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, and inventory. Topline performance Maintenance Capex Operational downtime 2 Predictive Maintenance Solutions by Indalyz AG
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 Sensors attached to software to present forecasts object of machinery integrity. Sensors attached to environment (e.g. weather stations, water flow, etc.) Manual data entry of pTec historical and present data 3 Predictive Maintenance Solutions by Indalyz AG
pTec is highly sophisticated having multiple facets and solution processes to provide the most accurate forecast possible. Process Uses historical & current artificial intelligence data algorithms Able to process by Multiple parts or masses time horizons without compromise in forecasting Robust Forecasting of filtering & projection future probability formalization techniques of defaults Customized condition Recommendation on Monitoring optimal conditions of machine status 4 Predictive Maintenance Solutions by Indalyz AG
How the basic process works for pTec. Data Data Input Data Output Processing Data that is collected from Using high-performance Data is presented in a multiple sources through computers, the collected user-friendly format and sensor-based systems: data is processed and the supports decision-making future state of the processes in order to • Vibration technical equipment is make cost-efficient • Temperature presented. planning of maintenance • Noise work by reducing • Oil pressure downtime and increasing • Etc. operational time. 5 Predictive Maintenance Solutions by Indalyz AG
Some of the pTec applications in the real world. Immobile Mobile 6 Predictive Maintenance Solutions by Indalyz AG
Our services with pTec. Installations Operations & maintenance Software updates Planning (sensor and hardware system) Customization of Graphical User Interface (GUI) Staff training Customization of maintenance software Analysis and report 7 Predictive Maintenance Solutions by Indalyz AG
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 8 Predictive Maintenance Solutions by Indalyz AG
pTec in comparison to other maintenance strategies Condition-based Predictive Reactive Maintenance Maintenance • Data-driven or model-based • Replacement of parts or the prognosis of the machines whole machine after a failure future condition has occurred • Requirements: prognosis • “Run until it breaks“ 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 Time-based Preventive Condition-based Preventive Maintenance Maintenance • Maintenance according to • Monitoring of the current timed manufacturer machine condition specifications. • Maintenance only after • “Fix it regardless” reaching the critical machine • Costly and labor-intensive condition • Frequently maintenance- • Often spontaneous machine related downtime shutdown • Application example: condition monitoring 9 Predictive Maintenance Solutions by Indalyz AG
Comparing the key elements of pTec to other strategies pTec Preventive Predictive Preventive Condition-based condition-based time-based Properties Monitoring 24/7 online 24/7 online Routine inspection Subjective Data sourcing Sensor Sensor diagnosis Prediction None Available None Repair criterion User fault function Predictive fault Running time Downtime Average Minimal Average Maintenance Running time Reactive Prediction-defined management 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 10 Predictive Maintenance Solutions by Indalyz AG
pTec values can simply minimize loss of revenue, reduce expenses, and tighten maintenance operations in a better way versus other strategies. Better IRR’s & ROI’s. 11 Predictive Maintenance Solutions by Indalyz AG
Value proposition of pTec versus other strategies. Optimized maintenance planning o Minimize costly damaging events o Reduce maintenance costs and o downtime Increase of plant availability and o production rate (increase in overall equipment effectiveness) Reduction of production costs o Forecast the remaining useful life o (increase asset lifecycle) 12 Predictive Maintenance Solutions by Indalyz AG
pTec process flow. Continuous data collection Sensor system & weather station Local application Data compression SQL-database Collective prognosis system & dynamic expert Vector database system 13 Predictive Maintenance Solutions by Indalyz AG
pTec trial study 800 wind turbines • 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 Results over 6 month Damaging event Damaging event NOT period prognosticated prognosticated Alarm signal 94.83 % 4.65 % No alarm signal 0.52 % • first-time pro-active maintenance planning • high accuracy of forecasting improves profitability • calculation of residual term of partially damaged components origin parameter 6-month forecast percentile curve curve 14 Predictive Maintenance Solutions by Indalyz AG
pTec quantified on savings based on 40MWp wind farm Time-based Condition-based maintenance maintenance pTec One-time reduction of mean electricity $0.00362/kWh 0.362 ct/kWh $0.00234/kWh production costs Mean reduction of operating expenses EUR 868,800 EUR 561,600 p.a. 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. Cost savings of pTec compared to preventive condition-based & time- based maintenance Postponement of down time Reduction of unscheduled down time preventive condition- Reduction of scheduled down time based maintenance preventive time-based maintenance Reduction of maintenance costs timely error detection - 100.000 200.000 300.000 400.000 500.000 (cost savings potential in EUR) 15 Predictive Maintenance Solutions by Indalyz AG
pTec A predictive maintenance software solution as integral part of Industry 4.0 solving the Big Data issue. 16 Predictive Maintenance Solutions by Indalyz AG
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) 17 Predictive Maintenance Solutions by Indalyz AG
More recommend
