloi
ire or
mark
its divisi materiallyThe scop
given
uct safet
t Corp
use an aimers of
s of Rega
and accep
oratio
ons
affec e of the
y, is
Warr
Rega
l Beloi
n, All
anty,
l Beloi
ted atwith respe t the appli techn the respo
Right
t
t Ame Limitation
ical
ct
custo
nsibi
s Reser Corporatio
rica,
mer’ to the use cation andand appli lity of
ved.
n or one
Inc. prod of Liabi
s risk.
the
catio
of prod
MCF0
oper
of its
n infor customer.
uct referlity and
ating
8024
ucts
E • Form affiliated
and compresults matio
Oper
red to Remedy,
n
comp
pleas
herei
# 9203
onen of the prodincluded ating and
n, inclu e conta
ts is given ucts
E • Print anies.
in this perfo
ct Custo
ding
rman
ed in
any perso
in goodand comppublicatio ce requ
mer
USA
n
onen
irem
faith
n who Service
and withots and is necessaril ents and
at
buys
the custo y limite pote
from 1-800-62
ut charg
ntial
a licen
6-21
assoc
e, and mer shou d. Unus
sed distri20. Thes
iated
ual
Rega
ld
e term
buto
l assum carefully operating
r of these
s and
revie
es no
w
bran condition
oblig
ded prod s of
ation its
or
ucts. sale, discla
imer
s and
limit
ation
s
• Save The Green® energy video. www.youtube.com
Thepowertransmission channel or Browning Save The Green
Regal Power Transmission Solutions
7120 New Buffington Rd
Florence, KY 41042
Customer Service: 800-626-2120
Fax: 800-262-3292
Technical Service: 800-626-2093
gy
load)
depend -2060. Calc gy - U.S. l Technoloted from
indepen
and proping on driv ulations Departm gies Ener
dent
test
er align e designs, are an estiment Of Ener gy Effic
ment.
gy DOEiency
conditio
ate.
/GO n of sheaEfficienc
ves, belty gains vary
tension,
3
v-belts are
Notched y responsible
an energ for
substitutestyle v-belts
wrapped
NOTCHED
BELTS
WRAPPED
BELTS
• Save The Green® energy responsibility flyer. (form #’s MCF08073
and MCF08024) – offers energy responsibility in three easy steps.
1/32"
Save
Ener
15
ngs
125 HP 0 HP
Impa
10
cts of
$2,12
75 HP0 HP
chan
from
$1
5.78
60
gin
$1,42 ,777.93
wr
50 HP HP
$1
notch apped to g
$860 ,081.172.00
40 HP
ed be
.16
$7
lts
30 HP
$576 17.71
25 HP
$430 .11
20 HP
$362 .93
10 HP
$294 .25
.27
7.5 HP
$148
“A sin
.79
drive gle 100H
$111
5 HP
n ap
.92
P be
$77.2
3 HP
drop plication lt
$45.7 5
95% s from 98 that
2 HP
5
in effi
% to
1.5 HP
$32.4
cie
$142
2.00 ncy costs
$23.5 4
1 HP
in ad
an
7
ded ele nually
0.75
$16.8
(Based
ctrici
HP
2
on $0.
SOURCE
ty.”
$13.0
12/kW
0.5 HP
day wk
results : Formulas
h, 18h
6
and Offi
for calc
usage
And
rs/7
Ren
ce
$9.46
ulat
at 75%
102005 ewable Of Industria ion adap
Ener