Predictive Maintenance

Key condition monitoring techniques:

Vibration Analysis:
The cornerstone of rotating equipment monitoring:

What It Detects:
- Bearing wear and defects
- Gear damage
- Imbalance
- Misalignment
- Looseness
- Resonance issues

Measurement:
- Accelerometers measure vibration
- Amplitude (how much)
- Frequency (how fast)
- Time waveform and spectrum analysis

Severity Assessment:
- ISO standards for acceptable levels
- Trending for change detection
- Spectral analysis for specific defects

Oil Analysis:
Reveals internal condition of lubricated systems:
- Wear particles (metal content)
- Contamination (dirt, water)
- Lubricant condition (viscosity, degradation)
- Schedule based on results, not time

Infrared Thermography:
Heat reveals problems:
- Electrical connections (loose, corroded)
- Motor and bearing overheating
- Process issues (blocked, restricted)
- Insulation failures

Ultrasonic Testing:
High-frequency sound detection:
- Bearing lubrication assessment
- Leak detection (compressed air, steam)
- Electrical discharge detection
- Early bearing fault detection

Motor Testing:
Electrical condition of motors:
- Insulation resistance (megohm testing)
- Motor current signature analysis
- Winding resistance
- Voltage imbalance effects

Turning measurements into actionable information:

Data Collection:

Manual Routes:
- Technician walks route with portable collector
- Consistent measurement points
- Regular intervals (monthly typical)
- Cost-effective for smaller programs

Online Monitoring:
- Permanently installed sensors
- Continuous or frequent data collection
- Critical machinery focus
- Higher investment, faster detection

Integration:
- CMMS integration for work orders
- Historian databases for trending
- Analytics platforms for advanced analysis

Analysis Techniques:

Trending:
- Track parameters over time
- Detect gradual degradation
- Establish baseline normal
- Set alarm thresholds

Spectral Analysis:
- Vibration frequency breakdown
- Identify specific defects
- Bearing frequencies, gear mesh
- Requires training to interpret

Machine Learning:
- Pattern recognition in data
- Anomaly detection
- Remaining useful life prediction
- Growing capability and adoption

Reporting:

Condition Reports:
- Current status of monitored equipment
- Severity ratings
- Recommended actions
- Priority ranking

Exception Reports:
- Only equipment with issues
- Focus attention where needed
- Actionable information

Building an effective PdM program:

Program Development:

Start Small:
- Pilot on critical equipment
- Prove value before expanding
- Build skills progressively
- Learn from experience

Equipment Selection:
- Focus on critical assets first
- High consequence of failure
- Expensive to repair
- Safety implications

Baseline Establishment:
- Document normal condition
- Set alarm thresholds
- Create equipment database
- Note measurement locations

Technology Selection:
Based on equipment and resources:
- Vibration for rotating equipment
- Thermography for electrical and thermal
- Oil analysis for lubricated systems
- Choose appropriate level of investment

Organization:

In-House vs. Contract:
- In-house: control, immediate response
- Contract: expertise without full-time staff
- Hybrid: routine in-house, specialized contracted

Training:
- Certification programs (Vibration Institute, ASNT)
- Vendor training on equipment
- Ongoing skill development

Integration:
- Connect PdM to maintenance planning
- CMMS integration
- Operations communication
- Management reporting

Success Metrics:
- Unplanned downtime reduction
- Maintenance cost reduction
- Failure prediction accuracy
- PM elimination (replace with PdM)

PdM expertise commands premium compensation:

Technical Roles:

PdM Technician:
Collect and analyze condition data:
- Route-based data collection
- Basic analysis and reporting
- Coordinate with maintenance planning
- $55,000-$75,000

Reliability Engineer:
Design and optimize PdM programs:
- Technology selection
- Analysis of complex problems
- Program development
- $75,000-$110,000

PdM Analyst:
Focus on data analysis and prediction:
- Advanced vibration analysis
- Machine learning application
- Multi-technology analysis
- $70,000-$100,000

Contractor/Consultant:
Provide services to multiple clients:
- Specialized expertise
- Multiple industries
- Higher earning potential
- $80,000-$150,000+

Certifications:
Essential for credibility:

Vibration:
- Vibration Institute: Category I-IV
- ISO 18436-2 based
- Widely recognized

Thermography:
- ASNT Level I-III
- Industry standard

Oil Analysis:
- ICML certifications
- Machinery lubrication specialist

Multi-Technology:
- CMRP (Certified Maintenance & Reliability Professional)
- CRL (Certified Reliability Leader)

Career Path:
1. Maintenance technician foundation
2. PdM technology exposure
3. Certification in one technology
4. Add technologies progressively
5. Reliability engineering role
6. Management or consulting

Industries actively seeking PdM professionals include pulp/paper, power generation, petrochemical, and heavy manufacturing.