Predictive Maintenance

Leverage the Power of Predictive Maintenance Solutions

When Predictive Maintenance programs are properly designed and executed, the results can have a significant impact on your operations. Discover how fully integrated predictive technologies can predict failures long before action is required. Drive better machine health with predictive analytics and condition monitoring to deliver improved operational performance.

25-35%

up to70%

10-20%

Reduction in Maintenance Costs

Reduction in Breakdowns

Increase in Uptime

20-30%

up to 50%

up to 30%

Reduction in Spares Inventory Spend

Reduction in Maintenance Planning Time

Increase Mean-time Between Failures (MBTF)

Key Business Drivers for Predictive Maintenance and Condition Monitoring

Maximum Safety

Reduction of health and safety incidents and prevention of unexpected failures for critical assets.

Environmental Impact

Reduction of the CO₂ emissions and support for corporate social responsibility initiatives

Asset Uptime

Planning of maintenance interventions based on risk profile and asset condition to avoid unplanned downtime

Operational Efficiency

Reduction of the operational cost base through optimized inspection and maintenance planning

Asset Lifecycle Extension

Maximization of the asset’s useful life by keeping it in its designated range of operation at all times

Production Quality

Optimization of the product quality by reducing process variability and excursions

Wi-care™ as a Service

Wi-care as a Service (WaaS) is a hardware-enabled, software as a service predictive maintenance delivery model that allows customers to implement our mounted monitoring solutions in conjunction with traditional route-based PdM. WaaS eliminates the upfront capital needs for monitoring products. It is an all-inclusive cost per machine including:

Hardware: Network, Sensors (based on your strategy)
Installation: Supported by your professionals or full install by I-care
Analysis: Monthly, Bi-Monthly, Alarm Management (based on your strategy, or criticality)
Reporting: Cloud-based integrated reporting
Support: Optional Expert Kits for monitoring troubled assets
Warranty: Full product warranty for the period of contract length

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EQUIPMENT IN SERVICE

Vibration Analysis

Vibration Analysis detects early problems and provides real-time reaction to the changing health conditions in rotating machinery, such as gearboxes, motors, fans, pumps, shafts, and diesel engines.

Vibration Analysis is the most frequently deployed technology on the market today and enables you to take maintenance action before a failure in service brings your plant to a halt. Check out this whitepaper on how vibration monitoring is the cornerstone for successful predictive maintenance.

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EQUIPMENT IN SERVICE

Infrared Inspections

Detect hot spots before they become problems using infrared inspection. Infrared Thermography is the safest, non-intrusive, and most efficient technique to identify faults and overheating early, before they become more serious and expensive to repair.

Ensure that facility equipment has the highest possible uptime and longevity with thermography in electrical maintenance and infrared thermography inspection services.

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EQUIPMENT IN SERVICE

Ultrasound Analysis

Ultrasound leak detection allows you to detect many inaudible or undetectable phenomena that other predictive tools do not detect.

Compressed air often uses more energy than most of equipment in the plant. Leaking air lines, couplings, air tools, hoses, and other defective compressed air components can be major sources of energy loss. That’s why a reliable leak detection solution and leak detection system are incredibly valuable.

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EQUIPMENT IN SERVICE

Oil Analysis

Often called the blood of the life of the equipment, oil can provide a great deal of information on the condition of the equipment and the wear of the installation to establish a relevant diagnosis on the mechanical state of the equipment system.

Oil Analysis is considered the most cost-effective service to prevent machine breakdowns. Monitoring industrial lubrication systems, oil technical analysis, and lubrication reliability ensures that equipment is fully optimized.

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EQUIPMENT IN SERVICE

Motor Circuit Analysis

Did you know that around 50% of mechanical problems are due to electrical motor failures with many caused by an electrical failure on stator windings and rotors?

Pollution and moisture can weaken even the strongest insulation systems.
Heat and time will irremediably age insulation and can lead to interturn or ground faults.
Thermal stressed squirrel cage rotor can suffer from the cracked brazed bar.

We guide and advise you in the application of online and offline methods and techniques to identify and resolve issues of equipment reliability.

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EQUIPMENT IN SERVICE

Motion Magnification

Motion magnification is an innovative technology in the world of Predictive Maintenance and Maintenance 4.0.

The technology is capable of registering 10 seconds of time with a high-speed camera.
Smart software will later amplify micro displacements and make structural problems visible, where they were not visible with the naked eye.
The software provides instant spectra from any cursor location with accurate frequencies and amplitudes.
It can be used on rotating machines, structures, and piping.

Now, what was not visible is now seen. Problem solved.

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CORRECTIVE ACTIONS

Onsite Balancing

Imbalance is defined as an unequal distribution of mass causing the mass axis to differ from the bearing axis. During rotation, the unequal mass along with the rotation creates a centrifugal force.

Causes of imbalance include:

Buildup of particulate matter on fan blades or in hollow fan blades
Differential temperatures between the top and bottom of the fan housing
Accumulations of dirt and particulate matter
Loose hub-to-shaft fit
Improper or makeshift balancing procedures

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CORRECTIVE ACTIONS

Laser Alignment

Misaligned shafts are recognized as one of the greatest contributors to plant breakdowns, due to the increased forces placed on bearing, mechanical seals, internal components, and motor drives.

This leads to: