The combination creates a compelling, mutually beneficial partnership that significantly strengthens both companies’ positions in the European elevator aftermarket by bringing together L+L’s strong presence in the DACH region with CPM/NDC’s leading position in the UK and US. It also establishes a group with a broader, more diversified offering across critical elevator components, with the combined business approaching EUR 40 million in revenue. For customers, the combination means broader technical capabilities and a more comprehensive one‑stop offering for modernisation, repair and maintenance of critical elevator systems across Europe and the US.

CPM, together with its subsidiary NDC, is an engineering group based in Manchester, specializing in 24/7 repair, replacement, and maintenance services for electronic, electrical and mechanical equipment, with a particular focus on elevators and associated drive systems, motors, and gearboxes. Through its rapid response field service teams and workshop capabilities, CPM/NDC supports a broad customer base of elevator companies, facility managers and building owners across the UK, the US, Spain and Germany.

Norvestor IX initially partnered with L+L in 2023, sharing an ambition to further both organic growth and implement a focused acquisition strategy to build a leading independent European platform within elevator drive, control and maintenance services. The acquisition of CPM and NDC clearly enacts this strategy, adding a complementary UK platform with a strong position in the US and capabilities in the repair and maintenance of critical elevator components, underpinned by deep experience in keeping elevator systems running safely and reliably.

“We are very pleased to welcome CPM and NDC into the L+L family. Both businesses have a strong heritage in the elevator market and share a clear focus on safety, reliability and minimizing downtime in critical elevator applications. By combining L+L’s leading retrofit door drive and control solutions with CPM/NDC’s 24/7 elevator drive service and workshop capabilities, we will be able to support our customers across multiple areas of the elevator,” say Florian Rauch and Carsten Blanke, Co-Managing Directors of L+L.

David and Jordan Griffin, Directors and co-owners of CPM, add “We are excited to partner with L+L and Norvestor IX for the next stage of CPM and NDC’s journey. We have built our business around being there for our customers when it matters most – keeping elevators moving safely and getting critical systems back up and running as quickly as possible. Joining forces with L+L gives us access to a broader portfolio, deeper technical expertise, and a strong foothold in continental Europe, while allowing us to stay true to the service-led culture that our customers value.”

“CPM and NDC are a strong strategic fit for L+L and an important step in building a leading independent European elevator aftermarket platform. The combined group brings together recognized specialists in critical elevator repair across drives, doors and controls. Together, they will be able to offer a broader, integrated proposition to elevator companies, building owners, and facility managers across Europe and the US, with best-in-class solutions for modernization, repair, and maintenance of elevator systems,” says Tor Erling Gunnerød, Partner at Norvestor Advisory and Chair of L+L.

About Langer & Laumann
L+L is a leading specialist in retrofit drive and control systems and critical elevator door components, with a strong market position in the DACH region. The company serves elevator OEMs, service companies and property owners with high-quality solutions for elevator modernisation and reliable operation. Read more at www.lul-ing.de

About Complete Plant Maintenance Engineering
Complete Plant Maintenance Engineering Ltd is a UK-based provider of elevator and industrial electromechanical maintenance services. CPM focuses on the maintenance and modernisation of critical elevator components, offering 24/7 service solutions to ensure safe, efficient and uninterrupted operation for its customers across the UK. Read more at www.cpm-uk.com and www.ndc-uk.com.

About Norvestor
Norvestor Advisory is a leading private equity company focusing on mid-market buyouts in the Nordic region. The team has worked together since 1991, making it one of the most experienced private equity teams in the Nordics, having executed 100 investments with more than 750 add-on acquisitions, in addition to executing 68 exits, including 16 IPOs. The Norvestor funds seek to invest in growth companies in the Nordic mid-market that have the potential to achieve a leading Nordic or international position, typically through organic growth, acquisitions across fragmented industries or by geographic expansion.

The post Langer & Laumann and Complete Plant Maintenance Engineering join forces to create a leading European elevator aftermarket platform appeared first on CPM Engineering.

They were staring down three.

