pTec Predictive Maintenance Solution Predictive Maintenance - - PDF document

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pTec Predictive Maintenance Solution Predictive Maintenance - - PDF document

Jan 28, 2024 1.09k likes •1.29k views

pTec Predictive Maintenance Solution Predictive Maintenance Solutions by Indalyz AG What if you were able to forecastwhen your equipment will fail, or when maintenance should really be performed? Being able to control budgets, downtimes,

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Predictive Maintenance Solutions by Indalyz AG

Predictive Maintenance Solution

pTec

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What if you were able to forecastwhen your equipment will fail, or when maintenance should really be performed? Being able to control budgets, downtimes, and inventory. Operational downtime Topline performance Maintenance Capex

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With pTec it takes past data, current data, all data possible through both manual data entry and sensor systems attached to machinery. Data is then processed through special proprietary software to present forecasts

  • f machinery integrity.

pTec

Sensors attached to

  • bject

Manual data entry of historical and present data Sensors attached to environment (e.g. weather stations, water flow, etc.)

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Predictive Maintenance Solutions by Indalyz AG

4 Process

historical & current

data Uses

artificial intelligence

algorithms Able to process by

parts or masses

without compromise Robust

filtering & projection

formalization techniques Multiple

time horizons

in forecasting Forecasting of

future probability

  • f defaults

pTec is highly sophisticated having multiple facets and solution processes to provide the most accurate forecast possible.

Recommendation on

  • ptimal conditions

Customized condition

Monitoring

  • f machine status
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Predictive Maintenance Solutions by Indalyz AG

5 Data Input Data Processing Data Output

Data that is collected from multiple sources through sensor-based systems:

  • Vibration
  • Temperature
  • Noise
  • Oil pressure
  • Etc.

Using high-performance computers, the collected data is processed and the future state of the technical equipment is presented. Data is presented in a user-friendly format and supports decision-making processes in order to make cost-efficient planning of maintenance work by reducing downtime and increasing

  • perational time.

How the basic process works for pTec.

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6 Immobile Mobile

Some of the pTec applications in the real world.

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Planning (sensor and hardware system) Customization of Graphical User Interface (GUI) Staff training Customization of maintenance software Analysis and report Installations Operations & maintenance Software updates

Our services with pTec.

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Innovative solutions for predictive maintenance is critical due to the complexitiesthat come with collecting and processing data.

¨ Technical equipment are highly complex to analyze and assess ¨ Multiple sources of data, and big data ¨ Unpredictability of events

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Condition-based Predictive Maintenance Reactive Maintenance

  • Data-driven or model-based

prognosis of the machines future condition

  • Requirements: prognosis

based on machine model or sufficient amounts of historical sensor data (long-term condition monitoring data)

  • Advantages: long-term

maintenance planning and reduction of downtime

  • Replacement of parts or the

whole machine after a failure has occurred

  • “Run until it breaks“

Time-based Preventive Maintenance Condition-based Preventive Maintenance

  • Maintenance according to

timed manufacturer specifications.

  • “Fix it regardless”
  • Costly and labor-intensive
  • Frequently maintenance-

related downtime

  • Monitoring of the current

machine condition

  • Maintenance only after

reaching the critical machine condition

  • Often spontaneous machine

shutdown

  • Application example: condition

monitoring

pTec in comparison to other maintenance strategies

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10 Properties Preventive Condition-based Predictive condition-based Preventive time-based Monitoring 24/7 online 24/7 online Routine inspection Data sourcing Sensor Sensor Subjective diagnosis Prediction None Available None Repair criterion User fault function Predictive fault Running time Downtime Average Minimal Average Maintenance management Reactive Prediction-defined Running time intervals Repair costs Moderate Optimal High Installation costs High* High* None Operating costs Moderate Moderate None Customer benefit Average High Low Scalability Any desired Any desired Any desired

Comparing the key elements

  • f pTec to other strategies

pTec

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pTec values can simply minimize loss of revenue, reduce expenses, and tighten maintenance

  • perations in a better way

versus other strategies. Better IRR’s & ROI’s.

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Value proposition of pTec versus other strategies.

  • Optimized maintenance planning
  • Minimize costly damaging events
  • Reduce maintenance costs and

downtime

  • Increase of plant availability and

production rate (increase in

  • verall equipment effectiveness)
  • Reduction of production costs
  • Forecast the remaining useful life

(increase asset lifecycle)

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Vector database SQL-database Local application

Sensor system & weather station Data compression

Collective prognosis system & dynamic expert system Continuous data collection

pTec process flow.

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  • Forecast of technical condition of 800 wind turbines over 3 years
  • Computer-based processing of historical condition monitoring data
  • Sensor data: approx. 2,000 technical parameters
  • Data processing of over 1.6 million time series
  • Forecast period: 3 - 6 months
  • first-time pro-active maintenance planning
  • high accuracy of forecasting improves profitability
  • calculation of residual term of partially damaged components

Results over 6 month period Damaging event prognosticated Damaging event NOT prognosticated Alarm signal 94.83 % 4.65 % No alarm signal 0.52 %

percentile curve 6-month forecast curve

  • rigin parameter

pTec trial study 800 wind turbines

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  • 100.000

200.000 300.000 400.000 500.000

timely error detection Reduction of maintenance costs Reduction of scheduled down time Reduction of unscheduled down time Postponement of down time

preventive condition- based maintenance preventive time-based maintenance

(cost savings potential in EUR)

pTec quantified on savings based on 40MWp wind farm Cost savings of pTec compared to preventive condition-based & time- based maintenance

pTec Time-based maintenance Condition-based maintenance One-time reduction

  • f mean electricity

production costs $0.00362/kWh 0.362 ct/kWh $0.00234/kWh Mean reduction of

  • perating expenses

p.a. EUR 868,800 EUR 561,600 pTec = forecasted data determines real required maintenance months in advance. Time-based = maintenance taking place at a predetermined and fixed time regardless of state. Condition-based = maintenance taking place determined by current state.

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A predictive maintenance software solution as integral part of Industry 4.0 solving the Big Data issue.

pTec

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Contact

Indalyz AG

Software Development Sales & Distribution Logistics Tel.: +41 41 743 07 28 Fax.: +41 41 743 07 33 email: getinfo@indalyz.com Web: www.indalyz.com Riedstrasse 7 CH-6330 Cham

Indalyz Monitoring & Prognostics GmbH A cooperation partner of Indalyz AG

Project Implementation Research & Innovation Tel.: +49 345 27 95 56 10 Fax.: +49 345 27 95 56 13 email: info@imprognostics.com Web: www.imprognostics.com Weinbergweg 23 D-06120 Halle (Saale)