On The Floor: Panelists Describe Payoff From Predictive Tools

At Efficient Plant, the topic of predictive tools is always hot. More precisely, our staff is always eager to hear how readers and their staffs (and, in the case of consultants/suppliers, their clients/customers) are leveraging these technologies in plants and facilities. For an update based on our Reader Panelists’ individual perspectives, we posed the following questions.

— What predictive tools/technologies are these sites using most, and where, why, and how?

— What’s the return on investment (ROI)?

— What predictive tools might be on the sites’ wish lists for future use?

— Edited for brevity and clarity, here are several responses.

Maintenance Engineer, Process Industry, Midwest…

We typically keep an IR (infrared) gun (for equipment hotspots), ultrasonic ears (for leaks and precision lubrication), and a vibration pen-type device (for quick checks and validation of in-situ devices) on hand. We’ve been relying on outside expertise for full vibration analysis and oil analysis programs, but are starting to develop some in-house competency. No one at our sites has yet been certified on these technologies.

To date, we haven’t really quantified any savings, but we do have scattered reports of early detections leading to planned shutdown and correction. The numbers may not be tallied, but theoretically we’ve “saved” by reducing unplanned outages.

Wireless machine-health technologies (vibe, temp) are on trial at one of our facilities. If successful, we may branch them out.

Maintenance & Reliability Specialist, Engineering Services, South…

We utilize numerous vibration routes and have a level-1, three level-2, and two level-3 vibration specialists on staff. We also have motor testing with five craftsmen trained and qualified on the different devices in use. We have one craftsman trained as a level-1 for ultrasound testing, and two IR level-2 technicians.

Our group captures every find and, utilizing an algorithm approved by both our customer and our leadership, provides a cost avoidance for each. This number is showing a very solid ROI, and our customer is pleased.

Regarding wish lists, we’ve recently begun adding real-time overall vibration monitoring to our predictive-maintenance (PdM) toolbox and expect that to grow to Delta P for filters and, possibly, real-time oil health. We also have begun using a rules-based software program that consolidates data from our vibration routes, on-line vibration data, and CMMS.

Plant Engineer, Institutional Facilities, Midwest…

Since our budget crisis we’ve been only able to use our existing trend logs and visual inspections. We, do, however, have all types of instruments to help us.

Our return on investment [from predictive technologies] is fewer equipment breakdowns than in the past. And, the time it takes to troubleshoot uncommon problems has been cut by more than half.

Industry Consultant, West…

Vibration analysis, ultrasonic testing, oil analysis, and IR are my clients’ most-used PdM tools. The technology vendors usually provide the training.  Seldom do techs receive advanced training, leading to plants feeling that potential ROI from the tools was overinflated to make the sale. (As a side note, I believe the most underutilized tools are the five senses of personnel who are in contact with very expensive equipment every day.)

Personally, it’s difficult to quantify predictive-technology ROI with my clients. They don’t track the saves that these tools generate, and tribal memory seems skewed in favor of a higher save rate than I actually see in their plants.

Most of my clients have wish lists. Usually, their only reason for not buying every tool available is lack of funds. It’s rare for maintenance teams to compile documentation to establish the business case for equipment purchases.

Facility Superintendent, Scientific Institution, West…

Our facility relies on several different types of PdM technologies: fluid analysis, IR, ultrasound and ultrasonic testing. Fluid analysis has become a staple with our gearboxes and glycol-cooling systems. We typically take oil samples bi-annually to ensure proper viscosity, test for contaminants, and look for bearing wear. Secondly, testing our glycol fluids has proven extremely valuable. It tells us if the freeze point is correct and gives us direction for adding inhibitors or correcting fluid pH. Not all testing is perfectly accurate, though. We once received a glycol fluid-analysis report indicating acceptable foaming levels when, in fact, they were causing circulation pumps to cavitate.

IR, a newer tool for our team, has proven its value. Unfortunately, training provided by the manufacturer wasn’t in depth. Most of our knowledge has come through on-the-job usage. We’ve leveraged this technology to uncover a range of problems. A routine IR inspection of our main building transformer room, for example, found a loose splice on one phase of our electrical main. Gone unnoticed, it might have single-phased the building, causing serious downtime or numerous equipment failures.

Ultrasonic testing is our newest tool. It provides data that benchmarks and tracks bearing health and makes our lubrication program more efficient by reducing man-hours and material use. It’s also paid for itself by locating small compressed air leaks that would otherwise have gone undetected. To properly use this tool and its software, it was imperative [for personnel] to attend a week-long training class provided by the manufacturer.

We use ultrasound to detect fatigue and cracks in large wheel shafts. It allows our technicians to trend log anomalies within the shaft that point to fatigue and impending failure. By trend logging, we can determine when to schedule shaft replacement and eliminate breakdowns.

Lubrication Consultant, Southwest…

I’m referring to a large process operation that had a long-standing, trained, certified, and successful vibration group. [Working there], I was eventually asked to start a lubrication program for the entire facility and try to ramp up rotating-equipment reliability. Becoming the site’s lubrication specialist/engineer, I attended training and obtained several certifications.

In time, we bought and started a lubrication laboratory and began pulling oil samples [from equipment] and testing them and any lubricants delivered to the site. In addition, we provided training necessary for many employees to achieve their own certifications in the lubrication field. Improvements in the rotating equipment were unbelievable.

We also bought and are continuing to use thermal imaging at the site.

[Basing this statement on personal experience], if sites would use these three tools, i.e., vibration analysis, lubrication analysis, and thermal imaging, they will capture great rewards in rotating-equipment reliability and save significant money. The key is to buy and keep up with the most modern equipment available. Technologies change more rapidly than most people think.

Finally, [plants should] provide much more professional training, for everyone. Sites will get more for their money from training than anything else. Keeping personnel trained and certified will always pay off. 

About the EP Reader Panel

The Efficient Plan Reader Panel includes approximately 100 working industrial-maintenance practitioners and consultants who have volunteered to answer monthly questions prepared by our editorial staff. Panelist identities are not revealed and their responses are not necessarily projectable. Note that our panel welcomes new members. To be considered, email your name and contact information to jalexander@efficientplantmag.com with “Reader Panel” in the subject line. All panelists are automatically included in an annual cash-prize drawing after one year of active participation.