With their entire production line out of action, no backup unit or spare parts and an estimated 16-week ’emergency’ replacement delivery, they were facing:

• £10k in lost production and wasted resources – every single hour
• A staggering £2m penalty for failing to meet a client’s strict 3-week delivery deadline
• A huge hit to their reputation that would severely jeopardise their future.

In short, disaster.  Or not.  Thanks to calm heads, a careful analysis of the situation and some creative CPM problem-solving. Read our case study below to find out how we reduced downtime from days to minutes for this customer.

For support with any aspect of repair or maintenance of rotating machinery, please get in touch.

The post Case Study: Reducing downtime from days to minutes for client in food manufacturing industry appeared first on CPM Engineering.

As a service provider, we see many examples of incorrect oils, greases and synthetics used in hundreds of applications each year.

If the lubricant isn’t designed for the duty or application of the machine or its operating environment, another preventable failure is only a matter of time.

Operational Conditions

Similar machines can be used in several applications; however, they may require different lubricants due to specific site conditions relating to temperature range, speed, and function they perform.
The correct lubricant is used to reduce friction between surfaces, when they come into contact, ensuring optimal performance of the rotating asset and extending its life span.

Improper Lubrication

It is imperative when choosing the right solution, for your machine, to take into consideration various properties of the lubricants as well as several other factors. Studies have shown that up to 80% of failures are caused by incorrect lubrication. This can include contamination caused by friction, unsuitable operating temperature further impacting the properties of the substance used, product recalls if the lubricant is not approved for the industry and many more.

While this may all appear simple and common sense, it happens all too frequently costing significant sums a year in avoidable repair costs and loss of production.

The correct lubricant can not only extend maintenance intervals but also extend the longevity of the rotating asset and assist with achieving cost savings.

CASE STUDY: How the correct lubrication can minimise repetitive failures

One of our customers’ machines was failing every few months due to repeated bearing failures. Following investigation using Root Cause Failure analysis techniques, it was determined that the failures were caused using an improper lubricant on site which occurred due to site personnel changes. This discovery was possible because we worked closely with the customer to gain an understanding of the patterns of failures, taking into account the extensive knowledge and experience of their engineering team and other external factors.

By using a lubricant that suited both the machine and the environment, we prevented repetitive failures and developed a time-based maintenance schedule to minimise production interruptions and unplanned downtime.

As a result of close collaboration, the machine now undergoes periodic checks instead of being repaired frequently!

Your reliability partner

We are here to help improve the reliability of your rotating assets. By understanding your operating environment, we can provide the advice and guidance you need to eliminate or reduce failures. Find out more about our rotating asset maintenance services or book your repair.

The post Extending MTTF In Rotating Machines: The Importance of Correct Lubrication appeared first on CPM Engineering.

This approach – to look beyond the initial repair – is ingrained in our DNA.

With decades of experience and a pursuit of excellence, we have established ourselves as leaders in the field of rotating machinery maintenance.

Our approach focuses on proactive measures aimed at increasing the reliability and longevity of rotating machines, rather than simply reacting to breakdowns. By leveraging cutting-edge technologies, innovative techniques, and a team of highly skilled engineers, we continuously strive to enhance the MTTF of our customers’ machinery, thereby minimising downtime, maximising productivity and reducing maintenance costs.

Additionally, we place a strong emphasis on continuous improvement. Our team of engineers is constantly researching and developing new methods and technologies to further enhance the reliability and performance of rotating machines. Understanding the root cause failure of machines allows us to make, often small, but effective changes like optimising lubrication processes, improving cooling efficiency, and enhancing sealing arrangements. Small changes that deliver big savings to our customers.

Furthermore, our comprehensive approach extends beyond individual machines to encompass entire systems and processes. By analysing the interaction between various components and identifying potential points of failure, we can implement holistic solutions that address underlying issues and improve overall system reliability.

A further key aspect of our strategy is predictive maintenance. Through the use of advanced monitoring and diagnostic tools, we are able to detect potential issues before they escalate into major problems. By identifying early warning signs of failure, we can take proactive measures to address them, preventing costly unplanned downtime and extending the lifespan of the equipment.

Improving the MTTF of rotating machines is not just a service we offer at CPM – it’s part of who we are. With our relentless focus on proactive maintenance, continuous improvement, and comprehensive solutions, we help our clients achieve greater reliability, efficiency, and uptime for their critical assets and beyond.

