Maintain Reliability Ltd

CASE STUDY - Poor Lubrication practices and Electrical Fluting damage in Bearings. When it comes to bearing maintenance, selecting the correct lubricant isn’t just a recommendation—it’s essential for ensuring reliability. Recently, our team encountered a challenging case where we identified a bearing defect due to mixing incompatible greases with polyurea and lithium thickeners. This incompatibility led to a deterioration in the lubricant’s consistency, ultimately increasing friction and causing premature bearing failure. We also identified a self lubricator was fitted and set to full dispense using a incompatible grease. Using vibration analysis, our DETECT team pinpointed the outer race defect and signs of failure. Our Solve team quickly mobilized to repair the defect on-site, minimizing downtime and used precision maintenance to ensure the bearing was fitted correctly we also installed a insulated bearing as we knew that there could be signs of electrical damage. As we investigated the root cause, we identified that electrical discharge was creating fluting damage in the bearing, accelerating wear over time. To counter this, we implemented a shaft grounding device that safely diverted current through a lower path of resistance. By mitigating the risk of electrical discharge, we not only resolved the immediate issue but also significantly improved the reliability and lifespan of the equipment. This experience is a reminder: using the right grease and taking proactive measures against potential electrical discharge issues can prevent costly downtime and extend equipment life. A big thank you to the team for their expertise and dedication to solving these complex challenges! #Reliability #Lubrication #VibrationAnalysis #BearingMaintenance #PredictiveMaintenance #RootCauseAnalysis #ElectricalDischarge #reliabilitygang

Hi #reliabilitygang If your facility depends on steam, maintaining an efficient steam system is critical—not only for energy savings but for reducing emissions and costs. At Maintain Reliability, we offer steam trap surveys using advanced thermal imaging and ultrasound technology to help you maximize your system's performance. What is a Steam Trap? A steam trap is a valve that releases condensate (water) from the steam system while keeping the steam in. It plays an essential role in ensuring that steam is delivered efficiently to processes or equipment by removing unwanted water that could lead to poor performance, equipment damage, and increased energy consumption. How Can Thermal Imaging & Ultrasound Help? 🔹 Thermal Imaging allows us to see the temperature profile of the steam trap. A healthy trap will show a specific temperature range indicating it is properly expelling condensate while keeping steam intact. In contrast, a faulty trap (either leaking or blocked) will display unusual temperature patterns, alerting us to inefficiencies. 🔹 Ultrasound Technology goes a step further by detecting sounds that indicate the internal behavior of the trap. Leaking traps produce a continuous sound pattern, while functioning traps have a rhythmic sound due to periodic discharge. Ultrasound helps pinpoint these sound differences that are otherwise inaudible, allowing us to diagnose issues even before they become visible. Our team combines these technologies to ensure precision in detection, helping facilities avoid unnecessary energy loss, reducing greenhouse emissions, and supporting sustainability goals. If your facility wants to unlock greater efficiencies and save costs, let’s talk! #SteamSystems #EnergyEfficiency #Sustainability #MaintenanceTechnology #IndustrialInnovation

Hi #reliabilitygang In the world of asset reliability, leveraging multiple tools and technologies can lead to more comprehensive insights and better maintenance outcomes. One powerful combination I've been working with is ultrasound and vibration analysis. Each of these technologies has its strengths—vibration analysis excels in detecting mechanical issues like imbalance, misalignment, and bearing faults, while ultrasound is incredibly sensitive to early-stage issues such as lubrication problems. When ultrasound and vibration analysis are used together, we gain a broader understanding of equipment health. Ultrasound’s high-frequency detection abilities allow us to pinpoint subtle changes, like slight increases in friction, that might go unnoticed until a vibration threshold is reached. This early detection enhances the predictive accuracy of vibration readings, giving us a layered, detailed understanding of asset health. It also allows us to use condition based lubrication to remedy poor lubrication at its earliest stage. Combining these tools not only extends equipment life but also reduces downtime and lowers repair costs. It’s a win-win for teams looking to maximize uptime and efficiency. What’s been your experience with combining different reliability tools in the field? I’d love to hear your thoughts! #PredictiveMaintenance #ReliabilityEngineering #Ultrasound #VibrationAnalysis #AssetManagement #MaintenanceInnovation #FieldTechnologies

The Importance of Laser Alignment in Precision Maintenance In the world of precision maintenance, laser alignment is key to ensuring optimal performance and reducing the risk of unexpected downtime. Misaligned equipment can cause excessive wear, vibration, and energy loss, leading to costly repairs and a shorter asset lifespan. At Maintain Reliability, we understand the critical role alignment plays in your operations. That’s why we’ve invested in cutting-edge @Acoem AT-400 laser alignment technology, ensuring precise measurements and adjustments. But it’s not just about the equipment—we pride ourselves on rapid response times with expertise and experience to tackle the most complex alignments. When you need us on-site, we act quickly to minimize downtime and get your machinery back to peak performance. Reliability is always our priority, and we’re committed to solving problems before they escalate. Trust Maintain Reliability to keep your operations running smoothly. #MaintenanceExcellence #LaserAlignment #ReliabilityEngineering #PrecisionMaintenance #PreventiveMaintenance #MaintainReliability #reliabilitygang

