Predictive Maintenance Programme

Predictive maintenance focuses on tests and inspections that detect deteriorating conditions and helps minimize unplanned equipment outages. Activities commonly involved in predictive maintenance include vibration analysis, motor current signature analysis, lubrication oil analysis, and periodic efficiency testing. As such actions highlight opportunities for corrective actions to improve system efficiency, they can help realize energy savings.

Development Status Products
Commercial

Predictive Maintenance ProgrammeCosts & Benefits

Parent Process: Pump Systems
Energy Savings Potential

This measure is estimated to offer following improvement potentials (UNIDO, 2010):
• 12% for low efficiency base cases;
• 9% for medium efficiency base cases;
• 3% 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  3348 36764
Canada 999 12445
EU 2403 22579
Thailand 250 2513
Vietnam 95 1359
brazil 353 3931
CO2 Emission Reduction Potential

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

US 2018
Canada 497
EU 1048
Thailand 130
Vietnam 47
brazil 52

Costs

Estimated typical capital costs of this measure for different system sizes (S) are:
• US $8000  for S < 37 kW;
• US $8000 for 37 kW < S < 75 kW;
• US $10000 for 75 kW < S < 150 kW;
• US $10000 for 150 kW < S < 375 kW;
• US $12000 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 189.0
Canada 182.0
EU 223.1
Thailand75.0 
Vietnam 70.6
brazil 87.3

Predictive Maintenance Programme Publications

Page Number: 

21-48