A New Era of Equipment Preventive Maintenance
10/23/2024
By Jay Holt, PE & PMP
Director of Engineering & Assets
Engineered Rigging
What if you could prevent an employee injury or work stoppage? Chances are, you’d grab the opportunity with both hands. You might be surprised to discover that a systematic approach to equipment maintenance can help you safeguard your workers and unlock a host of additional benefits. Let’s look at some sobering statistics, the business case for preventive equipment maintenance and how dynamic testing is a game changer in optimizing worker safety and equipment performance.
The Risk Is Real
When it comes to equipment, damage that looks minor has the potential to put your workers at serious risk. For example, a worn hose on a hydraulic cylinder may not seem especially critical. However, oil under 10,000 pound per square inch (psi) pressure escapes a hose with a speed of 1,200 feet per second and can cause what is known as a high-pressure injection (HPI) injury. HPIs require immediate medical attention. In fact, the average amputation rate from a fluid leak injury is 48%, and with pressures greater than 7000 psi, the amputation rate approaches 100%.
You may be wondering: How common are workplace injuries? According to OSHA, there were 169,600 injuries in the construction industry in 2022. Furthermore, the U.S. Bureau of Statistics reports “injuries resulting from contact with objects and equipment is the third leading cause of work-related death,” with 738 reported fatalities in 2022.
In addition to the physical harm caused to employees, workplace injuries are extremely costly. The National Safety Council estimates that the total cost of preventable workplace injuries across all US industries was $167 billion in 2022. These costs include medical expenses, workers’ compensation costs, OSHA penalties and more. Preventive equipment maintenance helps mitigate the risk of safety incidents and their consequences.
The Business Case for Equipment Maintenance
There are two types of equipment maintenance. Reactive maintenance occurs after the equipment malfunctions or breaks down. Preventive maintenance is a proactive approach that includes regularly scheduled inspections, service and testing. Let’s look at the difference and cost analysis.
When equipment breaks down during a project, unexpected costs are a given. Often, you may not have spare equipment in your fleet or replacement parts on your shelves, which extends the work stoppage. Not only is there employee downtime and lost productivity, but other equipment is idle until work can resume. There is no denying that equipment failures can ruin carefully planned project schedules, lead to missed deadlines and a blown budget.
“Reactive maintenance is always more expensive than preventive equipment maintenance,” explained Nick Darlage, Engineered Rigging’s Director of Projects. “In addition, preventive maintenance can maximize the service life of your equipment. Given that heavy lifting and specialized transport equipment can cost tens of thousands or even millions of dollars, preventive maintenance essentially helps you protect your investment.”
The good news is that preventive equipment maintenance helps reduce the risk of equipment failures and worker injuries—and it is more affordable than you might think. In fact, workplace safety experts estimate that construction companies save more than $4-$6 for every $1 they spend on workplace safety. In addition, Upkeep reports that running a piece of equipment to the point of failure could cost up to 10 times more than a proactive maintenance program. Preventive equipment maintenance is a critical component of workplace safety, and it delivers an impressive return on investment (ROI), which makes it a sound business strategy.
Components of a Preventive Maintenance Program
For a preventive maintenance program to be effective, it must be routine and instilled in everyone who uses or maintains the equipment. Consistency and repetition are essential to ensure the equipment’s performance, safety and longevity. Record keeping helps to keep everyone on the same pages and is another important component of preventive maintenance. Documentation allows you to monitor compliance with your maintenance program and track manufacturer recommendations for service.
“By making safety everyone’s business, you will create a system of checks and balances. Set expectations early and regularly remind everyone of the consequences of equipment failures,” shared Jesse Faulconer, Safety Specialist at Engineered Rigging.
Before every use, a comprehensive visual and functional inspection should be conducted to identify concerns. The specifics will vary based on the machine, but a general check list (before the equipment is turned on) includes:
- Clean all surfaces
- Check filters
- Tighten all screws, nuts, bolts and clamps
- Check welds and look for corrosion
- Identify any damaged, worn or missing components
- Empty drip pans and determine possible leak sources
- Ensure all hoses, wires and couplers are properly connected
- Evaluate fluid levels and ensure there is no dirt, water or other foreign substances
- Assess for damage caused by heat, chemicals or contamination which may affect seals
Once the visual inspection is completed and any issues are addressed, the operator should turn on the equipment and conduct a functional test:
- Ensure equipment functions normally. If present, check control buttons, valves and safety items such as e-stops.
- Check gauges to ensure temperature and pressure are within safe operating parameters.
- Inspect the hoses and valves for leaks.
- Monitor for unusual running noise.
Depending on the equipment and duty cycle, more in-depth service should be scheduled quarterly, semi-annually and/or annually or as required based on application. High-powered hydraulic equipment should be rigorously tested every 12 months to optimize safety and performance. Why? Normal wear and tear can lead to equipment malfunctions that may not be identified during a visual inspection. By incorporating dynamic testing into your high-powered hydraulic equipment maintenance program, you can identify issues that may otherwise go unchecked.
All Equipment Testing Is Not Equal
What Is dynamic testing? Dynamic testing of hydraulic equipment simulates a maximum load situation (105% of capacity) in a controlled environment to detect any internal scratches or damage to the hydraulic cylinder that could cause leaking or failure. During dynamic testing, the cylinder is pressurized for the full stroke giving proof that the equipment worked properly in the shop and is able to lift the required tonnage. In contrast, static testing only pressurizes the cylinder at a set number of levels, typically three, which can allow performance issues to go undetected. Dynamic testing is a game changer for identifying hidden issues and optimizing safety.
Dynamic Vs. Static Testing
Engineered Rigging recently upgraded our Equipment Testing & Service Center in Russellville, Arkansas to offer dynamic testing of hydraulic cylinders, pumps and other high-pressure hydraulic equipment. Clients can ship their equipment to our facility to be tested and serviced, which provides a convenient and affordable option. The dynamic testing conducted by our highly trained technicians includes four steps:
- A rigorous, multipoint visual inspection of all system components including pumps, hoses, manifold, etc.
- A dynamic test which simulates a maximum load and tests the cylinder across the entire stroke in a controlled environment.
- Repair or replacement of any worn or faulty components.
- A thorough cleaning of the equipment so it is returned to you looking its best and operating in top condition.
Upon passing the dynamic testing process, Engineered Rigging issues a Safety & Performance Tested Certificate which can be added to your equipment maintenance records.
When it comes to equipment safety, reliability and performance, preventive maintenance is a business imperative. Not only does it help protect equipment operators from injury, but it can also prevent equipment breakdowns that lead to unexpected project interruptions. Plus, it maximizes the service life of your equipment. With a preventive equipment maintenance program in place, everyone wins.
