REPAIR BEFORE FAILURE

Repair before failure is a motto commonly used in our practice. When performing weekly or monthly inspections, periodic maintenance or repairs of the machine during a scheduled overhaul or after a malfunction, we analyse how we can protect ourselves from unscheduled downtime. How can we avoid the unpleasant event of a malfunction? How do you avoid exposing the client to the additional costs related to a major repair and, consequently, machine downtime?

The above questions are valid for a generator providing an emergency power supply facility, a locomotive engine, a machine operating in the mining industry, as well as for a gas power generator operating in a CHP plant. After all, the problem of failure can affect any market segment and application powered by a Caterpillar engine or power generator.

No one likes unpleasant surprises, even less so when reliable support is needed. Each failure may have a direct impact on the financial result of a given project. Outages in power supply or plant operations generate costs, but they also hinder work organisation and generate stress.

Repair before failure is our recommendation, a certain philosophy of service approach. Keep in mind that sometimes a small thing such as an abrasion of the fuel hose, V-belt or electrical cable can cause trouble. A minor but important thing can cause a lot of damage. Just like constant dropping that wears away the stone, micron-sized contaminants from a damaged or improper filter in the fuel system can damage the pump injectors and put us at risk of costly repairs. And in much less time!

Routine maintenance of equipment versus daily operation

Our inspections conducted during routine maintenance are designed to diagnose such defects and respond in a timely manner. In this process, the role of the team responsible for the proper ongoing maintenance and operation of the machine is also of the utmost importance. Operators and maintenance personnel who observe the machine every day during its operation have a chance to act preventively on the first line. Many costly repairs and downtime can be prevented in this way. By following the maintenance rules provided by the manufacturer in daily use, it is easy to spot any worrying symptoms and then report all comments and observations to the service department.

Workshop repairs of engines

 During workshop repairs, we usually perform disassembly and verification of the entire engine. We clean, measure, inspect, view and compare parts and components. We act following the documentation and the experience of our mechanics and engineers.

We usually verify the disassembled engine together with the client. After joint actual evaluation and measurements, we find that certain parts or components are “within tolerance” of their dimensions and show no signs of damage or wear. In such situations, based on our experience, we consult with our clients on whether we allow the part to continue operating. We act consciously, bearing in mind the responsibility for the decision taken. A given component, even though it is functional and its dimensions are “within a given tolerance”, will wear out beyond the permissible limit after some time, e.g. within the next 2,000 operating hours. It can then pose a danger. The problem can arise when this component is inside the engine and, in addition, will function as a worn-out part when interacting with the new parts replaced during the repair. Sometimes replacing such a component involves disconnecting the generator, removing it from a machine, building, locomotive or powerhouse, or even taking apart the entire engine. The costs and efforts of such operations may exceed the initial cost of replacing a given part many times over.

Recommendations: repair before failure

Preventive solutions related to the repair before failure recommendation are most often suggested to users of applications in case of which it is extremely important to ensure a high level of machine availability. In practice, users are aware that in addition to the cost of replacing parts and dismantling the engine, they have to factor in the cost of machine downtime, especially when the shutdown is unforeseen and occurs (usually) at the least expected moment.

When performing maintenance, inspections, repairs and during the execution of service contracts, we establish service priorities with the user of the engine or power generator, so as to understand the essence of their needs. We strive to offer the optimal solution, both financially and in terms of ensuring the expected level of satisfaction and security of the user’s business venture.

Keep in mind that timely repair of a small defect or replacement of a part not yet completely worn out sometimes makes sense and, paradoxically, can save both money and time.

Written by: Łukasz Kaczyński

Parts & Service Sales Expert