Predictive Maintenance: The Role of Your Pressure Gauges

1 Predictive Maintenance www.WIKA-FAST.com

Maintenance Strategies

WIKA - Part of your business


51% Plant, property and equipment

make up the majority of their

total investments

Maintenance Challenges:

How do you maintain your company’s most

important assets?

Source: IDC Energy Insights, 2010


Three Most Common Approaches to Maintenance

Approach Technique Needed Human Body Parallel

Reactive Maintenance Large budget

Unplanned loss of

production

Stroke or heart attack

Preventive Maintenance Periodic component

replacement

Bypass or transplant

Predictive Maintenance Monitoring of heat,

vibration, pressure, flow,

alignment and other

indicators

Detection with regular

check-ups, EKG or other

monitoring


Predictive Maintenance: Impressive Cost Reduction

Statistics compiled by the U.S. Department of Energy and the Federal Energy Management Program

provide valuable insight into the need for predictive maintenance programs:


Maintenance and Reliability

Joined at the Hip

Many companies have moved to a Predictive

Maintenance approach to monitor “critical”

process equipment, such as large compressors

and turbines

However, monitoring second-tier, “essential”

equipment – such as small compressors,

pumps, blowers, pipes, or cooling towers – may

be deemed too cost-prohibitive

Yet, failures of these essential assets represent

the majority of unplanned slowdowns and

slowdowns (see Figure 1)

And can comprise 70% of your maintenance

budget (see Figure 2)

SOURCE: “Improve reliability with essential asset monitoring,” InTech, May/June 2012.

http://www.isa.org/InTechTemplate.cfm?template=/ContentManagement/ContentDisplay.cf

m&ContentID=89645

0%5%

10%15%

20%

70% of total maintenance budget consumed by only 7

asset classes

Fig

ure

1

Fig

ure

2

http://www.isa.org/InTechTemplate.cfm?template=/ContentManagement/ContentDisplay.cfm&ContentID=89645





Predictive Maintenance

Need for Early Identification

So how do you become more predictive?

One key is reading the warning signs so you can act before unplanned downtime

happens

A vast majority (81%) of

companies using Predictive

Maintenance have instituted

“alerts and alarm management”

as a core functionality*

* Source: Aberdeen Group


Rethinking Instrumentation

Gauges & Their Role in Reliability


“An Ounce of Prevention…”

What do all companies like yours

have that are relatively inexpensive

and can support predictive

maintenance efforts?

Gauges, which can:

Help you protect “essential”

equipment

Serve as a relatively low-cost alert

to potential problems, including

downtime


Gauges & Reliability

A mechanical gauge can serve as a low-cost,

mechanical back-up for your monitoring software

Or, it can serve as entry point to Predictive

Maintenance if you don’t have monitoring software

You can use gauges to:

Detect signs of degradation in process

performance

Diagnose causes of system and production

disruptions

Predict how long a piece of equipment can be

safely and economically run

Identify potential loss of process or loss of

containment

Challenge

• A gauge in a large chemical manufacturing

plant that transfers a brine/salt water solution

ruptured and released media

Solution

• WIKA examined gauge and found root cause

of failure was overpressure

• Brine solution became diluted and froze,

causing pressure system to expand and

rupture—when ambient temperature warmed,

media poured out from the gauge

Results

• WIKA recommended customer investigate the

installation to determine cause of overpressure

situation

• Pressure gauge served as early warning

system for much bigger problem with

• potentially disastrous results

• Company identified freezing issue before it

ruptured the piping system

Case Study


The Pressure Gauge:

Current State

of pressure gauges

reviewed have failed or are in

danger of failing.

40%


Where’s the Expertise?

“As many as 40% of

U.S. petroleum

engineers currently

employed by the

industry will retire by

2015.”

IDC Energy Insights

“The Role of Predictive Analytics in Asset

Optimization for the Oil and Gas Industry”

October 2010

To start using gauges as predictive indicators,

you first need the right gauges in the right

places…and that takes expertise

You may not know a lot about

instrumentation…or even care to learn more

Or maybe your engineers have retired…


A New Way Forward

WIKA Services


Let us be your gauge experts

Full Audit Service Team

Gauges, if used properly, can help you

identify an issue before costly problems

develop

Our Full Audit Service Team (FAST) will

take care of your gauges to help

o Lower inventory costs

o Improve reliability

o Reduce gauge maintenance costs

And best of all, FAST is the only solution

you need—a total care services program

at no additional cost to you


Full Audit Service Team (FAST)

16

FAST Expertise

Expertise

Over

250 Instrument

Audits

Over

150K Instruments

Reviewed


A Full Suite of

Services at Zero Cost

17

FAST Program

Instrument

Audit

Turnaround

Instrument

Planning

Instrument

Failure Analysis

Instrument Safety

Training

WIKA’s Instrument

Audit provides expert

analysis and solutions

form our FAST

engineers who help you

put the right gauges in

place for your

applications to improve

reliability and lower

costs.

Our team performs an

Instrument Audit,

standardizes the

instruments you need

and sends the products

to you when you need

them... before your

turnaround begins so

you can avoid delays.

Send us your failed

gauge, and our

engineers will conduct

a root cause analysis.

