Predictive Maintenance: The Role of Your Pressure Gauges

Predictive Maintenance www.WIKA-FAST.com 1
Maintenance Strategies
WIKA - Part of your business

51%
Plant, property and equipment
make up the majority of their
total investments
Maintenance Challenges:
How do you maintain your company’s most
important assets?
Source: IDC Energy Insights, 2010

Three Most Common Approaches to Maintenance
Approach Technique Needed Human Body Parallel
Reactive Maintenance Large budget
Unplanned loss of
production
Stroke or heart attack
Preventive Maintenance Periodic component
replacement
Bypass or transplant
Predictive Maintenance Monitoring of heat,
vibration, pressure, flow,
alignment and other
indicators
Detection with regular
check-ups, EKG or other
monitoring

Predictive Maintenance: Impressive Cost Reduction
Statistics compiled by the U.S. Department of Energy and the Federal Energy Management Program
provide valuable insight into the need for predictive maintenance programs:

Maintenance and Reliability
Joined at the Hip
 Many companies have moved to a Predictive
Maintenance approach to monitor “critical”
process equipment, such as large compressors
and turbines
 However, monitoring second-tier, “essential”
equipment – such as small compressors,
pumps, blowers, pipes, or cooling towers – may
be deemed too cost-prohibitive
 Yet, failures of these essential assets represent
the majority of unplanned slowdowns and
slowdowns (see Figure 1)
 And can comprise 70% of your maintenance
budget (see Figure 2)
SOURCE: “Improve reliability with essential asset monitoring,” InTech, May/June 2012.
http://www.isa.org/InTechTemplate.cfm?template=/ContentManagement/ContentDisplay.cf
m&ContentID=89645
0%
5%
10%
15%
20%
70% of total maintenance
budget consumed by only 7
asset classes
Figure 1
Figure 2

Predictive Maintenance
Need for Early Identification
So how do you become more predictive?
One key is reading the warning signs so you can act before unplanned downtime
happens
A vast majority (81%) of
companies using Predictive
Maintenance have instituted
“alerts and alarm management”
as a core functionality*
* Source: Aberdeen Group

Rethinking Instrumentation
Gauges & Their Role in Reliability

“An Ounce of Prevention…”
 What do all companies like yours
have that are relatively inexpensive
and can support predictive
maintenance efforts?
 Gauges, which can:
 Help you protect “essential”
equipment
 Serve as a relatively low-cost alert
to potential problems, including
downtime

Gauges & Reliability
 A mechanical gauge can serve as a low-cost,
mechanical back-up for your monitoring software
 Or, it can serve as entry point to Predictive
Maintenance if you don’t have monitoring software
 You can use gauges to:
 Detect signs of degradation in process
performance
 Diagnose causes of system and production
disruptions
 Predict how long a piece of equipment can be
safely and economically run
 Identify potential loss of process or loss of
containment

Challenge
•A gauge in a large chemical manufacturing plant that transfers a brine/salt water solution ruptured and released media Solution
•WIKA examined gauge and found root cause of failure was overpressure
•Brine solution became diluted and froze, causing pressure system to expand and rupture—when ambient temperature warmed, media poured out from the gauge
Results
•WIKA recommended customer investigate the installation to determine cause of overpressure situation
•Pressure gauge served as early warning system for much bigger problem with
•potentially disastrous results
•Company identified freezing issue before it ruptured the piping system
Case Study

The Pressure Gauge:
Current State
of pressure gauges
reviewed have failed or are in
danger of failing.
40%

Where’s the Expertise?
“As many as 40% of
U.S. petroleum
engineers currently
employed by the
industry will retire by
2015.”
IDC Energy Insights
“The Role of Predictive Analytics in Asset
Optimization for the Oil and Gas Industry”
October 2010
 To start using gauges as predictive indicators,
you first need the right gauges in the right
places…and that takes expertise
 You may not know a lot about
instrumentation…or even care to learn more
 Or maybe your engineers have retired…

A New Way Forward
WIKA Services

Let us be your gauge experts
Full Audit Service Team
 Gauges, if used properly, can help you
identify an issue before costly problems
develop
 Our Full Audit Service Team (FAST) will
take care of your gauges to help
o Lower inventory costs
o Improve reliability
o Reduce gauge maintenance costs
 And best of all, FAST is the only solution
you need—a total care services program
at no additional cost to you

Predictive Maintenance www.WIKA-FAST.com Full Audit Service Team (FAST)
16
FAST Expertise
Expertise
Over
250
Instrument
Audits
Over
150K
Instruments
Reviewed

Predictive Maintenance www.WIKA-FAST.com A Full Suite of
Services at Zero Cost
17
FAST Program
Instrument
Audit
Turnaround
Instrument
Planning
Instrument
Failure Analysis
Instrument Safety
Training
WIKA’s Instrument
Audit provides expert
analysis and solutions
form our FAST
engineers who help you
put the right gauges in
place for your
applications to improve
reliability and lower
costs.
Our team performs an
Instrument Audit,
standardizes the
instruments you need
and sends the products
to you when you need
them... before your
turnaround begins so
you can avoid delays.
Send us your failed
gauge, and our
engineers will conduct
a root cause analysis.
By understanding the
mode of failure, our
FAST engineers can
recommend a reliable
solution.
Our FAST engineers
train your team to look
for signs of instrument
failure when completing
a scheduled evaluation
of your instrumentation.

