Predictive Maintenance
Predictive or condition-based maintenance evaluates the condition of the [...]
Predictive or condition-based maintenance evaluates the condition of machinery and recommends whether or not to intervene based on its condition, resulting in great savings.
The predictive diagnosis of machinery was developed in industry in the decade from the mid-eighties to the mid-nineties of the twentieth century. Today, predictive philosophies are applied to critical machinery in plants with optimized asset management (RCM, ISO 55001, RBM...). Condition-based maintenance optimizes preventive maintenance in such a way that it determines the precise moment for each technical maintenance intervention on industrial assets.
Predictive maintenance is a set of instrumented techniques for measuring and analyzing variables to characterize in terms of potential failures the operating condition of production equipment. Its main mission is to optimize the reliability and availability of equipment at minimum cost.
Advantages and benefits of the application of predictive maintenance
Optimized management of maintenance scheduling brings the following advantages:
- Increased machine availability.
- Improved overall reliability.
- Less raw material losses due to unplanned shutdowns and restarts.
- Reduction in the rate of equipment interventions/year.
- Reduced risk of infant mortality (due to human error in repairs), as there are fewer maintenance interventions.
- Reduction of spare parts expenditure, as the number of interventions throughout the life cycle of the asset can be reduced by up to one fifth (e.g. on bearings).
- As a consequence of the previous point, labor is reduced.
- Monitoring has the effect of reducing accidents and increasing safety.
- If we take advantage of the monitoring data to establish a root cause failure analysis (RCFA) program, we will reduce failures in general and especially catastrophic failures.
- Lower cost of industrial insurance, as the plant achieves better KPIs and therefore reduces the risk for the insurance company.
European companies that do not follow Operational Excellence practices will disappear. The only way to compete against countries with cheaper labor is through automation and optimization of process management and maintenance of the means of production.
Download article, "Predictive strategy in industrial maintenance" - PDF 2.6 MB.
Video: Why apply predictive strategy in industrial maintenance. Predictive maintenance is the optimal way to plan the overhauls of your critical machinery. We invite you to watch this presentation by Francisco Ballesteros Robles (Preditec) of approximately one hour where the main arguments in favor of the predictive strategy are exposed.
The main predictive maintenance techniques and their application in industrial machinery are:
- Vibration Analysis
Vibration analysis is the main technique for monitoring and diagnosing rotating machinery and implementing a predictive maintenance plan. - Ultrasound applied to predictive maintenance
Ultrasonic pickup is a technique that has developed a lot in recent years, discover the applications of this predictive technique. - Lubricant Analysis
Lubricant analysis techniques are essential to determine lubricant deterioration, contaminant ingress and the presence of wear particles. - Analysis of Reciprocating Machines
Reciprocating engines and compressors can be diagnosed with high accuracy from the dynamic signal of pressure, ultrasound and vibration. - Partial discharges in electrical machines
The partial discharge study technique is applied to large electrical machines to evaluate the condition of the stator with the machine in service. - Monitoring parameters of large electrical machines
The criticality of large electrical machines justifies continuous monitoring by several complementary techniques. - Thermography
The reduction in the price of thermographic cameras has allowed any maintenance department to benefit from this powerful predictive technique. - Electric Induction Motor Analysis (ESA&MCA)
In recent years, technologies have been developed that allow the diagnosis of electric motors through the simultaneous measurement of current and voltage.
We offer predictive maintenance services for vibration, ultrasound, thermography, oil analysis and electric motor circuit analysis. See more.
We offer a selection of the best products available on the market: vibration analyzers, laser aligners, ultrasonic detectors, advanced monitoring systems, thermographic cameras, online sensors, equipment for analysis of electrical machines. See more.
Condition Monitoring Solutions for Predictive Maintenance - PDF Download 2.2 MB