By working together we can make the changes that matter.

The post Enhancing Rotating Machine MTTF: It’s In Our DNA appeared first on CPM Engineering.

To us, this is a vital step in demonstrating our commitment to setting the standard in our industry.

EASA confirmed our re-accreditation earlier this month following an external audit by SGS, the leading certification body, in which we needed to demonstrate that we have the correct equipment, trained personnel and quality-controlled procedures to meet the demanding standards required to deliver reliable quality electro-mechanical repairs that measure and maintain, if not improve, the efficiency of your AC electric motors after a repair. In so doing helping you reduce the ever-increasing energy costs.

We were first accredited in 2015, which made us the first EASA accredited Service Centre in Europe! Since then, we have been subjected to multiple audits, which we have passed every time.

The standards allow us to demonstrate to our customers that the repairs are completed to the same high standards ensuring reliability and consistency.

“This re-approval affirms CPM’s continuing commitment to excellence,” said Linda Raynes, EASA’s President & CEO. “It offers external validation that CPM Engineering adheres to good practices by submitting to an independent, third-party audit, on a triennial basis.” The criteria for becoming EASA Accredited are based on ANSI/EASA AR100: Recommended Practice for the Repair of Rotating Electrical Apparatus and The Good Practice Guide of The Effect of Repair/Rewinding on Motor
Efficiency.

CPM spokesperson said: “We are firmly committed to maintaining the very highest possible standards of repair and maintenance of our customers’ rotating equipment and therefore to extend the MTTF (mean time to failure). Our customers’ demands are ever-changing; hence we invest heavily in our equipment, services and people to ensure customers know they are in the best possible hands in choosing us. EASA accreditation – for the 9th year running– is evidence of this approach and should help our customers feel even more confident in working with us.”

What is EASA?

Recognized internationally as the leader in the electro-mechanical sales, service and repair industry. EASA provides an ongoing flow of industry information and education that helps its 1,700 members worldwide enhance their performance and achieve greater levels of success on behalf of their customers. EASA supports its members through its engineering consultation program, industry-specific training, business information, networking activities and exclusive technical resources focused on the sale, service and maintenance of motors, generators, drives, controls, pumps and other electromechanical equipment.

The post CPM Achieves EASA Re-accreditation – For The 9th Year Running! appeared first on CPM Engineering.

Ensuring you can access replacement parts when you need them is crucial.

That’s why we can supply replacement parts or manufacture what you need to OEM standards or better. This is particularly helpful if you have ageing equipment, and the parts are hard to get or obsolete.

Manufacturing parts when replacements are hard to get or obsolete – case study

We had a good example of this recently when a customer in the chemical industry needed help with an urgent repair of a pump that was critical to their operation.

We worked closely with the customer to learn more about the process as well as the ongoing problems. Due to the age of the equipment, it wasn’t possible to obtain replacement parts without causing a significant delay leading to downtime and loss of production.

Instead, we opted to try a rather unconventional solution – to re-build the damaged impeller.  This meant the site was able to get back to full manufacturing capability more quickly. In addition, due to the structural design improvements, we managed to achieve a much more efficient flow of the pump.

Manufacturing parts to modernise machines – case study

In-house manufacturing capabilities of parts means you can modernise the machine, plus you can customise it to perfectly suit the application, improving production output.

A short while ago, a customer approached us with drier fan motors that had repetitive failures due to the fan going out of balance. This was leading to the failure of the motors and ongoing loss of production.

By understanding the application and process-related issues, we worked closely with the client to re-design the bearing arrangement on the motor and fan to prevent failures.

We then went one step further by altering the chemical composition of the paint to prevent adherence of the product to the surface of the fan. These changes meant that motors would be more robust in the harsh environment in which the units are operating, and the customer is now enjoying a significantly improved MTBF.

“Understanding our customers is key. Knowing the customer, the application and history of the machine means we can come up with the best solution to obtain or manufacture replacement parts and extend the life of the asset.” Rishi Hirani, General Manager.

