Overview

Predictive maintenance is the monitoring of equipment operating conditions to detect any signs of wear that is leading to a failure of a component. The goal of the predictive maintenance program is to track the component wear with a methodology that insures that any impending failure is detected. Once detected, the component wear is tracked more closely. The component will then be scheduled for replacement before it fails during a scheduled run.

Monitoring the operating condition of the equipment can be accomplished by examining its operating dynamics. The most common techniques for measuring operating dynamics include:

• Vibration analysis

• Thermography

• Ultrasonics

• Oil analysis

• Lubricant condition

• Wear particles

Vibration analysis measures the physical operating vibrations of rotating equipment. Based on the type of equipment, the analysis can indicate problems with bearings, belts, chains, gears, shaft misalignment, and out-of-balance conditions. The major impact that vibration monitoring has in most plants is its use in detecting bearing problems. By knowing days, weeks, or even months in advance that a component is wearing and will fail, the maintenance department can change the part with minimal impact on the operations department.

Thermography measures the temperature of a component. This trending of temperature indicates wear because increased wear is generally accompanied by a temperature rise. The thermographic equipment can be anything from a small temperature strip to an infrared imaging system. The level of detail, coupled with the ability to measure the parameter safely, quickly, and accurately, determines the cost of the tool required. Thermography is...