By understanding the

mode of failure, our

FAST engineers can

recommend a reliable

solution.

Our FAST engineers

train your team to look

for signs of instrument

failure when completing

a scheduled evaluation

of your instrumentation.


FAST Instrument Audit

Visual inspection of pressure, temperature gauges to build a

comprehensive record of gauge installations and rate problematic

conditions

Data analysis to provide engineering-based recommendations that

improve, standardize and consolidate your population

Implementation support, including ERP imports, MOC

documentation, and Easy Order Guides

Improves reliability, and decreases inventory and maintenance costs

year after year

Establishes a Sustainable Gauge Maintenance

Program


25%

20%

30%

Average FAST Audit Savings

$51,171Ɨ in first year savings,

Ongoing annual savings of $21,073ƗƗ

Less gauge failures and less time to replace

Correct gauges for processing conditions

Standardize on full scale ranges, options for gauges

Decrease Maintenance Costs*

Reduction in Inventory*

Increase in Reliability*

First year savings only includes engineering resources for physical audit, storeroom review, data compilation, and implementation support. Based on average audit of 1,000 installations, requiring two instrumentation engineers for one week ƗƗ Ongoing annual savings. Inventory savings based on industry averages for overhead, inventory management, shrinkage, obsolescence, inventory tax, and cost of capital *Based on results from more than 250 WIKA instrument audits


Our team performs a full Instrumentation

Audit and standardizes what

instruments you need...before your

turnaround actually begins

With this advanced preparation, we

ensure that the right instruments are at

your plant at the exact time you need

them – eliminating the risk of delay

Action plan with part number, IOM and

data sheet for each installation

FAST Turnaround Instrument Planning

Ensure the Right Instrumentation for

Start-up


FAST Instrument Failure Analysis

Getting to the Root of the Problem

If you have gauges that are continually

failing, then send them to us

Our FAST engineers will perform a root

cause analysis

Can alert you to problems with more

expensive equipment

Reduces likelihood of downtime and

decreases maintenance costs


FAST Instrument Safety Training

Education and training are best tools to

maintain operational efficiency and

employee safety in your plant

Our Instrument Safety Training will teach

your team to look for warning signs

Held at your site or ours, the training helps

reduce maintenance costs and wrench

time

22

FAST FACT U.S. process plants lose more than $10 billion per year

from abnormal situations caused by human error.

Source: Abnormal Situation Management Consortium

FAST Instrument Safety Training


WIKA Products

Everything You Need for Your

Low-Cost Monitoring System


Years of testing culminated in premiere

process gauge that:

Reduces downtime from regularly replacing

worn-out instruments

Improves safety and efficiency

Produce most precise measurements with

its Swiss-made movements

Exceeds pressure gauge standards ASME

B40.100 and EN 837-1 (mandatory

performance testing)

Fire-resistant case with flammability rating

according to UL 94, V-0 test procedures

XSEL®: The Process Gauge You Helped Design

http://cdna.eventstreams.com/wika/wika_017_xsel_360.mp4


XSELTM Process Gauge Best-in-Class for Process Industry

XSEL Process Gauge

Culmination of German Engineering, Swiss Precision and

American Manufacturing…


All-Welded System

For the Most Extreme Environments

Diaphragm seal and pressure gauge

permanently welded together to create a

sealed pressure measurement system

Removes all threaded connections to

eliminate potential leak paths

Helium leak tested

Helium is the smallest stable gas

molecule, so if we can contain it, we

can contain your gases

Complies with EPA’s Dual Containment

Requirements

Removes possibility of misapplication or

tampering


Potential Leak Point

WIKA welds its stainless steel case to its

stainless steel socket

Other manufacturers screw the socket

into the gauge with a rubber O-ring,

which is prone to wear out and create a

leak point

With thousands of gauges in your

plant, it’s impossible to monitor

each one

That’s why WIKA has developed

solutions to protect against leaks


Liquid Filled Gauges

Longer Lifetimes and Greater Accuracy

Liquid filling absorbs vibration and

pulsation, which stabilizes pointer

Liquid filling shields internal components

from corrosion, moisture, icing, and shock

Liquid filling lubricates and cools moving

parts, dramatically reducing wear


Direct Drive Gauges Give Us Your Worst

One moving part – a helically-

wound Bourdon tube

A tube made of Inconel X-750 alloy,

highly resistant to temperature

extremes with excellent oxidation

and corrosion properties

No gears, linkages or springs to

wear or break

Direct Drive Gauges

Give Us Your Worst


Temperature Gauges

Performance Plus Peace of Mind

Silicone free and available in temperature

ranges not possible with case fill

Eliminates the need for case fill that can

leak or discolor under extreme

temperatures

All angle swivel connection allows

mounting in a variety of positions

World’s first dampened movement thermometer

eliminates pointer flutter caused by vibration


Gauge Accessories

When Your Gauge Needs Extra Protection


How much could you gain with a

FAST Audit?

Contact us to Learn More about WIKA’s

FAST Services.

1-855-651-FAST

[email protected]

Predictive Maintenance: The Role of Your Pressure Gauges

Engineering

Transcript of Predictive Maintenance: The Role of Your Pressure Gauges