FAST Instrument Audit
 Visual inspection of pressure, temperature gauges to build a
comprehensive record of gauge installations and rate problematic
conditions
 Data analysis to provide engineering-based recommendations that
improve, standardize and consolidate your population
 Implementation support, including ERP imports, MOC
documentation, and Easy Order Guides
 Improves reliability, and decreases inventory and maintenance costs
year after year
Establishes a Sustainable Gauge Maintenance
Program

25%
20%
30%
Average FAST Audit Savings
$51,171Ɨ in first year savings,
Ongoing annual savings of $21,073ƗƗ
Less gauge failures and
less time to replace
Correct gauges for
processing
conditions
Standardize on full
scale ranges, options
for gauges
Decrease
Maintenance Costs*
Reduction in
Inventory*
Increase in
Reliability*
First year savings only includes engineering resources for physical audit, storeroom review, data
compilation, and implementation support. Based on average audit of 1,000 installations, requiring
two instrumentation engineers for one week
ƗƗ Ongoing annual savings. Inventory savings based on industry averages for overhead, inventory
management, shrinkage, obsolescence, inventory tax, and cost of capital
*Based on results from more than 250 WIKA instrument audits

 Our team performs a full Instrumentation
Audit and standardizes what
instruments you need...before your
turnaround actually begins
 With this advanced preparation, we
ensure that the right instruments are at
your plant at the exact time you need
them – eliminating the risk of delay
 Action plan with part number, IOM and
data sheet for each installation
FAST Turnaround Instrument Planning
Ensure the Right Instrumentation for
Start-up

FAST Instrument Failure Analysis
Getting to the Root of the Problem
 If you have gauges that are continually
failing, then send them to us
 Our FAST engineers will perform a root
cause analysis
 Can alert you to problems with more
expensive equipment
 Reduces likelihood of downtime and
decreases maintenance costs

FAST Instrument Safety Training
 Education and training are best tools to
maintain operational efficiency and
employee safety in your plant
 Our Instrument Safety Training will teach
your team to look for warning signs
 Held at your site or ours, the training helps
reduce maintenance costs and wrench
time
22
FAST FACT
U.S. process plants lose more than $10 billion per year
from abnormal situations caused by human error.
Source: Abnormal Situation Management Consortium
FAST Instrument Safety Training

WIKA Products
Everything You Need for Your
Low-Cost Monitoring System

Years of testing culminated in premiere
process gauge that:
 Reduces downtime from regularly replacing
worn-out instruments
 Improves safety and efficiency
 Produce most precise measurements with
its Swiss-made movements
 Exceeds pressure gauge standards ASME
B40.100 and EN 837-1 (mandatory
performance testing)
 Fire-resistant case with flammability rating
according to UL 94, V-0 test procedures
XSEL®: The Process Gauge You Helped Design

XSELTM Process Gauge
Best-in-Class for Process Industry
XSEL Process Gauge
Culmination of German Engineering, Swiss Precision and
American Manufacturing…

All-Welded System
For the Most Extreme Environments
 Diaphragm seal and pressure gauge
permanently welded together to create a
sealed pressure measurement system
 Removes all threaded connections to
eliminate potential leak paths
 Helium leak tested
 Helium is the smallest stable gas
molecule, so if we can contain it, we
can contain your gases
 Complies with EPA’s Dual Containment
Requirements
 Removes possibility of misapplication or
tampering

Potential Leak Point
 WIKA welds its stainless steel case to its
stainless steel socket
 Other manufacturers screw the socket
into the gauge with a rubber O-ring,
which is prone to wear out and create a
leak point
 With thousands of gauges in your
plant, it’s impossible to monitor
each one
 That’s why WIKA has developed
solutions to protect against leaks

Liquid Filled Gauges
Longer Lifetimes and Greater Accuracy
 Liquid filling absorbs vibration and
pulsation, which stabilizes pointer
 Liquid filling shields internal components
from corrosion, moisture, icing, and shock
 Liquid filling lubricates and cools moving
parts, dramatically reducing wear

Direct Drive Gauges
Give Us Your Worst
 One moving part – a helically-wound
Bourdon tube
 A tube made of Inconel X-750 alloy,
highly resistant to temperature
extremes with excellent oxidation
and corrosion properties
 No gears, linkages or springs to
wear or break
Direct Drive Gauges
Give Us Your Worst

Temperature Gauges
Performance Plus Peace of Mind
Silicone free and available in temperature
ranges not possible with case fill
Eliminates the need for case fill that can
leak or discolor under extreme
temperatures
All angle swivel connection allows
mounting in a variety of positions
World’s first dampened movement thermometer
eliminates pointer flutter caused by vibration

Gauge Accessories
When Your Gauge Needs Extra Protection

How much could you gain with a
FAST Audit?
Contact us to Learn More about WIKA’s
FAST Services.
1-855-651-FAST
info@wika-fast.com

Predictive Maintenance: The Role of Your Pressure Gauges

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