Predictive Maintenance Program

Similar to other motor systems, in many applications, fan maintenance is reactive to already identified problems rather than proactive. This reactive approach leaves may fan system problems leaves unattended until they become a nuisance, by which time they may have resulted in significantly higher operating costs. Predictive maintenance approaches employ more sophisticated (and thus costly) methods –such as vibration analysis –to investigate the condition and operational performance of the equipment. They not only enable proactive maintenance measures to be taken in order to reduce the risk of an unplanned failure, but also keep the equipment close to its best possible operating conditions, which often reduces operational costs.

Development Status Products
Commercial

Predictive Maintenance ProgramCosts & Benefits

Parent Process: Fan Systems
Energy Savings Potential

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 3% for low efficiency base cases;
• 2% for medium efficiency bas cases;
• 1%for high efficiency base cases.

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

  Final (GWh/y) Primary (TJ/y)
US 674 7398
Canada 124 1540
EU 475 4465
Thailand 59 593
Vietnam 27 386
brazil 108 1204
CO2 Emission Reduction Potential

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

US 406
Canada 61
EU 207
Thailand 31
Vietnam 13 
brazil 16

Costs

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $260  for S < 37 kW;
• US $260 for 37 kW < S < 75 kW;
• US $1000 for 75 kW < S < 150 kW;
• US $2000 for 150 kW < S < 375 kW;
• US $5000 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 26.9
Canada 26.6
EU 28.2
Thailand 7.0
Vietnam 6.9
brazil 9.5

Predictive Maintenance Program Publications

Page Number: 

24, 64-76

Page Number: 

27