Predictive Maintenance starts with Condition Analysis.
The condition of a machine is analyzed to identify and
document any current or developing problems.
IMPACT Engineering begins most machine condition
surveys with vibration detection. Machine vibration is
one of the best indicators of the overall condition of any
rotating machinery. Machine defects such as misalignment,
imbalance, and bearing wear are detected with vibration
monitoring and analysis.
IMPACT Engineering also incorporates ultrasonic bearing
and coupling wear/fault detection to identify problems
long before vibration increases would indicate a fault is
present. Bearing lubrication problems or coupling fault
detection by a non-contact probe are other examples
where ultrasonic detection is used to detect potential
Lube Oil Analysis
Lube oil analysis, in conjunction with vibration and
ultrasonic data, allows IMPACT Engineering to create one
of the earliest fault detection models possible. Wear
particles, contaminants, degradation, and water content
are items analyzed in each lube oil sample.
Infrared imaging is used to detect electrical component
“hot spots” that result from overloading, loose
connections, or insulation damage. Like most detection
methods used by IMPACT Engineering, infrared imaging
is performed during normal uninterrupted operation to
extend machinery life and promote a more effective
electrical preventive maintenance program.
Predictive Maintenance (PDM)
Traditionally, two major types of maintenance strategies
have been utilized:
Predictive Maintenance (PDM) describes a maintenance
approach of determining a machine’s condition and its
need for maintenance without disturbing normal
- Reactive Maintenance (RM) – Run until failure.
- Preventive Maintenance (PM) – Overhaul at designated
time intervals prior to expected failure.
Predictive Maintenance is accomplished by utilizing
vibration analysis, ultrasonic analysis, lubricating oil
analysis, thermographic/infrared inspections, plus other
condition monitoring techniques for determining
operating condition and detecting faults. From trending
and diagnostic results of the PDM information, an active
approach of systematically finding and eliminating the
underlying causes of machine problems can then be
IMPACT Engineering takes Predictive Maintenance one
step further with Total Reliability Management (TRM).
This asset management strategy is results-driven to
achieve maximum reliability and has been designed for
the maintenance industry to minimize initial installation
related problems, highlight developing machinery defects,
reduce machine downtime, and defer open-and-inspect
requirements when justified. Well maintained, reliable
operating machinery produces substantial, wide-ranging
cost savings as illustrated in the above chart.
*Source: R.J. Hudachek and V.R. Dodd, ASME, “Progress and Payout
of a Machinery Surveillance and Diagnostic Program”.