FOOD AND BEVERAGE | SPAIN
Implementation of predictive maintenance strategy
+1300 rotating assets
PROJECT OBJECTIVE
Predictive Maintenance Strategy
Bunge International Limited is a global leader in the agri-food sector and a leading producer, handler, processor and trader of soybeans, canola, sunflower, corn, wheat and other crops.
Preditec has been collaborating with Bunge since 2012 in the implementation and operation of the predictive strategy within maintenance. The plan includes Bunge's assets in four of its plants in Spain, covering about 1300 rotating assets.
Date of execution:
2017
Location:
Spain
Sector:
Agrifood
Client:
How we made it happen
Predictive techniques, the key
Vibration measurement and visual inspection, ultrasonic inspection, ESA (Electric Signature Analysis) and MCA (Motor Circuit Analysis) are performed as routine tasks in the plant. Ultrasonic inspection is used for machines with slow speeds, as a complement to vibration measurement, and electrical measurement techniques are used for the most critical motors. ESA tests are performed with the motor energized and MCA tests with the motor de-energized. Another fundamental service is the detection of hexane leaks, a flammable and explosive compound that is the main production consumption for oil extraction.
With the correct application and combination of predictive techniques, we achieve a reliable diagnosis and an improvement in the monitoring of KPIs. We anticipate failures in order to plan corrective works at the next shutdown, which results in fewer unplanned shutdowns, lower cost and duration of repairs. Thus, we have a holistic view of the mechanical and electrical condition of the equipment, generating a history of asset behavior and being able to cross-reference data between similar machines to make decisions based on continuously updated real data. Thanks to these inspections, resources are invested in machines that really need it.
Although this is a variable figure, we can say that within an inspection, 5-10% of the assets require exhaustive follow-up and 10-15% require less follow-up. The rest of the machines, which represent the highest percentage, have a good condition (Green Asset) and can wait until the next inspection.
OUR CONTRIBUTION
Some of our products and services applied to this project
Service
Technology consulting
We advise on the best technological solution to apply according to the needs of each project. Learn more about our technology consulting.
Service
Industrial automation
To achieve effectiveness and efficiency in the digitization process of the industry. Learn more about our industrial automation service.
RESULTS AND ACHIEVEMENTS
Definition of criticality criteria
The inspections are documented in the Preconcerto web platform, where the database is generated with the relevant asset information, the status of the plant is updated, KPI's are tracked, bi-directional plant-analyst communication is enabled and customized reports are generated.
In addition to these inspections with portable equipment, there are assets that require continuous monitoring due to their criticality, the nature of the faults or their location in inaccessible areas.
their location in inaccessible areas. These are digitization projects where the machine is instrumented (with wired or wireless sensors) and the signals are taken to the monitoring hardware, managing the information remotely from the Asset Web Monitor (AWM) web platform. This tool allows us to centralize information from various sources, parameterize different failure modes, generate machine status with different alarms, plot multivariable trends for supervision and analyze both scalar data and associated graphs.
5-10%
of the assets requires exhaustive monitoring
10-15%
of assets requires less monitoring
OUR EXPERIENCE
