DXP Pacific Industrial Pumps

6 Ways to Improve Predictive Maintenance

All pump systems can benefit from predictive maintenance (PdM). There are different methods you can use to monitor equipment and track key performance indicators, allowing you to detect potential problems before they happen. This way, you can address them in advance of catastrophic failures and increase uptime helps avoid significant repair expenses.

Here are 6 of the most common predictive maintenance methods you can implement:

  1. Oil Analysis

Proper lubrication is vital to pump equipment performance and durability. If the oil is contaminated or the levels are too low, machinery components will wear faster and eventually fail. The predictive maintenance method of oil analysis focuses on monitoring lubricating fluids and greases throughout your pump system. In addition, you can analyze lubrication purity, viscosity, and chemical content to recognize any problematic changes.

2. Ultrasound Analysis

Many heavy equipment pieces can emit strong ultrasounds when early issues occur. These sounds may not be audible to human ears, but they are clear signs that something might be wrong. Ultrasonic monitoring equipment can recognize even the slightest changes in sound to detect potential failures and machinery malfunctions.

3. Infrared Thermography

Equipment temperature is another telltale sign that a problem is developing within your pump system. Most pump equipment is designed to operate within consistent and optimal temperature ranges. Infrared thermographic technology allows you to monitor temperatures throughout critical areas of the pump system precisely. If something is running too hot or cold, you will know it instantly.

4. Vibration Analysis

You can start seeing a simple pattern with all of these predictive maintenance methods as they focus on one key indicator of equipment performance and health. Excessive vibration is another common cause of system failure, leading to increased component wear and significant damage if left ignored. Machine-mounted accelerometers can monitor vibration levels across three axes: vertical, horizontal, and axial to detect any changes in standard vibration frequency.

5. Partial Discharge Monitoring

Partial discharges (small electrical sparks which do not completely bridge the electrodes) occur in the electrical and insulation components of the pump system. Generally, partial discharges are an early indicator of insulation deterioration. Sensors can be employed to catch these partial discharges and notify the operator to address insulation and electrical concerns before they worsen.

6. Motor-Current Signature

An electric motor drive system can develop current inconsistencies, leading to cracks in the rotor and other issues. Technology can easily monitor the motor-current signature and identify any inconsistencies or problematic frequencies.

These six predictive maintenance tips are some of the most common and effective. Some of these require specialized technology and training. Similarly, some can monitor equipment and keep track of many different sensors and indicators. Predictive maintenance is effective and saves you significant money over time through early problem identification and elimination of major failures.

To learn more about advanced monitoring systems, predictive maintenance equipment, and proven monitoring methods like these, contact DXP Pacific today.