Condition-Based Maintenance Using a Real-Time Data Infrastructure

Paul and Peter plan to build reusable equipment templates to simplify integration with their maintenance processes and streamline integration with other systems. The process of building equipment templates is the same as adding context to a process unit (see Chapter 3). There are additional ways to add context to data as required to solve particular problems, which are discussed later in this chapter.

Paul, the Proclndustries' maintenance manager, expects their asset management program should see drastic improvements over their current methodology. The strategy they use in maintenance can be applied to other functions such as production, quality, accounting, environmental conditions, safety, engineering, and marketing. The system capability to classify the data online as well as to generate triggers and alerts is the foundation for all performance metrics. The combined analysis of all these factors results in a balanced, environmentally safe, profitable operation.

Figure 6.5 shows the gathering of data for several sources, which is enabled by the EIDI in real time. The strategy is as follows:

  • 1. Data acquisition
  • 2. Analysis assessment and notification
  • 3. Maintenance program integration
  • 4. Work order change management

Tracking equipment health within the infrastructure also allows for web- based analytical tools to be used to integrate maintenance status information for any requested time range. It is imperative to test the logic and workflow of a condition-based monitoring process that intends to automatically send transactions to CMMS. This can be done over a period or history of data to ensure that there is confidence established once the process is automated.


CBM process workflows (data, assessment, maintenance policies, and work order).


Condition-based maintenance strategy using EIDI data.

Figure 6.6 shows operational intelligence strategy schematics. The diamond represents the analytics portion of the automated procedure. The boxes represent the outcomes, which are various ways that people and systems benefit.

To get the Proclndustries CBM initiative started, Paul and his team prepare sample templates for pumps and compressors. They include real-time collection of equipment sensor data and integration with targets or equipment parameters. They configure the object model and define proper analytics to trigger a notification to the appropriate people and their CMMS.

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