Predictive Maintenance Program

Predictive maintenance refers to scheduled testing and measurement, and trending of the results over time. Proper analysis of the results can predict an impending failure so that necessary action (repair, cleaning, or alignment) can be scheduled before a costly failure occurs. For compressed air systems, predictive maintenance may include vibration analysis, oil analysis, and thermographic surveys that can identify overheating issues and electrical faults.

As predictive control approaches tend to be more costly, they are usually justified for larger systems.

Development Status Products
Commercial

Predictive Maintenance ProgramCosts & Benefits

Parent Process: Compressed Air Systems
Energy Savings Potential

This measure is estimated to offer following improvement potentials:
• 10% for low efficiency base cases;
• 5% for medium efficiency base cases;
• 1% for high efficiency base cases.

Electrical and primary energy savings potential of this technology for diffierent countries is estimated as following (UNIDO, 2010): 

  Final (GWh/y) Primary (TJ/y)
US 1964 21572
Canada 519 6461
EU 1507 14160
Thailand 641 9925
Vietnam 288 4119
brazil 698 7787
CO2 Emission Reduction Potential

Total emisson reduction potential, as kt CO2/y for different countries are estimated as (UNIDO, 2010): 

US 1184
Canada 258
EU 657
Thailand 333
Vietnam 141
brazil 101

Costs

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $500  for S < 37 kW;
• US $1000 for 37 kW < S < 75 kW;
• US $2000 for 75 kW < S < 150 kW;
• US $5000 for 150 kW < S < 375 kW;
• US $10000 for 375 kW < S < 745 kW; (UNIDO, 2010)

Cost of conserved energy, expressed as US $/MWh-saved, in different countries are estimated as following: (UNIDO, 2010)

US 33.4
Canada 33.7
EU 36.9
Thailand 4
Vietnam 4
brazil 7.4

Parent Process:
Energy Savings Potential
CO2 Emission Reduction Potential

N/A

Costs

Predictive Maintenance Program Publications

Page Number: 

52-63

Page Number: 

22