Continuous Monitoring and Precision Maintenance expands the reliability process in the areas of data acquisition and analysis coupled with precision maintenance. PCA determines opportunities to combine business information systems to monitor the most critical equipment and processes. Process and maintenance management systems are combined to provide real-time condition monitoring and analysis. It is important to fix problems reliably when they first develop and not wait for the end of the month. Quality, compliance and safety, for example, cannot wait.

PCA’s Continuous Monitoring and Precision Maintenance service provides a method to enhance typical condition based monitoring and preventive maintenance. These activities are normally provided on an agreed upon timetable and assumes there is enough information to predict failure, and enough time to address it. Many times equipment is not accessible and cannot be effectively or safely monitored manually while running. Critical processes and equipment require “real-time” information that monitors many functions to determine overall capability and reliability. The needed system often already exists in the form of DCS or other PLC monitoring of process parameters.

PCA engineers will work with your information technicians in expanding this monitoring to include machinery condition. Real-time alarms can then be established that trigger the work management system to initiate corrective actions. Of equal importance is the installation and repair of equipment reliably. Precision maintenance opportunities are primarily focused on critical rotating equipment. Asset care techniques such as static and dynamic balancing, shaft alignment, bearing fit, lubrication, etc., are assessed for performance and effectiveness by PCA engineers. This entire optimization process typically takes 20 days.

The process involves the following levels:

• Level 1. Activities include: gap analysis, four-hour leadership workshop, and preparation of a detailed plan/schedule for optimization of continuous monitoring and precision maintenance activities, and correction of gaps. PCA reliability engineers conduct a complete critical equipment review.
• Level 2. Activities include the identification of the people and equipment that will be involved in the Continuous Monitoring and Precision Maintenance process. Once this step is completed, detailed training is provided, current technology gaps are corrected, and the data and reporting network and procedures are established. This includes assistance with developing the process of continuous monitoring, and precision maintenance standard tasks for targeted critical equipment.
• Level 3. The hands-on application of the continuous monitoring and precision maintenance principles and data to the actual plant equipment is the chief activity at this stage. During Level 3, the standard procedures of routine data collection and precision maintenance tasks are established, and actual monitoring of alarm conditions are initiated or modified, and integrated into work schedules for daily and repair-day work. In addition, the feedback loop is established, and actual data is collected and analyzed for the continuous optimization of the condition based and precision maintenance activities. Calibration requirements are also determined to ensure that hidden protective devices are not in failed states, which would inhibit alarm conditions of critical equipment.

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