Predictive maintenance (PdM) means applying a proactive and data-driven approach to asset maintenance, rather than a simple schedule-based approach (or even worse, fixing problems only after they have become bad enough to be noticed). Predicitve maintenance centers on careful performance tracking, so that technicians can diagnose and analyze the condition of key equipment, then planning maintenance and repair work based on the insights gained through monitoring.
Predictive maintenance is something requiring a systemic approach, and greater expertise than in traditional maintenenac. And while PdM is not a superpower, it is fair to say that a new wave of digital and AI-based technologies are allowing technicians to do work with unprecedented precision and efficiency by hearing telltale sounds that the human ear cannot pick up, and quickly seeing trends and indicators in a huge volume of performance data that an ordinary technician couldn’t have managed in the past.
But here’s the catch – there is a right way and a wrong way to do predictive maintenenace. In fact, it is not advisable or necessary to apply a PdM approach to every piece of equipment. The best predicitve maintenance plans center on core assets, the infrastructure which is truly “make or break” for facility and system perrformance.
In a recent visit, Eason Chen, an Aden Technical Services Specialist, spoke with us about predictive maintenance, and the importance of core assets, new technologies and more.
Bright spots
Prediction is the process of detecting and analyzing signals to anticipate equipment failures in advance, thereby increasing the reliability of the equipment.
The key assets are a number of systems and core equipment.
Some vibration sensors, ultrasonic detectors, infrared thermography etc. can be used as effective tools.
Not all equipment is subject to PdM and some core equipment, key assets, should be selected for predictive maintenance.
ADEN is experienced in different industries and can customize to do some predictive maintenance solutions that are more relevant.
Why use predictive maintenance (PdM)?
There are clear returns:
- Early detection of hidden dangers
- Reduce maintenance costs.
- Increase manufacturing capacity.
- Pertinence for core equipment
- Increase equipment uptime.
- Extend the service life of the equipment.
Key tools for implementing predictive maintenance (PdM)
- Vibration analysis. For rotating equipment, most of the fault is related to vibration. Vibration monitoring is characterized by direct and real-time detection of different kinds of faults.
- Infrared Thermal Imaging Inspection. It is a convenient technique to monitor device and equipment surface temperature, which can’t be easily interfered. Equipment status can be detected by temperature inspection.
- Ultrasonic Detection. It is a fast and accurate leakage detection technique. Can be used for compressed air pipeline, connecting place, end using connector and inner leakage detection in valve, etc.
- Oil Analysis & Management. Oil analysis can detect wearing of the equipment, oil contamination and oil aging problem at very early stage.
- Laser Alignment. For rotating equipment, more than 50% of the unscheduled downtime is caused by misalignment. Those unscheduled downtime reduce the operation time of the equipment, result in the increasing of repair cost and production loss.
- Dynamic Balance. Dynamic balance can be used for fans, pumps, machine tools and various rotating equipment. The good dynamic balance correction can extend the lifetime of equipment components by several, dozens or even hundred times.