Manufacturing for improved performance

Manufacturing whatever parts you need

We can manufacture the parts you need for pumps, gearboxes, motors and any other electro-mechanical equipment up to 15 tonnes in our state-of-the-art facility in Trafford Park, Manchester.

Where OEM information is no longer available our engineers can reverse engineer worn components accurately, enabling us to look at the best materials to suit individual applications.

“We have technical and test data going back 30 – 40 years on thousands of rotating machines. This means we have a reference to compare against to ensure the OEM standard can be maintained or improved. Quality repairs result in maximum up-time and output from your assets.” Rishi Hirani, General Manager

What’s special about our approach?

All rotating machines are manufactured to a particular standard. Our objective is to return your machine to its original standard or higher.

• Expertise – a great machinist can manufacture a component based on original drawings. But at CPM Engineering, our engineers are not just great machinists, they are also trained to develop their own designs and specifications. This means we can produce the best components for your specific application.
• Partnership – there are instances where changes during the repair stage can improve the performance or resistance to environmental conditions, therefore increasing MTBF.
• That’s why we work closely with you to understand the machine’s application. As a result, the solution can be fully customised to suit the application of the machine on your site, promoting productivity and efficiency, often beyond its performance before the repair.
• Reliability – after the repair and before the equipment is returned to you, it will undergo our extensive on-site testing regime which is second to none in our industry. This gives you peace of mind to know you can reinstall with confidence.

Let us help

Need help with a repair? Find out more about our services. We’re open 24/7 and offer free collection & delivery throughout the UK. Contact us today on 0161 865 6161 or book a 30-minute call with Operations Co-ordinator Edyta Sobczyk.

The post The Challenge: What Happens When Replacement Parts Cannot Be Obtained? appeared first on CPM Engineering.

When these machines fail, the consequences can be costly in terms of both downtime and repair expenses. That’s why, in the realm of equipment maintenance and repair, it’s not just about fixing what’s broken; it’s about understanding why it broke and ensuring it won’t happen again.

Testing rotating machines after repair is a crucial step in achieving this objective and driving reliability in industrial operations.

Understanding the Root Cause of Failure

Before we delve into the importance of post-repair testing, let’s emphasise the significance of comprehending the root cause of the failure. When a rotating machine breaks down, it’s essential not to treat the symptoms alone but to diagnose the underlying issue. Was it a mechanical failure due to wear and tear, a lubrication problem, an electrical fault, or something else entirely? Identifying the root cause is like solving a puzzle, and without this understanding, any repair is incomplete.

The Repair Specification

Understanding the root cause of failure is the cornerstone of executing an effective repair specification. It guides engineers and technicians in addressing the specific issues that led to the breakdown, ensuring that the repair process is not just a temporary fix but a lasting solution. Without this knowledge, the repair specification risks being a mere shot in the dark, leaving room for the same problem to recur.

The Role of Testing

But the role of testing is indispensable in the repair and maintenance of rotating machines. Here’s why:

• Pre-repair testing is critical to determining the Root Cause Failure Analysis (RCFA) stated above. If safe and possible to do so, static and dynamic testing of the failed machine can reveal much about its condition.
• Verification of repairs: Post-repair testing serves as a means to verify that the identified issues have been effectively addressed. It ensures that the machine is brought back to its optimal operating condition.
• Quality assurance: Testing guarantees the quality of the repair work. It’s a safeguard against human errors or oversights that can occur during the repair process.
• Simulation of production environment: While not every machine can be tested to perfectly match its production environment, simulating it as closely as possible is vital. Testing under conditions that mimic the machine’s normal operation helps detect subtle issues that might otherwise go unnoticed.
• Performance validation: Testing enables the assessment of a machine’s performance against established benchmarks. This is crucial, especially in industries where precision and reliability are paramount.
• Data collection for future maintenance: The data gathered during testing can serve as a baseline for future maintenance. It provides insights into the machine’s behaviour, which can aid in predictive maintenance efforts.

Driving Reliability through Testing

In industrial settings, reliability is the holy grail. Downtime is expensive, and unexpected breakdowns can have cascading effects on operations. By testing rotating machines after repair, industries can significantly enhance their reliability. They can be confident that the root causes of previous failures have been addressed, and the machine is fit to perform its duties under operational conditions.

