Tuesday, March 12, 2019

Plant-wide Condition Monitoring

In addition to the most important assets found in industrial facilities, there are often a host of “supporting” assets that make up the balance of the plant such as pumps, motors, blowers, heat exchangers, fans, and others. This auxiliary or plant-wide equipment may be spared or sacrificed, and its impact on the process stream may vary from moderate to minor. Regardless, such machines—just like their more highly important counterparts—can benefit from Condition Monitoring. Condition Monitoring provides affordable, effective portable and permanent condition monitoring solutions that are delivering tangible benefits for tens of thousands of customers around the globe.

Financial Justification

For many assets, failure can mean substantial or total loss of production, often worth millions per day. Or it can lead to the release of hazardous substances, fires, and even explosions— resulting in a severe safety hazard as well as fines for violating environmental regulations.

Maintenance Costs

When viewed on a per-asset basis, maintenance costs for plant-wide assets can appear modest. However, when viewed collectively across the dozens, hundreds, or even thousands of assets in a typical plant, these costs can be appreciable. Reducing the maintenance costs on each asset through effective condition monitoring—even by a mere 10%—has a large impact on plant profitability. Condition Monitoring is a planning tool that allows more effective insight in planning and asset management, allowing maintenance to be done in advance of a functional failure.

Things to think about as you move towards Predictive Maintenance:
  • 90% of failures are NOT time-based.
  • 50% of companies site maintenance and reliability as a top priority.
  • It costs 6x as much for unplanned events vs. planned maintenance in process industries.
  • A 60% estimated increase in environmental, health and safety spending among global exploration & production companies.
  • 50% of workforce to retire in the next 5 to 10 years. Knowledge & experience is not being transferred.
Potential impact of a conditioning monitoring program and the move towards Predictive Maintenance:
  • -70% Machinery breakdowns 
  • -40% Plant downtime
  • -50% Maintenance costs
  • +25% Production
For more information on Plant-wide Condition Monitoring, contact Classic Controls by calling 863-644-3642 or visit their web site at https://classiccontrols.com.