Predictive maintenance program establishment

The only useful function of broadband analysis is longterm trending of the gross overall condition of machinery. Typically, sets of alert/alarm limits are established to monitor the overall condition of the machine-trains in a predictive maintenance program. However, this approach has limited value and, when used exclusively, severely limits the ability to achieve the full benefit of a comprehensive program. 

Reference or baseline data sets should be acquired for each machine-train or process system to be included in a predictive maintenance program when the machine is installed or after the first scheduled maintenance once the program is established. These data sets can be used as a reference or comparison for all future measurements. However, such data sets must be representative of the normal operating condition of each machine-train. Three criteria are critical to the proper use of baseline comparisons reset after maintenance, proper identification, and process envelope. 

The chapters on establishing and maintaining a total plant predictive maintenance program will provide the practical knowledge required implementing a cost-effective vibration-based program that will provide maximum benefits. 

To be successful, a predictive maintenance program must be able to quantify the cost-benefit generated by the program. This can be achieved if the program is properly established, uses the proper predictive maintenance techniques and has measurable benefits. The amount of effort expended to initially establish the program plant is directly proportional to its success or failure. Proper implementation of a predictive maintenance program must include the items listed in Sections 50.5.1-50.5.5. 

Specific goals and objectives will vary from plant to plant. However, we will provide an example that will illustrate the process. Before goals and objectives can be developed for your plant, you must determine the existing maintenance costs and other parameters that will establish a reference or baseline dataset. Since most plants do not track the true cost of maintenance, this may be the most difficult part of establishing a predictive maintenance program. 

The initial database development required to successfully implement a predictive maintenance program will require man-months of effort. The extensive labor required to properly establish a predictive database often results in either a poor or incomplete database. In some cases, the program is discontinued because of staff limitations. If the extensive labor required establishing a database is not available in-house, there are consultants available that will provide the knowledge and labor required to accomplish this task. 

The ideal situation would be to have the predictive systems vendor establish a viable database as part of the initial capital equipment purchase. This service is offered by a few of the systems vendors. Unfortunately, many predictive maintenance programs have failed because these important first critical steps were omitted or ignored. There are a variety of technologies and predictive maintenance systems that can be beneficial. How do you decide which method and system to use ... 

A vibration-based predictive maintenance program is the most difficult to properly establish and will require much more effort than any of the other techniques. It will also provide the most return on investment. Too many of the vibration-based programs fail to use the full capability of the predictive maintenance tool. They ignore the automatic diagnostic power that is built into most of the microprocessor-based systems and rely instead on manual interpretation of all acquired data. 

The next step required to establish a predictive maintenance program is the creation of a comprehensive database. 

During the implementation stage of a predictive maintenance program, all classes of machinery should be monitored to establish a valid baseline data set. Full vibration... 

The labor and knowledge required to properly establish a predictive maintenance program is often too much for plant staff to handle. To overcome this problem, the initial responsibility for creating a viable, total plant program can be contracted to a company that specializes in area. 

The accountability expected of the predictive maintenance group is another factor that is critical to program effectiveness. If measures of program effectiveness are not established, neither management nor program personnel can determine if the program s potential is being achieved. 

The labor-intensive part of predictive maintenance management is complete. A viable program has been established, the database is complete and you have begun to monitor the operating condition of your critical plant equipment. Now what ... 

Implementation Routes and timing are established, people are trained, and the program is implemented. Readings are taken, analyses are performed, and recommendations for action are provided to maintenance, engineering, and operations. A strict condition-monitoring discipline will lead a plant to a successful predictive maintenance environment where people at all levels of a plant will be able to visualize the resultant equipment saves. ... 

RCM is a method for establishing a progressive, scheduled, preventive maintenance program while integrating predictive technologies that will efficiently and effectively achieve safe, and inherently reliable, plants and systems. 

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