While it may involve some investment in terms of time and resources, this approach pays off. It reduces the risk of costly breakdowns, extends the lifespan of equipment, and ultimately contributes to smoother and more efficient industrial operations.

In conclusion, testing rotating machines after repair is not just a formality; it’s a strategic imperative. It ensures that repairs are effective, addresses the root causes of failure, and contributes to the overall reliability of industrial equipment. In an era where downtime is expensive and operational efficiency is paramount, investing in post-repair testing is an investment in the future success of any industrial operation.

Learn more about our maintenance support and rotating machinery management services.

The post Ensuring Reliability: The Vital Role of Testing Rotating Machines After Repair appeared first on CPM Engineering.

However, the reliability of rotating machines can significantly impact the cost of the processes. Unplanned breakdowns and downtime can lead to costly repairs, loss of production, and potential safety hazards. Therefore, achieving high reliability in repairing rotating machines is of utmost importance.

Importance of Reliability in Rotating Machines

Reliability refers to the ability of a machine to perform its intended function under specific conditions for a given period without failure. In the context of rotating machines, high reliability ensures consistent performance, minimises unplanned downtime, and maximises the Mean Time Between Failures (MTBF). Many of CPM’s customers make MTBF a critical metric used to measure the reliability of a machine and represents the average time between consecutive failures.

Several reasons highlight the importance of reliability in repairing rotating machines:

• Minimising Downtime: Downtime due to unexpected failures can lead to production or operational delays, loss of revenue, and increased maintenance costs. High reliability ensures that rotating machines function as intended for extended periods, reducing the frequency of unscheduled maintenance and downtime.
• Improving Safety: In industries where rotating machines operate under high loads and speeds, unexpected failures can also pose significant safety risks. A reliable machine is less likely to experience sudden malfunctions that may result in accidents or injuries to operators.
• Optimising Maintenance Costs: We all recognise that regular preventive maintenance is necessary to keep rotating machines in top condition. However, unnecessary maintenance can be costly and can disrupt operations. By maximising MTBF, maintenance activities can be better planned and executed, leading to reduced maintenance costs.
• Enhancing Productivity: Reliable rotating machines support smooth and uninterrupted operations, contributing to increased productivity and efficiency. Organizations can meet production targets and customer demands more consistently with minimal interruptions.
• Extended Service Life: A reliable machine is less likely to experience premature wear and tear. This extended service life leads to reduced capital expenditures on replacements and an overall better return on investment.
• Sustainability and Environmental Impact: Machines with higher reliability often lead to reduced energy consumption and emissions. Alignment, CBM, lubrication and smart sensors can also contribute to increasing the life of machines leading to lower environmental impact over their lifecycle.

Our Approach to Maximise MTBF

CPM Engineering is a leading provider of rotating machine repair and maintenance services, known for its commitment to ensuring high reliability and maximising MTBF. The company employs a comprehensive set of strategies and practices to achieve this goal:

• Skilled Technicians: CPM Engineering employs skilled technicians with extensive expertise in diagnosing, repairing, and maintaining various types of rotating machines. The team’s experience and knowledge and adherence to sound procedures developed within its ISO 9001 registration play a crucial role in ensuring reliable repairs and ongoing maintenance.
• Root Cause Analysis: If you don’t know why a machine has failed the corrective actions could be floored. CPM Engineering conducts a thorough root cause analysis to identify the underlying reasons. This analysis helps to address the root issues rather than just the symptoms, reducing the likelihood of recurrent failures.
• Quality Parts and Components: During repairs, CPM Engineering uses high-quality parts and components that meet or exceed original equipment manufacturer (OEM) specifications. This practice ensures that repaired machines perform optimally and reliably.
• Predictive Maintenance: CPM Engineering utilises advanced predictive maintenance techniques, such as smart sensors, vibration analysis, thermal imaging, and oil analysis, to detect potential issues before they escalate into failures. By identifying early warning signs, corrective actions can be taken proactively, maximising MTBF.
• Preventive Maintenance Programmes: The company designs tailored preventive maintenance programmes for its customers based on specific operational requirements and equipment conditions. These programmes aim to proactively maintain the health of rotating machines and extend their service life.
• Continuous Improvement: CPM Engineering emphasises a culture of continuous improvement. They regularly assess repair and maintenance processes and update equipment. They also learn from past experiences, and implement best practices to enhance the reliability of their services. Case studies are also used to compare with other sectors.
• Testing: Without testing machines following repair how can CPM’s customers have confidence that it will operate successfully when returned to production. Testing is a critical part of any repair organisation’s facility to ensure it operates within the OEM’s specification.
• Customer Support and Training: CPM Engineering provides comprehensive training. They educate their team and also customers in maintenance and repair techniques, best practices, and early fault detection, empowering the operators to contribute to the reliability of their rotating machines.

