October 2019

Ten point asset maintenance challenge L eading companies, who use assets intensively, know that effective asset maintenance is a foundation stone for long-term competitiveness. Even today, research has shown that fewer than 2% of company sites in the UK have mastered maintenance and therefore are unable to claim to be leaders in their field or ‘World- class’. MCP highlights its 10 Point Asset Maintenance* Challenge - where are you in terms of your current asset maintenance journey? Take the following 10-point asset maintenance challenge: 0 1. Are you following a long-term plan to apply asset maintenance best practice and ways of working? 0 2. Are you confident that each physical asset has an appropriate, risk- based annual maintenance plan? 0 3. Are you using a planning process so that the technician’s time is planned one week in advance? 0 4. Are you sure you have the ‘right’ engineering spares and consumables in stock? 0 5. Are you confident that your asset repair/refurbish/replace decisions are optimal? 0 6. Is it clear that operations and project leaders care about the processes for effective asset maintenance? 0 7. Do operational roles include asset maintenance duties, tasks and objectives? 0 8. Do you apply asset maintenance key performance measures that are regularly compared to targets? Are these actively use to drive continuous improvement? 0 9. Are there partnering arrangements with key outsourced providers or suppliers that allow for sharing risk and rewards? 10. Are you confident that the full scope of effective asset maintenance is understood by all employees? If your response is NO to even a few of these challenges, then an effective asset maintenance programme will deliver benefits to your organisation. *Based on over 30 years’ experience in benchmarking major companies worldwide, The AMIS Assessment enables companies to assess accurately how their maintenance and manufacturing operation compares with their competitors. Maintenance Matters Problem Solver 26 | Plant & Works Engineering www.pwemag.co.uk October 2019 A sealing solution provided by FPE Seals has helped Jackweld with the design of a welding method for joining rail tracks. Specialist machinery designers Jackweld are working on the EU project WRIST, to develop an orbital friction welding method, which aims to deliver a longer lifetime of the rails and welds, increased reliability, combined with a reduction of the maintenance cost. The high energy application that Jackweld had designed, required a seal for an internal diameter that was rotating at speed and spinning off-centre. The problem Jackweld faced with the machinery design, was finding a seal that would work effectively on a moving object that was constantly compressing and relaxing. This presented a challenge to find two types of seal: An orbiting seal, which is constantly compressing and relaxing with each cycle, A face seal, which seals against an orbiting face at 2000 rpm and seals against 500 litres per minute of hot hydrodynamic journal oil. No such seals were in existence, including any existing seal that could be adapted. Stuart Jackman, managing director of Jackweld worked with the experienced team at FPE Seals. Following in-depth discussion, deliberating different designs and drawings, the ideal sealing solution was agreed. This was then manufactured in- house by FPE Seals machined seal team. The final solution for the orbiting seal was a bespoke cup seal made from Polyurethane, with an extra-long lip that would seal against the oscillating diameter. The solution for the face seal was based on a large bronze-filled PTFE ring with three lubrication grooves, to seal the end of the application which rotates against a stainless- steel plate. Detailed collaboration took place between the FPE engineers and design engineers at Jackweld. This ensured the optimum integration of the seal design into the machine design. Testing proved that the sealing was a success first time. All functioned well, with both seals withstanding the rigors of the speeds, temperature and vibrations. Jackweld was then able to complete its WRIST prototype, ready for the new welding method to be tested for the EU project. Stuart commented: “The most critical part of the entire project was the oil seals. No such seals had ever been produced before and there was no prior art to go on. “We had to develop them from scratch. If the seals did not work 100% effectively first time the project would have failed because there would not have been time or funds to take the machine apart, design, develop and install improved seals. “The success of the project and the technological achievements literally revolved around the innovative FPE oil seals, which were the critical showstopper for the project.”. For further information on EU project WRIST please visit: http://www.wrist- project.eu/page/en/about-wrist/objectives- and-targeted-results.php Sealing solution for welding method