Many tasks essential to installation, troubleshooting, and repair are routinely done as maintenance tasks. In many cases, performing those as maintenance tasks squanders limited maintenance resources while introducing human error that can cause additional unplanned downtime.
Here are three examples of instrumentation that can replace manual maintenance testing.
• Point-to-point voltage measurements. If checking voltages must be done routinely, why would you want someone manually taking measurements while exposed to live conductors or terminals if you don’t have to? One solution is to install panel-mounted voltmeters for local indication. Another is to install voltmeters that connect to your network for remote indication.
• Manually testing connection tightness. Some people think it’s a good idea for the PM to include the task “Tighten connection if loose.” This is typically interpreted as “Put a wrench on the connection and force it a little tighter.” What normally happens is a perfectly good connection goes bad due to overtorqueing. One (expensive) solution is to replace all the hardware and make a new connection. A more practical solution, if you can get the downtime approved and don’t mind all the lockout/tagout hassle, is to use a resistance tester across each connection. Infrared thermography is usually your best “connection checker.”
• Alignment checks. Realignment can be costly. Vibration monitoring makes this necessary only if there’s a problem.