CASE STUDY - 2 Plane Balance 🚨 When Reliability Matters, Speed is Everything! 🚨 At Maintain Reliability, we understand that fan balancing issues can happen without warning, and when they do, every second counts. That’s why we are committed to immediate response and rapid problem-solving—no matter how complex the challenge. Whether it's a simple single-plane balance or a complex 2-plane balancing, our expert technicians have the tools and skills to restore balance to any type of fan, anywhere, anytime. We don’t just fix the problem—we help prevent further downtime and ensure your equipment keeps running smoothly. Our on-site balancing services are designed to get you back up and running quickly, minimizing disruption and keeping your operations efficient and safe. When it comes to fan balancing, trust Maintain Reliability to act fast, solve the problem, and get you back to full speed. This customer required a urgent balance and we was able to have an engineer available the next day, as seen in the report this was a challenging balance but we managed to significantly reduce the vibration from 62 mm/s to 1.2 mm/s. #Reliability #FanBalancing #OnSiteService #EquipmentMaintenance #Maintain #reliabilitygang

Hi #reliabilitygang At Maintain Reliability, we understand that maintaining equipment reliability requires not only expertise but also the right tools for the job. When it comes to bearing changes, precision is everything. By using the correct equipment, we ensure that every installation or removal is done with maximum care and accuracy, minimizing downtime and prolonging the life of your machinery. Precision in Bearing Fitting. Proper bearing fitting is critical to reliability. Poorly fitted bearings can lead to premature failures, unnecessary costs, and extended downtime. That's why we prioritize precision by using specialized equipment like bearing heaters to expand bearings uniformly, allowing for smooth and accurate fitting. For removal, we use the correct bearing pullers to ensure safe and efficient ejection without damaging shafts or housings. We also ensure precision alignment of every job we complete that has belt or coupling driven drivetrains. Our approach is built around our Detect, Solve, Improve model: Detect: We start by identifying potential bearing issues before they escalate, using condition monitoring and advanced diagnostics. Solve: Once an issue is detected, our team applies the right tools and solutions to address it with precision. Improve: We don’t stop at solving problems. By continuously analyzing equipment performance, we make improvements that enhance long-term reliability. This process allows us to deliver the full circle of reliability, ensuring your equipment runs smoothly, efficiently, and with reduced risk of unexpected failures. Let's talk about how we can help your operations stay reliable with precision maintenance #ReliabilityEngineering #MaintenanceSolutions #BearingFitting #PredictiveMaintenance #MachineryHealth #PrecisionMatters

Good evening #reliabilitygang When it comes to the health and performance of large industrial gearboxes, vibration analysis is one of the most reliable tools in our toolkit. However, the effectiveness of this analysis is only as good as the sensors we use and, most importantly, where we place them. Mechanical transmission paths play a critical role in how vibration is picked up by sensors. Improper placement or the use of less sensors, can lead to misleading data, missed faults, and potentially catastrophic equipment failures. Vibration energy dissipates as it travels through the machine’s structure, and poor sensor placement will result in weaker signals or even the wrong frequencies being detected. That’s why understanding these paths and ensuring correct sensor placement is paramount. Best practices exist for a reason. By following them, we ensure data accuracy, early detection of faults, and better decision-making for maintenance strategies. Cutting corners by choosing to have less sensors or testing in poor locations can save costs upfront but will likely lead to expensive repairs, unscheduled downtime, or even safety risks later on. In vibration analysis, precision and consistency matter. The costs of doing it right are far outweighed by the costs of getting it wrong. #VibrationAnalysis #ReliabilityEngineering #Maintenance #ConditionMonitoring #GearboxMaintenance #IndustrialAutomation #PredictiveMaintenance

Hi #reliabilitygang! Its a new week and we dropped a brand new podcast. We had an amazing response from the last podcast on VA strategy so we decided to carry on the concept to VA best practice. We talk standards, sensor positioning, collection frequency and mechanical transmission paths. ‼️VIEWING DISCRETION ADVISED‼️ We get extremely passionate in this video ! #reliability #vibrationanalysis #conditionmonitoring #maintenance #engineering

🔍 Detecting Methane Leaks: The Power of Optical Gas Imaging at Biogas Sites At Maintain, we understand the critical importance of detecting and mitigating methane leaks in biogas facilities. That's why we're excited to offer cutting-edge optical gas imaging (OGI) solutions using our advanced Opgal EyeCGas C camera. This incredible tool not only quantifies leaks but also boasts exceptional video resolution—allowing us to pinpoint even the smallest emissions with precision. What sets us apart? It's not just about detection—it’s about giving you the control and insight you need. Our customized online portal provides: ✅ A comprehensive view of all detected leaks. ✅ A user-friendly interface to easily locate and review leaks. ✅ Real-time updates on the repair status of each leak, ensuring full transparency and peace of mind. If you're looking to take control of methane emissions and enhance operational safety and efficiency at your biogas site, get in touch! We’re here to help you make a measurable impact on both the environment and your bottom line. 🌍📊 #MethaneDetection #OGI #Biogas #MethaneReduction #Sustainability #Opgal #GasDetection #reliabilitygang

🔧 Enhancing Electrical Panel Reliability with Frequent Thermal Imaging 🔧 When it comes to maintaining electrical panels, annual thermal imaging is a great start—but it's not enough for optimal reliability. Electrical systems are dynamic, with varying loads and conditions throughout the year. Conducting thermal imaging more than once per year provides key benefits: 🌡️ Catch Early Issues: Components can overheat due to loose connections or overloading, and these issues often arise unpredictably. More frequent imaging helps detect problems before they escalate into costly failures. 📈 Monitor Load Fluctuations: Seasonal changes and operational demands can cause different parts of your system to heat up at different times. Regular imaging throughout the year provides a comprehensive view of how your system behaves under varying conditions. ⚡ Minimize Downtime: Identifying hot spots early allows for planned maintenance instead of reactive repairs, reducing unexpected shutdowns and improving overall reliability. Investing in more frequent thermal imaging ensures safer, more reliable operations—and that’s a win for your team and your bottom line! #ElectricalSafety #PreventiveMaintenance #ThermalImaging #Reliability #FacilitiesManagement #reliabilitygang