Predictive Maintenance

Leverage the Power of Predictive Maintenance Solutions

 

What is Predictive Maintenance?

Predictive Maintenance is a proactive approach to machine maintenance that uses predictive analytics tools and condition monitoring solutions to predict failures before they occur.

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 such as cavitation and bearing failure long before action is required. Drive better machine health with predictive analytics, condition monitoring and monitoring solutions, allowing management 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

Reduce health and safety incidents and prevention of unexpected failures for critical assets through improved asset health monitoring

Environmental Impact

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

Asset Uptime

Implement proactive maintenance interventions based on risk profile and asset condition to prevent machine downtime and avoid unplanned maintenance

Operational Efficiency

Reduce the operational cost base through optimized inspection and maintenance planning to improve asset management 

Asset Lifecycle Extension

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

Production Quality

Optimize product quality using condition monitoring solutions to reduce process variability and excursions 

Maintenance worker uses a vibration analyzer
EQUIPMENT IN SERVICE

Vibration Analysis

What is Vibration Analysis?

Vibration Analysis is used in predictive maintenance to monitor and analyze the vibration patterns of equipment and machinery. 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 causes significant damage to equipment resulting in costly downtime. Check out this whitepaper on how vibration monitoring and vibration training are the cornerstones for successful predictive maintenance.

Vibration Analysis
Thermogram showing detected temperature distribution
EQUIPMENT IN SERVICE

Infrared Inspections

Infrared Thermography is the safest, least intrusive and most efficient technique to identify faults and overheating before they become more serious and expensive to repair. 

Early detection of faults and hotspots ensures that facility equipment experiences maximum uptime and longevity. Thermography and infrared thermography inspections as a routine part of electrical maintenance helps minimize equipment downtime and maintenance costs.

Infrared Inspections
Worker performing ultrasound analysis on machines
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. Our reliable leak detection solutions provide early detection of defective components so repairs can be made quickly to increase efficiency and reduce costs. 

Ultrasound Analysis

Explore Energy Savings
I-Care worker conducting an oil analysis in a lab
EQUIPMENT IN SERVICE

Oil Analysis

Oil is often referred to as the lifeblood of equipment. Oil Analysis can provide a great deal of information on equipment condition and wear of the installation to establish a relevant diagnosis on the mechanical state of the equipment system.

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

Oil Analysis
Electrical motor failure due to lapsed motor circuit analysis
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 offer a complete panel of online and offline service to detect and help resolve motor failures and equipment reliability issues, increasing optimal performance and minimizing downtime. 

Motor Circuit Analysis
Worker using high-speed camera
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 to quickly identify and solve problems that were previously undetectable

With motion magnification, what was once invisible is now seen. Once identified, issues can be resolved quickly and accurately, ensuring optimal equipment performance. Problem solved.

Motion Magnification See in action
Industrial fans after onsite balancing
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

Detecting and correcting imbalances in rotating equipment saves electricity, reduces temperature and vibration and extends the lifespan of your equipment.

Balancing
I-Care worker performing an alignment service
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:

  • Premature wear of bearings, seals, gaskets, etc.
  • Bearings overheating
  • Excessive Vibration
  • Additional energy consumption

Regular alignment services are essential to promote asset health. By utilizing alignment systems and asset monitoring solutions, our experts can identify and correct misalignment issues, reducing the risk of breakdowns and prolonging the life of equipment.

Laser Alignment

Ready to Get Started?

Learn more about predictive maintenance and predictive analytics that support the health and reliability of your machinery. 

Contact us