POWER PLANT PREDICTIVE MAINTENANCE BASIC INFORMATION AND TUTORIALS

The basic application of predictive maintenance involves taking measurements and applying the technology or processes to predict failures. The approach should include the assessment of the equipment as it relates to the business or personnel safety, prioritizing the equipment, and targeting the critical equipment.

For predictive maintenance, one other criterion must be utilized in the assessment process: the monetary value of the equipment. Even if the equipment is not critical, its value may warrant the use of predictive maintenance to reduce potential catastrophic failure of expensive equipment.

It is important to target this most critical and valuable equipment for predictive maintenance because there is an associated cost to predictive maintenance implementation. Predictive maintenance technologies are valuable tools if applied appropriately. These include the following:

● Vibration analysis

● Motor circuit analysis

● Infrared imaging

● Ultrasound

● Oil analysis

● Ferrography (wear-particle oil analysis)

These technologies, when applied properly, can reduce catastrophic failure, and thus maintenance cost. One other application is statistical process control (SPC). This predictive tool can be used to predict failures, but a plan must be in place first, for the data collection process is critical.

If a CMMS is used, then the proper system architecture must be developed, along with associated processes and procedures that allow for accurate data collection. Mean time between failures (MTBF) is determined using the technologies and processes listed previously.

This will allow for proper planning of preventive maintenance based on information, not just on recommended schedules. Using these technologies and SPC should reduce the cost of equipment maintenance over time. One of the key approaches to a good predictive maintenance program is consistency or standardization.

For example, if data on equipment failures (problem, cause, and remedy) do not include a list of standards, utilizing SPC becomes difficult and will require extensive research to identify what the data really mean. The cost savings will be lost because of the hours expended researching this information.

Developing a strategy and approach is the key to program success. Predictive Maintenance Cost Savings and Avoidance Potential. Utilizing predictive maintenance can reduce the overall cost of facilities operation. In a facility where rotating equipment is prevalent, applying vibration analysis, ferrography, and laser alignment to coupled equipment may reduce power consumption.

This is assuming that the coupled equipment is out of alignment, or has undetected wear condition. Utilizing thermographic imaging will reduce power loss by detecting loose connections and following up with corrective action.

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