The newest trend among modern day industrial operations is a focus on total plant health through the use of proactive maintenance services, which improves the availability of individual machines and boosts the reliability - and therefore the productivity - of the plant.

Key elements of any condition-based monitoring are oil analysis, vibration and thermography; while proactive maintenance enhances component health through alignment, balancing, oil filtration and purification.

With the recent formation of its reliability services division, WearCheck has positioned itself as the only company in Africa – and one of only a handful globally – that can provide a complete condition monitoring service to the mining, power, pulp and paper, sugar, manufacturing  and other industries.

The philosophy of optimal plant maintenance has evolved significantly over the years, with each subsequent approach ensuring longer component life, greater plant reliability and fewer breakdowns with a strong focus on being cost effective rather than cheap.

Originally, plant operators used preventative, or time-based, maintenance, where machine parts were simply replaced as soon as they reached their life expectancy, regardless of their condition.

The predictive maintenance approach came next, where routine monitoring of the real conditions of the machinery components could reveal early failure, giving plant managers the chance to react timeously and avoid breakdowns. According to WearCheck’s reliability solutions manager Philip Schutte, ‘If you can’t plan it, you can’t control it.’

The latest approach - proactive maintenance - is the search for ways to extend the life of components to prevent premature failure, thereby boosting general plant health.  Says Schutte, ‘Any good proactive maintenance programme will boost both plant availability as well as plant reliability.’

Some of WearCheck’s reliability solutions services include alignment, balancing, oil filtration and purification. Pictured here is WearCheck technician Shiven Brijlal taking a vibration reading on an industrial vent fan.

For further information on total plant health and reliability services, please visit www.wearcheck.co.za, or contact Philip Schutte on (011) 392 6322.

Technical Bulletin 56 explores the properties of acids and bases and their influence on lubricants. The importance of assessing acids and bases is discussed, as are the methods of assessment, and the positive and negative effects of acids and bases on industrial and mobile equipment.

Using the analogy of ‘Spy vs. Spy’ (the 1960s cartoon from Mad Magazine), the acid base chemistry of lubricating oils is clearly explained.

Click here to download Technical Bulletin 65

Monitor 65 is filled with stories on important milestones in WearCheck Africa’s world, the burgeoning wind industry, the latest from the international oil analysis scene and useful technical information.

Some of articles featured include: yet another WearCheck diagnostician notches up her millionth sample; an in-depth discussion on Total Base Numbers (TBN); a handy lube tip and news of WearCheck’s bismuth first.

The Reliability Solutions team is introduced, and there is news of local and international quality accreditation.

The 2013 dates for oil analysis training courses appear in this issue of Monitor – make sure you book early, as places fill up fast.

Click here to view Monitor 65.

One million . . . and counting!

In February, senior diagnostician Steven Lumley became the fourth member of the WearCheck diagnostics team to have diagnosed a million oil samples. She joins diagnostic manager John Evans and diagnosticians Rowan Maartens and Michelle Allis in reaching this milestone.

‘There are very few oil analysis departments anywhere in the world that can boast this level of experience. The WearCheck department consists of seven diagnosticians with a combined 120 years of experience and over seven million samples between them,’ says diagnostic manager John Evans, who has spent the last thirty years in the oil analysis field.

‘It is important to note that with this degree of expertise, there are very few things that the group has not seen before or can't explain. It also means that should something start to go wrong, either mechanically or with a lubricant, the team will become aware of it very quickly and can aid customers, OEMs, and oil companies alike with a wealth of statistical data and advice.

‘Knowing whether the problem is restricted to a particular machine, or developing on other sites or with other customers on a local, national or global scale can be enormously useful. Our database contains data on almost ten million oil samples and that is a real treasure trove of information,’ said John.

Senior diagnostician Steven Lumley (centre, standing) of WearCheck recently diagnosed her millionth sample. In reaching this milestone, she joins diagnosticians Rowan Maartens (left) and Michelle Allis (inset) and diagnostic manager John Evans (seated at microscope)

In just 5 days we see the kick-off of the largest and longest rugby tournament in the Southern Hemisphere.
WearCheck has made it easy for you to follow your team’s progress with a viewing schedule highlighting all the matches and television times.

