Maintenance Technology September 2016 - 8

ON THE FLOOR An outlet for the views of today's maintenance & reliability professionals Panelists Describe Payoff From Predictive Tools Jane Alexander Managing Editor A t Maintenance Technology, the topic of predictive tools is always hot. More precisely, our staff is always eager to hear how readers and their staffs (and, in the case of consultants/suppliers, their clients/ customers) are leveraging these technologies in plants and facilities. For an update based on our Reader Panelists' individual perspectives, we posed the following questions. 1. What predictive tools/technologies are these sites using most, and where, why, and how? 2. What's the return on investment (ROI)? 3. What predictive tools might be on the sites' wish lists for future use? Edited for brevity and clarity, here are several responses. "Our return on investment is fewer equipment breakdowns than in the past." Maintenance Engineer, Process Industry, Midwest. . . We typically keep an IR (infrared) gun (for equipment hotspots), ultrasonic ears (for leaks and precision lubrication), and a vibration pentype device (for quick checks and validation of in-situ devices) on hand. We've been relying on outside expertise for full vibration analysis and oil analysis programs, but are starting to develop some in-house competency. No one at our sites has yet been certified on these technologies. To date, we haven't really quantified any savings, but we do have scattered reports of early detections leading to planned shutdown and correction. The numbers may not be tallied, but theoretically we've "saved" by reducing unplanned outages. 8| MAINTENANCE TECHNOLOGY Wireless machine-health technologies (vibe, temp) are on trial at one of our facilities. If successful, we may branch them out. Maintenance & Reliability Specialist, Engineering Services, South. . . We utilize numerous vibration routes and have a level-1, three level-2, and two level-3 vibration specialists on staff. We also have motor testing with five craftsmen trained and qualified on the different devices in use. We have one craftsman trained as a level-1 for ultrasound testing, and two IR level-2 technicians. Our group captures every find and, utilizing an algorithm approved by both our customer and our leadership, provides a cost avoidance for each. This number is showing a very solid ROI, and our customer is pleased. Regarding wish lists, we've recently begun adding real-time overall vibration monitoring to our predictive-maintenance (PdM) toolbox and expect that to grow to Delta P for filters and, possibly, real-time oil health. We also have begun using a rules-based software program that consolidates data from our vibration routes, on-line vibration data, and CMMS. Plant Engineer, Institutional Facilities, Midwest. . . Since our budget crisis we've been only able to use our existing trend logs and visual inspections. We, do, however, have all types of instruments to help us. Our return on investment [from predictive technologies] is fewer equipment breakdowns than in the past. And, the time it takes to troubleshoot uncommon problems has been cut by more than half. Industry Consultant, West. . . Vibration analysis, ultrasonic testing, oil analysis, and IR are my clients' most-used PdM tools. The technology vendors usually provide the training. SEPTEMBER 2016

Table of Contents for the Digital Edition of Maintenance Technology September 2016