In the world of Industrial equipment, maintaining optimal performance is crucial for operational efficiency and cost-effectiveness. We sat down with Mike Piazza, Air Handling Manager, to learn more about ProcessBarron’s IAQ inspection process.
IAQ stands for “Inspect, Advise, and Quote.” The systematic approach supports plant managers and leadership looking to maximize their equipment’s lifespan and performance.
The Basics of the IAQ Program
The IAQ program is ProcessBarron’s unique approach to equipment inspection and maintenance. Through thorough inspection, expert advice, and transparent quoting, ProcessBarron identifies potential issues with equipment/machinery and provides a tailored suggestions on options, including help deciding whether to replace, rebuild or repair.
This inspection aims to determine if the equipment is repairable, to identify which components need repair, and to assess which parts can be reused. The systematic approach helps clients maintain optimal equipment efficiency, reduce downtime, and make informed decisions about their industrial assets.
With quick turnarounds, around the clock service, a machine shop and stock materials on hand, ProcessBarron is equipped to handle everything our customers need better.
The IAQ Process: A Step by Step Guide
Regular inspections ensure equipment is working as designed. Based on project history, the ProcessBarron team can predict wear life and help schedule maintenance. Additionally, experts are skilled at identifying components that maybe wearing out, and detect signs of corrosion or erosion. These issues often indicate that surrounding equipment is not functioning properly.
The typical IAQ process follows these steps:
- Initial Consultation/ On-Site Inspection: The ProcessBarron team gathers information such as:
- Site Specific Details: application, types of fans and screws used to convey specific materials
- Performance parameters of the original design: speed, operating temperature, and special material types
- Visual inspection: to determine if repair is worthwhile (if severely damaged, we recommend replacement to be more cost effective.)
- Equipment history and lifecycle: How long has the equipment been running? (Some need annual replacement, while others can last several years.)
- Equipment Delivery: A customer’s equipment is delivered to ProcessBarron’s facility.
- Quality Control Inspection: Skilled Quality Control team examines the equipment, assessing its condition and identifying any issues that require attention.
- Comprehensive Reporting: A detailed report is created, outlining all necessary repairs.
- Estimate Provision: Based on the inspection results, the team provides the customer with an accurate estimate for the required work.
- Repair Assessment: The team determines whether the equipment can be repaired, which components need repair, and which can be reused.
Mike explains, “Our IAQ process is a team effort. We have in-house estimators who assist in getting equipment to our shop for inspection. Once the equipment arrives, our shop employees move and clean the equipment as needed throughout the process. Then our quality control team thoroughly inspects it. The estimators then take the results from the shop inspection and develop a proposal for the customer.
In the interview, Piazza highlighted that in some circumstances, the cost of repairing is a small percentage of the cost of a new assembly, and in others, it’s more expensive.
ProcessBarron’s detailed IAQ inspection service delivers excellent long-term outcomes for customers across various industries. In steel mills, the team has analyzed equipment and dramatically improved its lifespan. With expertise that also extends to cement mills, power plants, and pulp and paper facilities. ProcessBarron consistently enhances equipment performance and longevity.
Tools and Technology We Use:
ProcessBarron utilizes a range of specialized tools and technologies during the IAQ inspections to ensure thorough equipment assessment.
Ultrasonic testing equipment is employed to detect internal imperfections that are not visible to the naked eye. This non-destructive testing method is crucial for thorough inspections on items such as fan shifts and hubs.
Magnetic particle testing devices and dye penetrate testing kits are used to identify fine cracks and other hidden issues.
For precise measurements, micrometers and dial indicators are used to measure shaft tolerances to the ten thousandth of an inch. Surface roughness testing allows the team to measure in micro-inches, ensuring detailed analysis of equipment surfaces.
Thickness indicators are employed in areas where physical measurements are not possible, allowing for accurate assessment of material thickness.
These tools and technologies enable ProcessBarron to detect internal and external imperfections, supporting informed decision-making for repairs or replacements. It’s a comprehensive process, given that the equipment is large and needs to be moved around the shop for various tests and inspections.
Why Should IAQ be a Priority In Your Plant?
IAQ helps with scheduling maintenance, predicting equipment lifespan and potential failures, and determining the need for spare parts as a form of insurance.
“When faced with the stress of equipment failure, operators must determine the best option that most effectively reduces the probability of recurrent or related issues, ” said Piazza. “They appreciate the opportunity to learn how repairs can provide the results they are looking for. Our goal is to be the guide and offer the best solution.”
“Our clients’ equipment often handles materials with abrasive particles, which can lead to wear and tear,” he continued. Structural failures, particularly on rotating assemblies are a significant concern. That’s why maintaining equipment in these high-wear applications is crucial for safety.
Lead time for the inspection and quote process varies depending on the product. It can range from a few hours to a couple of weeks. If the team needs to source materials externally, this can extend the lead time further.
Benefits of ProcessBarron’s IAQ Inspection Process
In cases of catastrophic failures, our team springs into action. Our team of engineers and technicians bring decades of experience to every inspection. Trained to handle rush projects, they ensure quick turnaround times without compromising on quality. Typically, the team can even turn proposals around within hours. This swift service minimizes downtime and keeps your operations running smoothly, even when faced with unexpected equipment failures or obsolescence.
As a team who specializes in rapid response for urgent needs, ProcessBarron can also duplicate equipment that’s no longer commercially available. Our engineers meticulously measure rotating assemblies, housings, and other components. We can even reverse engineer parts when necessary.
Additionally, when utilizing the IAQ service, plant managers are getting access to a team of professionals who can expertly assess equipment and offer tailored solutions to enhance its performance. Piazza pointed out, “We don’t just look at the immediate issues. Our ‘total system solution’ approach considers how repairs or replacements will affect efficiency and budgets in both the short and long term.”
The ProcessBarron sales team stays informed about planned outages and equipment needs. Additionally, they offer a spare parts program where clients access backup components, like spare rotating assemblies. This approach allows for quick swaps during maintenance, preventing lengthly downtimes that would otherwise occur while waiting for equipment to arrive.
The necessity for on-site spares varies depending on the equipment type. Most mills and plants prefer to keep critical spares on-site, especially for long-lead items that are crucial to prevent plant shutdowns. For instance, when lead times can stretch to 14-16 weeks or longer, it’s vital to have essential equipment readily available at the plant.
Clients don’t typically hesitate to invest in spare parts, as they recognize that time is often more critical than cost when it comes to essential equipment. This is particularly true for larger plants, where downtime can result in losses of hundreds of thousands or even millions of dollars. ProcessBarron’s ability to minimize downtime by quickly turning around repairs or replacements can significantly impact a plant’s bottom line. “We strive to provide concrete examples of how our rapid response and efficient service translate into substantial cost savings for our clients,” said Piazza.
Work with ProcessBarron
Don’t let equipment issues slow down your plant operations. Experience the ProcessBarron difference with our IAQ program, which is designed to provide you with optimal longevity and efficiency of your equipment and machinery.
With its focus on overall equipment effectiveness, ProcessBarron’s IAQ service creates opportunities to effectively plan outages and maintenance cycles that include specific plans for equipment to be serviced and repaired. In fact, after implementing ProcessBarron’s IAQ recommendations, businesses regularly see improvements in equipment function and lifetime.
By identifying potential issues early and offering preventative solutions, we help reduce the likelihood of expensive failures and maximize equipment lifespan.
Contact us to learn how regular IAQ evaluations can improve your equipment’s performance and longevity, saving you time and money. Reach out to your salesperson today for more information.