Engineering Maintenance for Machine Safety

Machines are an important part of modern society. They are needed in almost all walks of life from small machines such as coffee grinders to the massive industrial machines which manufacture our consumer products. All of these machines need to be properly maintained in order to ensure that they continue to work correctly. Without this machine maintenance, the devices could break down, stopping production and sometimes risking the health of the people operating them. In large industrial machines, engineers need to regularly maintain the system, often stripping it down and inspecting every part.

Engineering Maintenance is a discipline which ensures that machines are serviced and maintained regularly. This practice helps to ensure machine safety, helping to keep it running for longer and preventing accidents which could seriously damage the business. By regularly arranging machine maintenance, whether it needs repairs or not, companies keep their tools working for longer and ensures that they comply with government health and safety directives. Effective Engineering maintenance should be performed at a time when the machine is not needed for quick jobs, in order to allow the engineer to closely inspect the device and ensure that it is in good working order.

As well as ensuring machine safety through the inspection and maintenance of the machine, workers need to be protected against the possibility of harm. Engineers can help in this process by installing custom-built machine security guards. These are designed to defend the operator against flying parts or broken pieces from the production line. Working rather like riot shields, these machine security guards deflect the pieces causing them to fall harmlessly to the ground. With new health and safety laws being implemented every year and with people struggling to catch up with the latest design improvements in machinery, these safety guards have become an important part of factory life.

By operating a regular engineering machine maintenance schedule owners of factories can ensure their productivity and the safety of their workers. Machines which are serviced regularly will last for many years and the production line will continue to function. Regular inspections, either yearly or bi-yearly, will allow the engineers to spot problems the minute that they occur and also guarantee that the machines will keep working. Breakdowns cost an industry hundreds of thousands every year and there is no alternative to maintenance. The cost of an annual inspection, even if it means shutting off part of the production, is nothing compared with the cost of losing several weeks work due to the failure of a machine. Keeping the maintenance regular will also keep the machine working safely, which is vital if owners and managers of factories which wish to keep their business running.

NFPA 110 Requirements for Transfer Switch Maintenance

The National Fire Protection Association (NFPA) develops and maintains minimum safety standards for commercial and large residential buildings. Expressed as safety codes, the standards address the safety of various building systems, including emergency power supply systems (EPSS). Requirements for EPSS maintenance inspections are contained in the NFPA 110, which also addresses generator testing. Below are requirements for generator transfer switch maintenance according to the NFPA 110.

Transfer Switch Maintenance Requirements
The following is an overview, not a complete documentation, of transfer switch inspection requirements. For full documentation of NFPA 110 requirements, building managers should contact the NFPA, or an emergency power solution provider.

Maintaining a transfer switch is a critical part of generator maintenance. The NFPA's inspection requirements for switches for Level 1 and Level 2 generators are as follows:

Examination for Overheating
Overheating eventually produces visual evidence, particularly the discoloration or blistering of insulation found on conductors. The surfaces of conductors may also show signs of pitting or melting. These signs may be the result of arcing, and usually precipitate repairs and/or parts replacement.

Examination for Dust and Dirt
Regardless of the cleanliness of a generator room, dust and dirt gradually accumulate on the surface and inner workings of switches. Removing dust and dirt prevents their accumulation from sabotaging electrical connections and contacts.

Examination of connections
If the electrical connections of a switch malfunction, it will not transmit the signal to initiate generator startup. Connections should be inspected for looseness and signs of overheating. If looseness or overheating is detected, connections should be tightened or replaced.

Examination of contacts
Contacts should be inspected for looseness, signs of corrosion, and overheating. Signs of corrosion may appear as oxidization or acidic deterioration, and overheating may leave carbon traces. If the first two signs are present, contacts should be replaced. If the third sign is present, further examination should occur.

The inspections above are recommended on an annual basis. However, the 2005 edition of the NFPA 110 recommends them on a quarterly basis, with a single major inspection and three minor inspections every year. This inspection schedule could be valuable for buildings that require constant electricity to support critical functions, such as hospitals, data centers, and first response organizations.

Scheduling Transfer Switch Inspections
Maintenance and testing requirements for transfer switches are contained in Chapter 8 of the NFPA 110. Section 8.4.5 states that a "properly instructed individual" (i.e. a person with extensive training in EPSS examination procedures) should oversee routine EPSS inspections. If you do not employ a worker who is trained in EPSS inspection, hiring a commercial power solution provider that specializes in emergency power equipment testing and inspection is the best option.

In addition to performing the inspections above, a commercial power solutions provider may also perform infrared scanning-a preventative maintenance measure that identifies problems in EPSS components before they cause more extensive problems. Other services performed by a commercial power solutions provider include: retrofits and modernization measures, breaker testing, new installations, repairs, arc flash analysis and training, healthcare utility management, generator rentals, scheduled maintenance, and load bank testing.

Welding Tips for Plant Maintenance

Maintaining a plant can encompasses many tasks, welding typically plays a significant roll. As welding repairs may not occur on a day-to-day basis, here are some tips to ensure that your welding skills are kept up to par.

1. Safety.

First you must ensure that you have read the instruction manual for your equipment. This will include important safety information plus instructions to get the most out of your welding equipment. Even if you're only doing a quick weld, you should wear the proper safety equipment: welding gloves, non-flammable pants and shoes, welding jacket, beanie or hat, and proper welding helmet. You should also cover all exposed skin to avoid effects of arc rays. You should also try not to breathe in any of the welding fumes as it can be quite hazardous to your health. Another excellent tool is a helmet that automatically darkens. This way you can position your gun or electrode without having to remove your helmet.

2. Preparation.
You should always wipe the area that you're going to weld first before starting. This will ensure the best quality of weld. It is common for plant welders to use one wire for MIG welding. The one with the most flexibility is.035 in. along with a 75/25 Argon gas mixture. Your contact tube, gun liner and drive rolls should always match the wire size you are using. You should also clean the gun liner and drive rolls every once in a while, and keep your gun nozzle clean of spatter. The contact should be replaced if it is blocked or not feeding well. Stick welding usually calls for a 3/32 in. diameter for material that is one-eighth of an inch or thinner and a one-eighth diameter rod for anything larger. The common electrodes are 6010, 6011, 6013, 7018 and 7024. If you are working on higher strength steels, you should use a 7018 rod. This will also present a better bead appearance.

3. A good weld.

One of the most important things to making a good weld is the position that you hold the gun. Always find a comfortable position that will allow you to use both hands to steady the gun if necessary. If you are making an especially long weld, it is always a good idea to rehearse the weld beforehand so that you can keep up a steady travel speed, arc length and electrode angle. To create a good weld, you must also keep a steady speed along the length of the weld, as going too fast or going too slow in certain spots will be obvious on the weld when complete.

For all your plant welding needs contact Ace Custom Fabrication today. Our team of certified welders will ensure that your project is completed quickly and efficiently.