Unplanned downtime and unexpected equipment failures cost facilities time and money. These challenges are often a reality for facilities utilizing clean air technologies. Predictive maintenance can change this reality. Predictive maintenance turns data into action, ensuring maintenance can be done before there is a costly problem.
Dustex®, Geoenergy®, and Western Pneumatics are now part of ANDRITZ, a leader in clean air technologies and services. Keep reading to learn more about predictive maintenance for clean air technologies.
What Is Predictive Maintenance?
Predictive maintenance is one of many maintenance strategies that should be incorporated into facility operations. Predictive maintenance allows maintenance to be scheduled when it is needed instead of waiting for costly breakdowns. Predictive maintenance utilizes sensors and analytics to provide real-time data that drives maintenance decisions. As technology improves, so does the available data, allowing for quicker decisions and improved operations. Predictive maintenance is a proactive approach, and when combined with preventative maintenance, can help to extend the life of equipment and optimize performance.
Where to Begin?
Predictive maintenance begins with an audit. During an audit, our knowledgeable and experienced team provides a comprehensive assessment of all clean air technologies and equipment. The audit will include an inspection of all equipment and facilities.
The audit also helps our team to establish a baseline for the equipment and systems. A baseline is the operating norm that is used to track operating trends and provide insight regarding ongoing operations. After the initial audit, our team provides a written service report and a tailored maintenance plan. The maintenance plan includes both preventative maintenance and predictive maintenance.
ANDRITZ is your partner for audits of clean air technologies and equipment. Our experienced team provides a comprehensive suite of services, including recommendations and solutions based on your specific needs.
Preventative Maintenance Checklist
A preventative maintenance checklist combined with a predictive maintenance checklist ensures operational efficiency and optimal performance for clean air technologies and equipment. A preventative maintenance checklist is tailored to each company’s specific needs. While each checklist is different, some tasks that may be included are discussed below.
Inspect
Preventative maintenance includes regularly scheduled inspections. Inspection needs will vary based on the facility and equipment, but may include some or all of the following:
- Fanit
- Motors
- Belts
- Bearings
- Couplings
- Ductwork
- Housings
- Joints
- Filters
- Bags
- Dampers
- Venttiilit
- Scrubber sprays
- Pumps
- Electrodes
- Insulators
- Power supplies
Clean
The cleaning schedule should include all equipment, and depending on the system, may include hoppers, conveyors, and discharge equipment.
Test
Scheduled testing should be comprehensive and based on the equipment and applicable regulations. This may include the cleaning systems, control panels, and alarms.
Calibrate
All sensors and monitoring instruments for the clean air technologies and equipment should be calibrated to ensure accuracy and functionality. Calibration frequency varies according to regulatory requirements, manufacturer recommendations, sensor or instrument type, usage, and environment.
Document
All ongoing maintenance and compliance activities should be thoroughly documented.
Schedule
Maintenance schedules should be regularly checked to ensure adherence and updated as needed. Maintenance logs should be regularly checked. Any issues that were identified should have a follow-up schedule for timely resolution. From inspection to lasting solutions, ANDRITZ is your partner for every step of the preventative maintenance process.
Predictive Maintenance Checklist
A predictive maintenance checklist complements a preventative maintenance checklist for efficient ongoing operations of clean air technologies and equipment. As with the preventative maintenance checklist, the predictive maintenance checklist is tailored to each company’s specific needs and individual equipment. Each checklist is different. Some tasks that may be included are those discussed below.
Monitor
Data-based monitoring provides a proactive response to equipment issues. The basis of predictive maintenance is monitoring. Monitoring will vary based on the needs of the clean air technologies and equipment. Systems and trends that may be monitored include the following:
- Paine
- Pressure drop
- Airflow
- Temperature
- Cleaning effectiveness
- Voltage/current stability
- Collection efficiency
Track
Consistent and reliable tracking is also part of predictive maintenance. Tracking will vary by equipment and needs. Fan vibration, motor load, liquid flow, and pH may all be tracked.
Analyze
Data must be consistently analyzed to ensure ongoing system operations. Analysis should include awareness of performance changes and other potential issues. Even gradual changes can have a significant impact over time.
Plan
Monitoring, tracking, and analyzing are all important tools to help plan for potential issues and maintenance needs. All available information can and should be utilized to resolve any potential issues before they become actual problems. Unlike reactive maintenance, predictive maintenance can be planned to accommodate the schedule of the facility.
Document
As with preventative maintenance, all ongoing maintenance and compliance activities should be thoroughly documented.
Contact ANDRITZ
At ANDRITZ, we are at the forefront of maintenance for clean air technologies and equipment. Our trained and knowledgeable team offers the expertise you need to keep your facilities operating efficiently.
Are you ready to reduce downtime, extend equipment life, and improve performance? Contact ANDRITZ today to schedule your equipment audit and develop a predictive maintenance plan.
