Machinery wear is an unavoidable aspect of operating mechanical equipment. However, organisations should still look to minimise the rate at which components deteriorate, by putting in place the right maintenance strategy.
Understanding the primary causes of wear, as well as adopting proactive measures such as the use of quality machinery protection products like oils, greases, and other lubricants, can help reduce friction, slow down wear, and boost asset lifespan.
Table of Contents
- 5 Reasons Why Equipment Becomes Worn, And the Steps to Reduce It
- Inadequate or Incorrect Lubrication
- Contaminants Such As Dirt, Dust, And Moisture
- Misalignment, Imbalance, And Improper Installation
- Overloading And Excessive Operating Stress
- Corrosion And Chemical Attack
- Final Thoughts: Don’t Allow Rapid Equipment Wear To ‘Just Happen’
5 Reasons Why Equipment Becomes Worn, And the Steps to Reduce It
Machinery wear occurs as a result of surfaces or components gradually deteriorating through contact, movement, environmental exposure, or other conditions.
A broad range of components can be affected by wear, including (but not limited to) bearings, gears, shafts, seals, chains, or belts.
In some cases, deterioration happens slowly enough to be noticed during routine inspections. However, there can also be instances of excessive wear leading to rapid and sudden equipment failure.
The specific causes of machinery wear can vary greatly. Facilities teams and maintenance engineers need to be familiar with the potential causes of such issues, not least because simply replacing a worn component may not resolve the problem.
The below list of common causes, and ways to slow down the rate of machinery wear, should not be treated as exhaustive:
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Inadequate or Incorrect Lubrication
The most common driver of wear is friction. When moving parts don’t have the right lubricant film applied to them, metal-to-metal contact will generate heat, scoring, and progressive damage to surfaces.
However, failing to apply enough lubrication isn’t the only potential issue. Over-lubrication can be a cause of machinery wear too, because of how it can attract contaminants and increase drag.
To minimise this cause of machinery wear, organisations should select lubricants that are well-matched to the given application. It is also important to follow manufacturer-recommended intervals and quantities. The monitoring of lubricant condition through regular sampling and analysis can further help detect degradation.
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Contaminants Such As Dirt, Dust, And Moisture
Contamination can be a particularly frequent challenge when it comes to the maintenance and operation of machinery in parts of the world with variable climates, such as the UK.
If abrasive particles and moisture are allowed to take hold, these contaminants can speed up wear by embedding in surfaces or breaking down lubricant films.
To minimise this cause of machinery wear, organisations should look to fit effective seals, breathers, and filtration systems on the gearboxes, bearings, and hydraulic circuits for which they are responsible. They should also maintain clean working environments and use protective covers where practical.
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Misalignment, Imbalance, And Improper Installation
Uneven loading can happen when shafts are misaligned, rotating components are imbalanced, or assemblies are incorrect. This can lead to such issues as accelerated bearing wear, shaft fretting, and vibration-related fatigue.
Poor installation practices or foundation settlement, as can frequently be an issue in older industrial buildings, may exacerbate the problem.
To minimise this cause of machinery wear, teams are advised to use precision alignment tools during installation and after major maintenance. They should also take care to balance rotating equipment and check for soft foot or foundation issues.
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Overloading And Excessive Operating Stress
The running of machinery beyond its design limits, such as through prolonged continuous duty, heavier loads, or higher speeds, can also spell bad news for equipment in the long run. This might manifest in such significant issues as plastic deformation, fatigue cracking, and accelerated abrasive wear.
Machinery can be pushed hard by the often extremely high demand pressures in the manufacturing and logistics sectors.
To minimise this cause of machinery wear, organisations should respect rated capacities and avoid sustained overloads. Putting in place the right process controls or load-monitoring systems, as well as upgrading components where operational demands have increased, can also make a big difference.
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Corrosion And Chemical Attack
Particularly across coastal sites, chemical plants, or food and beverage facilities, there can be a high risk of moisture, process chemicals, cleaning agents, or corrosive atmospheres degrading surfaces and promoting pitting or fretting corrosion.
To minimise this cause of machinery wear, technicians can make sure they select corrosion-resistant materials or protective coatings for settings where they know exposure will be high. It is also important to control humidity where possible, alongside the use of lubricants and greases with robust anti-corrosion additives.
Final Thoughts: Don’t Allow Rapid Equipment Wear To ‘Just Happen’
Machinery wear can occur due to a broad range of factors. Yes, some degree of wear is inevitable. However, this should not be used as an excuse to neglect the maintenance practices that could greatly help slow down such wear.
By taking a systematic approach to tackling the root causes of equipment wear, organisations can put themselves in a strong position to reduce unplanned downtime, improve energy efficiency, and extend the service life of critical assets.