Condition-based Maintenance

Condition-based Maintenance (CBM): A Strategic Guide

Condition-based Maintenance
Marvin Oosterhof

Marvin Oosterhof

Marketing & Sales

We help energy companies with independent consulting services and software plant & IT solutions to improve the effiency.

Introduction

In an era where operational efficiency is key, Condition-based Maintenance (CBM) emerges as a strategic approach to not only solve but also prevent equipment-related issues. By adopting CBM, organizations can ensure the optimal use of resources, leading to enhanced efficiency and productivity.

 

Understanding Condition-based Maintenance

Condition-based maintenance is a forward-thinking maintenance strategy focused on prevention. It operates on the principle of conducting maintenance when it is needed, based on the equipment’s condition. This allows you to avoid costly unplanned downtime and equipment failure while improving equipment reliability.

At its core, CBM is systematic and proactive. It eliminates the guesswork in maintenance schedules, ensuring that critical components are never overlooked and maintenance is performed correctly the first time. This approach not only prevents breakdowns but also extends the lifespan of equipment.

 

Key Advantages of Condition-Based Maintenance

  • Cost Reduction: By minimizing unscheduled downtime and preventing equipment failure, CBM significantly cuts costs.
  • Enhanced Efficiency: It optimizes the use of resources by addressing potential issues before they escalate, avoiding production or safety impacts.
  • Improved Equipment Performance: Predictive analytics facilitate the early detection of problems, reducing repair times and preventing revenue loss.

 

Approaches to Condition-Based Maintenance

Condition-based maintenance (CBM) is a strategy within predictive maintenance that focuses on maintaining equipment efficiency by performing maintenance only when necessary. It relies on advanced sensor technology to monitor various parameters such as vibration levels, temperature, and pressure in real time or at specific intervals. This monitoring helps in detecting changes that may indicate potential equipment failures. By analyzing this data, CBM allows for the early identification of issues, enabling proactive maintenance actions to prevent unserviceable conditions.

The approach not only helps in maintaining equipment reliability but also significantly reduces the costs and operational disruptions associated with unscheduled shutdowns and repairs. CBM’s effectiveness lies in its ability to provide continuous insights into equipment health, ensuring that maintenance efforts are both timely and precisely targeted to where they are needed most, thereby optimizing the overall maintenance process.

Condition-based maintenance can be applied to a wide range of assets, like process analyzers, and it is most effective when combined with analyzer management and data acquisition system, (AMADAS) that allows you to track and manage your equipment.

Avoid Bad Actors Today

AML-AMADAS is key. Optimizing the performance to increase uptime, reliability and availability, minimize costs and reduce risks.

Avoid Bad Actors

AML-AMADAS is key to avoid bad actors. We helped +130 major companies to improve their uptime, reliability and availability, minimize costs and reduce risks.

Condition-Based Maintenance vs. Preventive Maintenance

Unlike preventive maintenance’s schedule-based approach, CBM is condition-oriented, focusing on real-time equipment status rather than predetermined timelines. This flexibility allows for maintenance based on actual need, regardless of equipment age or usage patterns.

 

Is Condition-Based Maintenance Suitable for Your Business?

CBM could be your strategy of choice if your operation involves:

  • A large number of assets requiring constant monitoring.
  • Complex and costly equipment like process analyzers.
  • The need for centralized monitoring across various locations.

If transitioning from preventive to condition-based maintenance is feasible in terms of costs and risks, CBM might be the ideal solution for maintaining your equipment efficiently.

 

AML-AMADAS: Your Condition-Based Maintenance Partner

AML-AMADAS enables organizations to transition from reactive problem-solving to proactive error prevention by offering real-time data on online equipment performance through process, diagnostic, historical, and maintenance monitoring. This shift towards prevention enhances profitability, safety, and sustainability. It incorporates ASTM Standards such as ASTM D3764 for system validation and ASTM D6299 for Statistical Quality Control (SQC) evaluation. By improving equipment reliability, performance, and safety, AML-AMADAS helps reduce maintenance costs and downtime, aiming for a lower Total Cost of Ownership (TCO).

View AML-AMADAS Walkthrough: https://www.hint-global.com/demo-aml-amadas/

 

Case Study: Sadara Chemical Company

Sadara Chemical Company, a joint venture between Saudi Aramco and Dow, established in October 2011, features the world’s largest chemical complex built in a single phase in Jubail Industrial City, Saudi Arabia. It comprises 26 integrated manufacturing plants with over 3 million metric tons of capacity yearly and a $20 billion investment. The complex is equipped with 1400+ process analyzers, 24 continuous emission monitoring system analyzers, and 1800+ gas detectors.

Hint’s project scope with Sadara included supplying the AML-AMADAS software package and delivering comprehensive project services for system implementation, from specification and design to startup and commissioning. This deployment stands as one of the largest of its kind, with the AML software distributed across multiple servers, including an AML Enterprise Server for the web application and central database, and IO servers for real-time field system interaction.

Benefits of AML-AMADAS for Sadara include approximately $2 million in annual savings through efficient resource management, an 80% reduction in routine laboratory line samples, real-time analyzer monitoring, predictive analyses capabilities, a needs-based maintenance program, scalable enterprise solutions, automated validation management, and enhanced control over Planned Preventive Maintenance (PPM) activities. This comprehensive system allows for improved performance, cost reduction, and predictive maintenance capabilities. Download Case Study here

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