Can Your Maintenance Program Predict the Future?

They say no one can predict the future, and the same goes for maintenance staff. With a predictive maintenance program in place, however, your facility can enjoy a future with lower energy costs, reduced downtime and longer equipment life.

Three types of maintenance strategies

Every facility has its own maintenance policies, but one of three maintenance strategies is typically employed - reactive, preventive or predictive.

• Reactive maintenance is performed when a problem is detected, or equipment failure occurs.
• Preventive maintenance is scheduled at regular intervals
• Predictive maintenance is scheduled as needed based on equipment conditions.

Reactive maintenance can be cheaper and require less staff, but it can increase the risk of unplanned downtime and costs for equipment repair or replacement. Preventive and predictive maintenance can help reduce operating costs and equipment failure and increase equipment lifespan.

The benefits of predictive maintenance

What's the difference between preventive and predictive maintenance? Essentially, predictive maintenance is based on the actual condition of the equipment rather than on a preset, time-based schedule, as in preventive maintenance.

Predictive maintenance has many advantages. A successfully implemented predictive maintenance program can significantly reduce the risk of equipment failure. It's also a much more efficient use of labor and staff resources. Also, with maintenance activities based on actual equipment conditions, you can save on inventory and order parts as needed. Other proven benefits of predictive maintenance include:

• Energy cost savings
• Reduced equipment downtime
• Increased equipment operating life

According to the U.S. Department of Energy, studies have estimated that a properly functioning predictive maintenance program can provide savings of 8% to 12% over a program using only preventive maintenance.

Predictive maintenance technologies

Effective predictive maintenance requires consistent monitoring and analysis of system conditions, which in turn requires an investment in the appropriate diagnostic equipment. Although predictive maintenance technologies vary depending on the application, commonly used devices include infrared cameras, ultrasonic detectors and vibration analyzers.

Infrared cameras sense the infrared (IR) energy emitted by any material and convert it to a temperature reading. The wavelength operating range of the camera determines what application is most suitable. Infrared cameras provide a fast, non-contact, non-hazardous testing method for a wide range of applications.

Ultrasonic detectors use sensors to translate vibrations from high-frequency ultrasounds to low-frequency sounds audible to humans. A major application is the location of liquid or gas leaks in pressure or vacuum systems, such as boilers and chillers.

Vibration analyzers measure the vibration levels of machines. An internal accelerometer captures vibration data and converts it into an electrical signal proportional to the power and frequency of the vibrations. That signal is then displayed on a screen. Vibration monitoring and analysis can be used to diagnose a variety of problems related to rotating equipment - such as unbalance, misalignment or bearing defects.

Artificial intelligence (AI) systems use complex algorithms to perform tasks usually requiring human-like intelligence, such as learning, reasoning and problem-solving. AI algorithms can analyze real-time data from sensors and equipment to predict potential failures, allowing for proactive maintenance scheduling.

Getting started

Predictive maintenance technology can be expensive. Detection and monitoring devices, along with the associated software for data analysis and recording, can cost thousands of dollars, depending on features and capabilities. Training is also critical. Staff must know how to properly use the technology for the maintenance program to be successful.

Prioritize the equipment in your facility based on its importance to your operations. Determine what data you need to assess the equipment's performance or condition. Make sure you have installed the right instrumentation and a plan for continuous monitoring and analysis.

Maybe you can't predict the future, but with a predictive maintenance program, you can reduce operating costs and improve equipment performance for years to come.

We're here to help with all of your energy-saving needs. Contact us and see how we can help.

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