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What are the most important predictive maintenance techniques for plant operations?

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Predictive maintenance is a proactive approach to keeping plant equipment in optimal condition and avoiding costly breakdowns. It involves monitoring the performance and condition of assets, identifying potential failures, and scheduling timely interventions. In this article, we will explore some of the most important predictive maintenance techniques for plant operations and how they can benefit your career.

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1 Condition monitoring

Condition monitoring is the process of collecting and analyzing data from sensors, meters, gauges, and other devices that measure the physical parameters of plant equipment, such as temperature, vibration, pressure, and flow. Condition monitoring can help you detect signs of wear, deterioration, or malfunction before they lead to failure or damage. You can use condition monitoring to establish baselines, trends, and thresholds for your assets and compare them with historical or expected values. Condition monitoring can also help you optimize your maintenance schedules, reduce downtime, and extend equipment life.

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Eamonn Caswell

NEBOSH Cert OHS / 40 yrs in cement ind, Process operations to Manufacturing Eng / experienced in buildup removal, HPWJ and Preheater blockages / LEV management / Planned Maint and shutdown planning / Uttoxeter crafts
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The above is for a running process, there is another CBM that uses plant inspectors/operators to carry out CBM on things that all the above cannot do! Such as wear measurements on chains, rollers belts and internals of filters and oil samples of critical plant. Gaining analysis is critical to enable a decision for replacement or leave it until another maintenance period. Making sure that maintenance costs are controlled effectively at all times. The analysis will also give you opportunities to possibly change future specifications to increase the life or gain more efficiency within the plant. When CBM is implemented you need to have historical data to work with new knowledge. If its a new plant then you have to go by OEM recommendation

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2 Fault detection and diagnosis

Fault detection and diagnosis is the process of identifying and locating the root cause of a problem in a plant system or component. Fault detection and diagnosis can help you prevent or minimize the impact of failures, improve safety and reliability, and reduce repair costs and time. You can use fault detection and diagnosis techniques such as fault tree analysis, root cause analysis, failure mode and effect analysis, and statistical process control to analyze the symptoms, sources, and consequences of faults. Fault detection and diagnosis can also help you implement corrective actions, prevent recurrence, and learn from failures.

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Eamonn Caswell

NEBOSH Cert OHS / 40 yrs in cement ind, Process operations to Manufacturing Eng / experienced in buildup removal, HPWJ and Preheater blockages / LEV management / Planned Maint and shutdown planning / Uttoxeter crafts
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Having sat through many RCA’s it’s critical that the whole management team have a “No blame culture” as it could easily be human error that could the root cause. You will get nowhere quickly and no buy in to improve reliability, so read carefully. The most important thing identifying is the actual root cause and ensure that the weaknesses are identified and any training requirements are laid out as well. Ensure you have the right people at the RCA as if not then you may never find what it actually was, you need people there that reacted to the event. Pictures, plant trends and historical data are all key to getting the right outcome. The MM doesn’t need to be at the RCA, that can be delegated to suitably trained personnel.

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3 Predictive analytics

Predictive analytics is the process of using advanced mathematical and statistical methods to analyze data and make predictions about future events or outcomes. Predictive analytics can help you forecast the performance, behavior, and condition of your plant equipment and systems, as well as the demand, supply, and cost of your operations. You can use predictive analytics techniques such as regression, classification, clustering, and machine learning to identify patterns, trends, and anomalies in your data and generate insights and recommendations. Predictive analytics can also help you optimize your processes, improve your decision making, and enhance your competitiveness.

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4 Digital twin

A digital twin is a virtual representation of a physical asset, system, or process that simulates its real-time behavior and performance. A digital twin can help you create a dynamic and interactive model of your plant equipment and systems, as well as the environment and context in which they operate. You can use a digital twin to monitor, control, and test your assets remotely, as well as to explore different scenarios, configurations, and alternatives. A digital twin can also help you improve your design, innovation, and collaboration, as well as your operational efficiency and effectiveness.

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5 Reliability engineering

Reliability engineering is the process of applying engineering principles and techniques to ensure that plant equipment and systems perform their intended functions consistently and dependably. Reliability engineering can help you design, build, and maintain your assets to meet or exceed your quality, safety, and performance standards and expectations. You can use reliability engineering techniques such as reliability testing, reliability modeling, reliability allocation, and reliability optimization to evaluate, improve, and optimize your assets' reliability. Reliability engineering can also help you reduce your risks, costs, and waste, as well as increase your customer satisfaction and loyalty.

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Eamonn Caswell

NEBOSH Cert OHS / 40 yrs in cement ind, Process operations to Manufacturing Eng / experienced in buildup removal, HPWJ and Preheater blockages / LEV management / Planned Maint and shutdown planning / Uttoxeter crafts
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Building in reliability has an impact on the project costs. Putting it simply, if you wanted a plant consistently do 100 TPH and wanted to put in one with a capacity of 150 TPH as you predict it would improve reliability then that has a knock on effect with the total project cost. A feasibility study needs to be done to evaluate if the extra investment is worth going ahead with, if not then you need to look at projected plant reliability and what you could gain / loose. Looking at existing plants that are running with the installation is also a great investment of time, brilliant for networking as well.

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6 Asset management

Asset management is the process of planning, organizing, and managing the lifecycle of plant equipment and systems, from acquisition to disposal. Asset management can help you align your assets with your organizational goals, strategies, and values, as well as with the needs and expectations of your stakeholders. You can use asset management techniques such as asset inventory, asset tracking, asset valuation, and asset performance management to optimize your asset utilization, availability, and profitability. Asset management can also help you comply with regulatory and ethical standards, as well as enhance your social and environmental responsibility.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What are the most important predictive maintenance techniques for plant operations?

1

2

3

4

5

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7

1 Condition monitoring

2 Fault detection and diagnosis

3 Predictive analytics

4 Digital twin

5 Reliability engineering

6 Asset management

7 Here’s what else to consider

Plant Operations

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What are the most important predictive maintenance techniques for plant operations?

1

2

3

4

5

6

7

1 Condition monitoring

2 Fault detection and diagnosis

3 Predictive analytics

4 Digital twin

5 Reliability engineering

6 Asset management

7 Here’s what else to consider

Plant Operations

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