In addition to significant maintenance costs,rotating machinery stoppages can prove very expensive in the event of a plant or process shutdown. According to insurance statistics, more than 50% of the malfunctions and failures in newly acquired turbomachinery are attributed to manufacture faults related to design, material or manufacturing.
Two strategies, therefore, may serve to maximize productivity and reduce costs: During operation, execute optimized maintenance technology such as reliability centered maintenance (RCM) based on condition monitoring and diagnosis; and when procuring machinery, engaging in retrofit upgrades, correcting failed or worn-out machines execute an Integrated Reliability Engineering and Audit (IREA) program.
An IREA can be of assistance in preparing specifications, can analyze and review a manufacturer’s process, material selection and management practices. It can also serve to provide acceptance decisions based on mutually agreed acceptance criteria, offer suggestions or recommendations for manufacturing improvements and provide a useful maintenance database.