Page 344 - Intro Predictive Maintenance

Establishing a Predictive Maintenance Program 335

support all of the predictive maintenance is not available, you must decide on the spe-
cific techniques that must be used to support your program. Some of the techniques
may have to be eliminated to enable the use of a single predictive maintenance system.
In most cases, though, two independent systems will be required to support the
monitoring requirements in your plant.

Most plants can be cost-effectively monitored using a microprocessor-based system
designed to use vibration, process parameters, visual inspection, and limited infrared
temperature monitoring. Plants with large populations of heat transfer systems and
electrical equipment will need to add a full thermal imaging system in order to meet
the total-plant requirements for a full predictive maintenance program. Plants with
fewer systems that require full infrared imaging may elect to contract this portion of
the predictive maintenance program. This option will eliminate the need for an addi-
tional system. A typical microprocessor-based system will consist of four main com-
ponents: a meter or data logger, a host computer, transducers, and a software program.
Each component is important, but the total capability must be evaluated to achieve a
system that will support a successful program.

15.4.1 Fundamental System Requirements
The first step in selecting the predictive maintenance system that will be used in your plant
is to develop a list of the specific features or capabilities the system must have to support
your program. At a minimum, the total system must have the following capabilities:

• User-friendly software and hardware
• Automated data acquisition
• Automated data management and trending
• Flexibility
• Reliability
• Accuracy
• Training and technical support

User-Friendly Software and Hardware
The premise of predictive maintenance is that existing plant staff must be able to
understand the operation of both the data logger and the software program. Because
plant staff normally has little, if any, computer or microprocessor background, the
system must use simple, straightforward operation of both the data acquisition instru-
ment and software. Complex systems, even if they provide advanced diagnostic capa-
bilities, may not be accepted by plant staff and therefore will not provide the basis for
a long-term predictive maintenance program.

Automated Data Acquisition
The object of using microprocessor-based systems is to remove any potential for
human error, reduce staffing, and automate as much as possible the acquisition of