Conclusion

In conclusion, the importance of reliability in repairing rotating machines cannot be overstated. It directly impacts productivity, safety, maintenance costs, and the overall success of the process. By maximising MTBF, organisations can reduce unplanned downtime, increase productivity, and achieve better returns on investment. CPM Engineering’s approach to ensuring reliability through skilled technicians, root cause analysis, quality parts, predictive maintenance, preventive maintenance programs, continuous improvement, testing and customer support, pushes the standards for the industry. As technology and maintenance practices continue to evolve, reliability in rotating machines will remain a key focus for industrial success and sustainable operations.

The post The Significance of Reliability in Repairing Rotating Machines appeared first on CPM Engineering.

A common problem in the pursuit of optimal alignment and seamless operation is what is termed a “soft foot” condition.

Soft foot is often a serious condition that emerges when the feet of a machine case fail to rest evenly on its supporting base. The consequence of tightening foot bolts in such a scenario is a distortion of the machine case itself. This seemingly minor disturbance not only complicates alignment efforts but also introduces unwanted load on bearings and induces internal misalignment between the stationary and rotating elements of the machine. The outcome? Poor performance and elevated levels of vibration are factors that can often lead to premature failure of the machine.

The prevalence of soft foot scenarios, though widespread, finds common ground in four-footed electric motors. Within this realm, soft foot can manifest in two key categories: non-coplanar feet and individual feet that are not flat. For the latter, corrosion damage presents a particularly challenging issue. Unlike shimming, corrosion damage necessitates a more extensive approach, demanding re-machining of the feet to rectify the effects of a soft foot condition.

Effective detection is the foundational step in addressing soft foot dilemmas. An array of methods exists, but one of the most robust entails inserting feeler gauges between each foot and the base foot pad. This technique is simple to perform and the absence of elaborate setup, rendering it an essential practice during machine installation or reinstallation.

Shaft alignment instruments can double as tools for soft foot detection. This is especially convenient given that similar equipment is employed for both situations. One technique involves selectively loosening a single foot bolt and monitoring the corresponding movement signalled by the shaft alignment indicators. Although this approach may provide insights into potential soft foot existence, it is not recommended for actual correction. A more effective alternative involves leveraging dial test indicators, which are instrumental in achieving accurate and efficient soft foot correction.

Soft foot correction, while pivotal, necessitates distinct strategies for varying scenarios. Two common manifestations are diagonal soft feet and single soft feet. Diagonal cases often stem from short feet, where shimming and removal of shims play a crucial role in correction. Conversely, single soft foot situations are often indicative of bent or angled feet, demanding a more intricate correction process involving profile measurements and fabrication of staggered shims.

A general guide and recommendations for shims are:

• Shim area should be at least 80% of the foot area.
• Shims over 0.020″ (0.51 mm) should be measured for accurate thickness.
• The total shim stack’s thickness should be measured.
• A maximum of five shims per foot (excluding angle correction) should be used, with at least one shim over 0.003″ (0.08 mm) thickness.
• The combined thickness of the three thinnest shims should be 0.010″ (0.25 mm) or more.
• No more than five stepped shims should be applied in one direction.
• Detecting and resolving soft foot challenges during machine installation offers manifold benefits. It streamlines shaft alignment procedures, curbs frame or casing distortions that erode machine efficacy, mitigates heightened vibration levels, and ultimately secures machinery’s operational longevity. In an arena where precision reigns supreme, addressing soft foot emerges as an indispensable endeavour.

