1. Vibration Measurement, Analysis, Control and Condition Based Maintenance 14 Predictive maintenance
Dr. Michiel Heyns Pr.Eng. T: C:

2. Section 14. Predictive Maintenance
Objective
To give an introduction to predictive maintenance in a maintenance management programme – with specific focus on vibration-based predictive maintenance
After completion you will be able to:
Describe predictive maintenance
List PM management types – Is done in other PMM subjects
List the important factors in a PM programme – Is done in other PMM subjects
Start a predictive maintenance programme – Is done in other PMM subjects
PMM Students: Because these topics are presented in other parts of you course, only an overview will be given in class
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3. Maintenance management types
Run-to-Failure
Preventive
Time-driven
Mean-time-to-failure (Bathtub curve)
Predictive
Monitor condition = actual operating condition
Condition-driven preventive maintenance program
Proactive
Root cause-based
To eliminate failures in plant components.
Reliability-based Maintenance
Balance of preventive, predictive and proactive maintenance.
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4. Benefits of PM Lower maintenance costs (50-80%)
The statistics documented in this part was found from a 1988 survey of 500 plants that have successfully implemented predictive maintenance methods. Industries in the United States, Canada, Great Britain, France and Australia were included in the sample group.
Lower maintenance costs (50-80%)
Fewer machine failures (50-60%)
Less repair downtime (50-80%)
Overtime premiums (20-50%)
Reduced parts inventory (20-30%)
Longer machine life (20-40%)
Increased productivity (20-30%)
Improved operator safety
Verification of new equipment
Verification of repairs
Overall profitability (25-60%)
Programs fail because of a lack of planning and management support.
Further reading:
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5. Predictive Maintenance Techniques
Vibration monitoring
Thermography/Temperature monitoring
Tribology/Lubricant monitoring
Process parameters
Visual inspection
Ultrasonic monitoring - NDT
Acoustic emissions, eddy currents, magnetic particles, residual stress
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6. Selecting a PM system – Is done in other PMM subjects
The complete system
User-friendly software and hardware
Automated data acquisition, management and trending
Flexibility
Reliability
Accuracy
Training and technical support
System and operating costs
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7. Selecting a PM system – Is done in other PMM subjects
The microprocessor
Expertise required to operate
Accuracy of data
Alert and alarm limits
Data storage and transfer
The host computer
The software program
User-friendly
Automatic trending
Automatic report generation
Simplified diagnostics
Transducers
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8. Establishing a PM programme – Is done in other PMM subjects
You need
Clearly defined objectives and goals with measurable benefits
Financial analysis
Management support
Dedicated personnel
Efficient data-collection and analysis procedures
Record-keeping & information organisation procedures
Communications capability
Evaluation procedures
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9. Objectives, goals & benefits from Predictive Maintenance
Eliminate unnecessary and unscheduled maintenance
Reduce rework costs
Reduce lost production
Reduce repair parts inventory
Increase process efficiency
Improve product quality
Extend operating life
Increase production
Reduce maintenance costs
Increase overall profits
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10. Management support
Invest in capital equipment and personnel, training, consulting support
Management must understand the long term benefits
Start with most critical machine
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11. Personnel Full attention in achieving goals
Part-time personnel not recommended
Accountability of PM group and measures of program effectiveness
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12. Data-collection Concentrate in areas that will provide maximum results
On-line systems will provide efficient data analysis, but is expensive
Include methods, schedule, parameters for data acquisition, analysis and report generation in the programme
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13. Condition data base
On-line systems with software and built-in data management
If too expensive, use consultants
Cloud computing offers attractive solutions
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14. On which equipment must I start?
Do plant survey to class equipment according to their impact on production capacity etc.
Essential : On-line or plant down
Critical : Reduce production capacity by 30%
Serious : Not dramatic impact on production
Others : Replacement < Monitoring costs
Selection of method:
Characteristics of failure mode and class of equipment
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