Predictive Maintenance - Technology Selection Matrix

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Pumps                
Electric Motors                
Condensors                
Generators (Diesel)                
Cranes / Heavy Equipment                
Circuit Breakers                
Valves                
Piping                
Tanks                
Heat Exchangers                
Electrical Systems (General)                
Electro Mechanical System                
Transformers                
Conveyor - Belt                
Conveyor - Screw                
Screen (Shaker, Wet, Dry)                
Dryer                
Heater               
Fan                
Mechanical Systems (Gearboxes, Reducers etc)                
Crushers (Cage, Roll, Hammer)                

Vibration Monitoring
 Measuring vibration displacement, velocity, or acceleration using transducers like accelerometers and velosometers.
Lubricant Analysis
 Analyzing oil condition and its ability to lubricate according to design specifications (viscosity, acidity, etc.).
 Analyzing oil chemical composition to ensure additives are present in correct concentration (corrosion inhibitors).
 Testing lubrication circuit integrity by looking for contaminants such as water and silicon (Karl Fischer Water Test etc.).
Wear Particle Analysis
 Machine health monitoring and wear life quantification by examining wear particles inside the lubricant (ICP Spectroscopy etc.).
Bearing Temperature Analysis
 Monitoring temperature of the bearings using an infrared thermometer or other thermo-graphic imaging technology.
Performance Monitoring
 Monitoring and trending of process performance parameters such a pressure, temperature, and flow rates to optimize equipment reliability.
 Conceptually similar to “Operating Dynamics Analysis”.
Ultrasonic Noise Detection/Ultrasonic Analysis
 Monitoring and trending ultrasound waves emanating at a frequency over 20 kHz (outside of human hearing rage). Small, lightweight hand-held
ultrasonic detectors can be used for this type of analysis.
Infrared Thermography
 Monitoring thermal profile of equipment using IR cameras.
NDT Thickness Testing
 Using ultrasonic thickness testing (UTT) techniques to access loss of thickness due to metal loss.
Visual Inspection
 Visually checking machine components to ensure that equipment is running safely.
Insulation Resistance Testing
 Detecting insulation failures resulting from excessive heat/cold, vibration, and aging wear (e.g. spot reading tests can be conducted by using a meg-
ohmmeter across the insulation windings –a test voltage can then be applied for a fixed time duration).
Motor Current Signature Analysis (MCSA)
 Current signature analysis is non-intrusive method for detecting equipment health problems in motor driven rotating equipment.
 Concept – An Electric motor running mechanical equipment senses load fluctuations within that equipment and converts them into electric current
signatures that can be monitored using MCSA.
Motor Circuit Analysis (MCA)
 Motor circuit health monitoring through electrical testing (using: Ammeter, Meg-Ohmmeter, Volt Ohm Meter, LRC bridge, Oscilloscope etc.)
Polarization Index (PI)
 PI ratio is a measure of the insulation resistance of the motor - taken at different points in time.
 PI ratio can be used to monitor the health of the insulation system and power circuit of the motor.
Electrical Monitoring
 Electrical power quality monitoring/ voltage quality monitoring.
 Energy monitoring & power metering (voltage/current harmonic distortion, kWh usage, kVA, kVAR, voltage, and current).
 Identification of power factor correction related problems.
 Harmonic voltage and current monitoring (prevents overheated equipment, breaker trips etc.).
Crack Growth Monitoring
 Fatigue crack growth propagation monitoring using smart sensors (ultrasonic, image analysis, piezoelectric wafer active sensors etc.).
Part of Project VAULT Predictive Maintenance (PdM) Philosophy Document – AGU-RPT-00335 – Amit S. Aulakh, P.Eng. – Jan 14, 2010