For further information or advice on soft foot correction call CPM Engineering on 0161 865 6161 or email info@cpm-uk.com or find out more about our services.

The post The Importance of Precision Alignment: Detecting & Resolving Soft Foot Challenges in Machinery appeared first on CPM Engineering.

This gives cost certainty to our customers and incentivises both the plant operator and the service provider to work together to achieve greater levels of cooperation, to make sure production levels are maintained, and downtime is minimised. One of our customers made the switch after CPM developed a solution for recurring failures which had been ongoing for several years.

The issue was that many of the cooling fans on the site were failing, and with around 200 fans of various makes and models in operation across the plant, many in difficult-to-reach locations and needing a mobile crane to replace, the cost of failure was high.

Initially, we dealt with each failure as it arrived, identifying the make and model of the fan then diagnosing the faults, and repairing the unit.

Due to the wide range of fans, there was often a requirement to order parts which could take up to a week, this downtime coupled with the crane hire, maintenance hours and repair costs made failures expensive, resulting in production losses and valuable time lost.

With a large number of fan designs on-site, it was not practical for our client to stock all the spares for each type due to the cost and space needed, expense, and uncertainty over failure rates.

It became clear this was an ongoing issue and becoming ever more disruptive. We approached our customer and opened a discussion as to how the problem could be addressed, it was apparent the failures were a result of the environment in which the fan operated, and the huge variety of fans on site only complicated matters further.

With our commitment to being a solution provider, we were not satisfied with offering a basic repair service. We knew we could assist in improving the client-side approach to maintenance, using our knowledge of the solutions available, and our experience of the practical implementation of these solutions.

To keep repairing or replacing the fans on a like-for-like basis merely allowed the issues to continue. Our aim was simple, reduce failures, limit the range of fans in use to streamline maintenance, and reduce spare part inventory.

To do this we developed a bespoke interchangeable fan design which would enable flexible configuration of the production line, whilst allowing production to continue unchanged. We applied condition monitoring techniques, and coupled with our experience our team was able to identify the root cause of the failures (RCF). The main issue was a build-up of material on the fan blades causing unbalance which in time caused bearing damage and subsequent shaft wear to the 75KW electric motor.

The production line (in a mineral processing plant) had high levels of airborne particulate, and as the air moved through the system this material was bypassing the filtration systems and coating the fan blades.

This increased the weight of the fan, with material settling on different areas of the fan blades, for example, a larger accumulation at the root where the rotational speed is slowest, with accumulation of the mineral increasing the weight of the fan by around 10-15%.

While this may not sound like much, fans are precisely balanced to operate at maximum efficiency, and motors are designed to operate at particular speeds with a stated load, changes to these parameters can greatly affect performance, efficiency and lifespan.

Further to additional rotating load, the moment of inertia is larger during start-up, drag increases, and uneven distribution of the additional weight increases strain on the shaft and bearings, leading to repeat failures. It was clear that the build-up of the mineral on the fan was the main cause of the problem and any solution we provided would need to address this issue first and foremost.

CPM redesigned the fan unit, sourced and applied a low friction coating to the fan blades, and made changes to the cowling, seals and motor cooling system to improve the IP rating.

Further to these alterations we devised a standardised coupling for the fan which allows two different fan sizes to be fitted to the existing motors, eliminating the need for major changes to the motor sets.

The coating proved to be a success as the mineral was no longer able to stick as easily to the fan blades, and therefore the fans were able to operate much longer than previously before needing to be cleaned or changed.

Not only have failures been reduced but as CPM now holds fans in stock as part of our fixed-price service, the change-outs can be undertaken in just a few hours.

Additionally, the interchangeable fans allow production capacities to be altered quickly and easily and have added a new dimension of flexibility to the operation of the plant. The savings for the client from this project have been huge, not only do they save on maintenance hours and plant hire, but downtime as a result of the fan failures has been drastically reduced.

If you would like to learn more about our fixed price service contracts, condition monitoring or how CPM can provide a solution to streamline your maintenance activities contact one of the team today.

This post was originally published in March 2015 and was updated September 2023.

The post Low friction coating proves a solution to repetitive failures appeared first on CPM Engineering.