In the effort to improve reliability the focus is typically on the assets presently being operated. Management is continuously trying to determine how and what we need to do to maintain our assets. We look at Failure modes and effects, determine criticality, develop asset strategies, perform countless hours of condition monitoring, and so on and so forth. One component in all of this that is typically not even considered is; when we have a failure is our spare going to be reliable? Have we done a good job maintaining our spares? In most cases the answer is no.
Your spare equipment is not as important as the equipment running, UNTIL YOU NEED IT. Think about this for just a moment. Does maintaining your spares make sense? We have been performing these type inspections for over ten years and typically 20% of the capital spares we have inspected are already in a failed state. Is this the kind of reliability you are expecting?
What is capital spares preservation?
Capital spares preservation is the process of maintaining and protecting spare equipment so that it is fully reliable when needed. This includes inspections, proper storage, lubrication, and preventive measures that prevent spares from failing while sitting idle.
Why is it important to maintain spare parts?
Many plants assume that stored spare parts are “ready to go,” but studies show that up to 20% of inspected spares are already in a failed state before use. Without proper care, spares can degrade due to improper storage, corrosion, contamination, or lack of rotation. Preserving spares ensures that backup equipment is ready when you need it most.
What problems can occur if spares are not preserved?
Common issues include bearing failure, dried seals, electrical degradation, corrosion, and lubrication breakdown. If a non-preserved spare is installed during an emergency, it could fail immediately leading to extended downtime and higher costs.
How does Reliability Solutions perform capital spares preservation?
Our process includes:
- Video scoping internals annually to detect hidden issues
- Filling with oil and preservatives to prevent corrosion
- Performing quarterly rotations to keep parts lubricated and functional
- Providing detailed inspection reports with photos for complete visibility
Can you also help with storing smaller spare parts?
Yes. Beyond large capital spares, we also audit storage areas and provide recommendations for extending the life of bearings, belts, shafts, and electrical components. Proper handling and storage practices are key to long-term reliability.
What are the benefits of a spares preservation program?
- Peace of mind knowing your spares are ready to run
- Reduced downtime during unexpected failures
- Lower repair and replacement costs
- Extended lifespan of spare assets
- Increased overall plant reliability
How often should capital spares be inspected or rotated?
We recommend video scoping at least once per year and quarterly rotation for equipment. This proactive approach ensures spares remain in operable condition and avoids surprises during emergencies.
How can I get started with a spares preservation program?
Contact our service team at [email protected] or call (251) 490-2999. We can perform a sampling inspection of your current spares and provide recommendations for managing and maintaining your spare asset inventory.
HOW WE DO IT
Our process consists of video scoping the internals of your spares yearly, filling with oil and a preservative, and performing rotations on at least a quarterly basis. We then provide a detailed report of every unit inspected with photo’s so you can actually see the condition of your spares. The peace of mind and reduced down time because your spares will be ready to run is a very important part in the journey to Reliable Manufacturing.
We can also perform an audit of your stores area and make recommendations to improve the way you are storing and handling other parts to maximize their life such as bearings, belts, shafts, electrical components and others.