Click here to download (2.4MB)

Oil – an asset, not a consumable 

In previous years, oil was considered merely a ‘consumable’.  However, with the all-important focus on boosting the bottom line, it makes sense for businesses to treat oil as a valuable asset and manage it accordingly. 

In Technical Bulletin 55, WearCheck’s diagnostic manager John Evans presents a practical, seven step management programme for oils, and discusses key factors in gaining the maximum benefit from a maintenance programme – including the handling, storage, dispensing and disposal of lubricants.

Click here to view Technical Bulletin 55

News of our two brand new laboratories, the acquisition of ABB’s condition monitoring division, a new branch in the Northern Cape, the launch of the first Wind Turbine test kit, exhibits at Electra Mining and Windaba . . . these are just some of the stories that are featured in the latest edition of the WearCheck Monitor newsletter.

On a practical note, you will find advice on oil additives for extreme conditions, as well as ‘who’s who’ in the new reliability solutions division, and the winner of our lucky draw prize in the customer survey.

The 2013 training course dates appear in this issue of Monitor, and a new location for on-site training is added to the growing list.

We would like to take this opportunity to wish all our customers, staff, colleagues and friends a wonderful, relaxing festive season, followed by a prosperous year in 2013. Remember – WearCheck is open throughout the festive season to process samples.

Click here to view Monitor 64

The African Cup of Nations is just around the corner. Commencing on the 19^th of January 2013!
To build up some hype and to show our support we have created a Viewing Schedule highlighting all the matches and times so you can keep track of your teams progress.

Click here to download (1.1MB)

South Africa-based oil analysis specialists WearCheck recently acquired the Condition Monitoring division of ABB, making WearCheck the only company in Africa - and one of only a handful globally - that can provide a highly sophisticated, complete condition monitoring service to all industry and mining.

The acquisition of the ABB division fits into WearCheck’s strategy to offer a complete industrial condition monitoring solution – which also includes the analysis of heat transfer, turbine and transformer oils.

The former ABB division was responsible for most of the condition monitoring carried out by ABB in the fields of vibration analysis, infrared, laser alignment, shaft balancing and oil analysis, which WearCheck had been doing on behalf of ABB for a number of years. This business unit has been incorporated into WearCheck’s recently-formed Reliability Solutions division, adding significantly to their capability in this field, and transforming WearCheck into a ‘one-stop shop’  for condition monitoring.

All current ABB condition monitoring contracts and staff are in the process of being transferred and welcomed into WearCheck.

Neil Robinson, WearCheck’s managing director, is quick to assure all ABB condition monitoring customers that the transition to WearCheck will be a seamless one. 

‘We are committed to honouring all existing ABB contracts, and aim to exceed our new customers’ expectations. In addition, the ABB customers will now have access to WearCheck’s vast range of alternative predictive maintenance products and services.

‘Our customer services team is on standby to handle any queries, and we look forward to welcoming all new customers to WearCheck.’

Robinson is optimistic about the integration of the new division into the WearCheck business model, which is characterised by advanced analytical technology, custom-designed systems and processes, coupled with a strong service ethic and decades of experience. ‘We welcome all the new staff members, and hope they will enjoy long and successful careers with WearCheck. Most of the new staff will stay where they are currently based and some will join our Isando and Middelburg offices.’

Gavin Howard, Minerals and Mining Services Manager of ABB, would like to thank their existing condition monitoring clients for their support over the years and will be grateful if they would afford WearCheck the same loyalty and support.

‘We are confident that the new enterprise will service the industry well,’ says Howard.

WearCheck is currently one of the largest oil analysis companies in the world, operating seven laboratories, employing 161 people, and with a presence in eight countries (South Africa, Zambia, India, Dubai, Madagascar, Mauritius, Zimbabwe and Namibia).

Future expansion plans include laboratories in several key African countries in early 2013 – with the aim to support our customers as they too build their businesses in Africa.

WearCheck’s oil and speciality laboratories serve a cross-section of industry sectors, including mining, earthmoving, aviation, marine, transport and electrical organisations and major industrial plants such as paper mills and refineries.

WearCheck’s reliability solutions manager, Philip Schutte, has integrated the highly-skilled ABB team into WearCheck’s reliability solutions division, which has boosted the range of thermography and vibration maintenance solutions on offer.