Do you know if your plant is Predictive or Preventive?

Have you given a thought about Industrial plants can be predictive?

Yes, you read it correctly!

Plants can be predictive if you have Predictive maintenance tools in your plant. Predictive Maintenance (PdM) tools are powerful tools that predict the fate of your equipment in the plant. PdM tools use condition-based monitoring and identify potential failures and prevent your equipment from catastrophe.

Maintenance summary at a glance

Run to Failure (RTF) or Corrective MaintenancePreventive or Periodic Maintenance (PM)
Pros
•Cost effective for small, non-critical Equipment
Cons
•Costly downtime, extensive secondary damage, highest cost approach overall for critical and larger capital equipment
Pros
•Provides the first line of defense & basic
•Proactive strategy
Cons
•Often wasteful does not prevent some failures, can introduce problems, requires a large parts inventory
Predictive Maintenance (PdM)Proactive Maintenance (PrM)
Pros
•Reduces maintenance costs, downtime, secondary damage, and unnecessary parts replacement
Cons
•By itself, does not address the root cause of problems, can miss productivity improvement opportunity due to lacking a financial history of equipment/maintenance
Pros
•Addresses the root cause of failures reduces maintenance costs beyond predictive levels, reduces downtime, secondary damages, unnecessary parts replacement/inventory, and extends equipment life
Cons
•None ( If life cycle costs are appropriately considered)

Condition Based Monitoring

Condition Based Monitoring is a maintenance strategy that monitors the real-time condition of equipment, extracting information to understand the equipment‘s wear and tear, degradation, and if a relevant change has occurred. The data collected can be used to establish trends, predict failure, and calculate the remaining life of an asset.

Benefits of Condition Based Monitoring

  • Reduction in downtime
  • Improvement in productivity
  • Reduction in spares inventory
  • Reduction in consumables
  • Remote monitoring

trends in maintenance

Predictive Maintenance tools

There are six primary PdM tools available:

  • Vibration analysis
  • Ultrasonic analysis
  • Infrared analysis
  • Oil analysis
  • Laser-shaft alignment
  • Motor circuit analysis

Vibration Analysis

Vibration analysis is a process of monitoring the levels and patterns of vibration signals within machinery to detect abnormal vibration events and to evaluate the overall condition of the test machine.
Vibration analysis is used for the condition monitoring of rotating equipment like

  • Gearboxes, Motors, Fans, and Drive-Trains
  • Bearings, Gears, Shafts, and Freewheels

Advantages of Vibration Analysis

  • Real-time monitoring to the change of health conditions
  • Supports remote condition monitoring
  • Well defined processing and signal analysis
  • Predictive maintenance is possible with Vibration Analysis
  • Various sensors are commercially available for supporting vibration analysis
  • Machine faults discover at an early stage
  • Avoids unexpected downtime
  • Avoid replacing parts that are in good condition saving on inventory

About Infinite Uptime

Infinite Uptime is a global industrial edge solution provider for mechanical predictive maintenance in the engineering and process industries.

Infinite Uptime’s Industrial Data Enabler (IDE), patented edge-computing Vibration monitoring system for predictive analytics and maintenance remotely gathers tri-axial vibrations, noise, and temperature of any mechanical rotating equipment in real-time. It empowers the Maintenance team to monitor the machine uptime, reduce unplanned downtime, and combat impending equipment damage in advance. Moreover, the end-to-end solution with visual indicators ensures maximum machine-availability, decreased inventory of spares and maintenance costs, and complies with the guidelines on safety and physical distancing directed by the Government. Not only does it help reduce maintenance fixed costs at a time where a reduction in costs and manpower is a dire need, but it also enhances social distancing by allowing remote monitoring of a plant without physical intervention.

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