Every industry has applications that are critical to overall production and have a serious impact on maintenance staffing and budget. When you partner with Perceptiv, our reliability experts work with you to understand your processes, and the impact of critical equipment and applications. We work hard to keep you up and running.
Perceptiv remote condition monitoring and predictive maintenance solutions help industrial maintenance teams:
- Keep equipment up and running longer
- Schedule maintenance and avoid unplanned downtime
- Extend equipment life
- Reduce route-based inspections
- Prioritize and plan inspections
By leveraging Perceptiv solution’s prescriptive, actionable reliability reports, your team will have clear guidance for maintenance and troubleshooting, including recommendations for repairs or replacements as needed.
When predictive maintenance is guiding the maintenance approach, manpower needs are decreased and safety improves because maintenance personnel are not climbing over equipment, rushing through urgent repairs or working around other operating equipment. Improved safety, increased labor efficiency, decreased inventory stocking, and reduced downtime all lead to an overall decrease in operational costs.
Conveyors
Keep an eye on critical industrial food and beverage conveyors, as well as heavy industry material handling conveyors (i.e. mining, timber, aggregate), to reduce downtime and proactively plan maintenance.
Perceptiv remote vibration and temperature monitoring provides early detection of issues on gearboxes, motors and bearings, including:
- Gear wear or damage
- Bent components
- Misalignment
- Bearing defects (cage, outer/inner race rolling elements)
- Mounting issues (i.e. bolt looseness)
Coilers
When coilers have issues, it inhibits an entire line from producing rolls of steel or aluminium. Perceptiv wireless vibration and temperature monitoring detect:
- Mandrel issues
- Gear wear or damage
- Bent components
- Misalignment
- Motor and gearbox bearing defects (cage, outer/inner race rolling elements)
Aggregate Vibratory Screens
When vibratory screen decks are clogged, production output decreases while excessive loads accelerate the degradation of components such as springs. It is also difficult for maintenance teams to inspect and clean clogged screen decks. When vibratory screens are monitored, clogs will be detected sooner resulting in less time spent cleaning or conducting unnecessary inspections.
Perceptiv continuous wired vibration and temperature monitoring provides:
- Early detection of throughput reduction due to jams/plugs
- Alerts to component wear for motors, bearings
- Elimination of unnecessary inspection and part replacements
Cooling Towers
Unplanned cooling tower failures can shut down a facility. Cooling towers can have undiagnosed issues that go overlooked until an unexpected failure occurs. Perceptiv remote condition and predictive monitoring helps your team proactively take action and avoid unplanned downtime by staying in tune with assets' current conditions without needing to climb towers or exposing teams to harsh environments.
Perceptiv remote vibration and temperature monitoring of gear drives and motors provides early detection of:
- Imbalance (Fan, shaft)
- Misalignment
- Gearbox or motor bearing issues
Cooling Tower Basin Pump Area
Undetected water screen clogs can burn out water pumps and shut down cooling towers. Early notification of water level drops (an indication of clogs) allow teams to quickly take corrective action.
Perceptiv Water Level Detection Monitoring provides:
- Early warning alerts of low water levels due to screen clogs to avoid pump failure
- In addition to condition and predictive monitoring, learn about our new Cambridge® traveling water screen solution to help teams effortlessly remove debris
Fan Drives
Bearings may be inexpensive components, however, when monitored, they are a great early indicator of equipment problems. For example, severe fan drive issues can easily go unnoticed in a loud facility, especially for air handling in baking ovens or HVAC units.
Perceptiv vibration and temperature monitoring of motors and bearings in a fan drive can provide an early detection of:
- Fan imbalance
- Drive misalignment
- Belt drive faults
- Bearing lubrication or defects
- Motor bearing, stator and rotor faults
- Looseness of frame, motor or bearing bolts which can lead to early drive failure
Aggregate Dewatering Basins
An aggregate dewatering basin is paramount to keeping water away from production pits. Therefore, unplanned pump failure can be a big problem.
Perceptiv remote water level monitoring supports risk mitigation planning by providing timely alerts to water level changes and significant pump activity. This helps maintenance teams:
- Reduce visual, regular interval inspections
- Remotely see intermittent water rising due to flooding
- Monitor pump performance, supply power and connectivity
- Protect expensive equipment from flooding
- Reduce expensive downtime
Compressor
Unplanned compressor downtime can require maintenance teams to scramble to make repairs, which may even require waiting for a service call from the original equipment manufacturer.
Perceptiv wireless vibration and temperature monitoring detect:
- Misalignment (i.e. couplings, shafts)
- Process problems
- Bearing defects (cage, outer/inner race rolling elements)
- Mounting issues (i.e. bolt looseness)
Pumps
While sometimes overlooked, in most industrial manufacturing facilities, keeping pumps operating in top performance is critical.
Perceptiv vibration and temperature monitoring keeps watch for early detection of:
- Motor and pump deterioration
- Misalignment (i.e. couplings, shafts)
- Process problems
- Bearing defects (cage, outer/inner race rolling elements)
- Mounting issues (i.e. bolt looseness)
- Cavitation
Fillers
Keep an eye on critical industrial food, beverage, household and cosmetic container fillers to reduce downtime and proactively plan maintenance.
Perceptiv remote vibration and temperature monitoring provides early detection of issues on gearboxes, motors and bearings including:
- Gear wear or damage
- Bent components
- Misalignment
- Bearing defects (cage, outer/inner race rolling elements)
- Mounting issues (i.e. bolt looseness)
Overhead Conveyors
Maintaining overhead conveyors requires extra time, lift equipment and proper safety gear. Issues can easily go unnoticed until unplanned downtime occurs, which could be during a busy season. When using Perceptiv vibration and temperature sensing devices and predictive monitoring services, material handling maintenance teams can know what to fix when and where before even getting onto a scissor lift.
Perceptiv remote monitoring provides early detection of issues on gearboxes, motors and bearings including:
- Gear wear or damage
- Bent components
- Misalignment
- Bearing defects (cage, outer/inner race rolling elements)
- Mounting issues (i.e. bolt looseness)
Rolling Mills
If you're like many mills, your rolling mill equipment is running at or beyond rated capacities. This means torsional failure events are likely lurking around the corner, which can cause unplanned downtime and productivity loss at any moment.
Perceptiv transient torque monitoring and torsional trend analysis proactively alert hot mill teams of:
- Torsional fatigue
- Torque spikes
- Equipment being operated beyond design capabilities
Transient torque monitoring services utilize advanced torsional analysis techniques such as pattern recognition and torsional vibration trending, as well as industry experience to provide actionable and prescriptive maintenance recommendations and their urgency.
These recommendations can include visual inspections, non-destructive testing (NDT) or component replacement, and often suggest product improvements like alternative couplings to help prevent future failures.
Plastic Extruders
Remote monitoring of critical equipment, like plastic extruders can help maintenance teams plan and catch equipment degradation before unplanned downtime impacts production.
Perceptiv remote wireless vibration, temperature and electrical current monitoring provides early detection of:
- Anomalies in power
- Gear wear or damage
- Bent components
- Misalignment
- Bearing defects (cage, outer/inner race rolling elements)
- Mounting issues (i.e. bolt looseness)