Palestine Polytechnic University

College of Engineering
electrical Engineering Department

Fault Diagnostic and IA system Maintenance

Predictive Maintenance

By:
Mohammad Shanti

Supervisor:

Dr : Abdelkarim Daud
Predictive Maintenance :-
Predictive maintenance is a technique that uses
condition-monitoring tools and techniques to track the
performance of equipment during normal operation to
detect possible defects and fix them before they result in
failure.
Ideally, predictive maintenance allows the maintenance
frequency to be as low as possible to prevent unplanned
reactive maintenance, without incurring costs associated
with doing too much preventive maintenance.
How does predictive maintenance work?
Predictive maintenance uses condition-monitoring
equipment to evaluate an asset’s performance in real-time. A
key element in this process is the Internet of Things (IoT).
IoT allows for different assets and systems to connect, work
together, and share, analyze and action data.
IoT relies on predictive maintenance sensors to capture
information, make sense of it and identify any areas that
need attention. Some examples of using predictive
maintenance and predictive maintenance sensors include
vibration analysis, oil analysis, thermal imaging, and
equipment observation.
Choosing the correct technique for performing condition
monitoring is an important consideration that is best done
in consultation with equipment manufacturers and
condition monitoring experts.
DESIGNING A PREDICTIVE MAINTENANCE PROGRAM
An effective predictive maintenance program must include
both condition-driven and time-driven tasks. These tasks are
determined by the specific equipment and systems that
constitute the plant. At a minimum, each plant should
evalute:
• Failure data
• Improving equipment reliability
• Improvement process
• Failures that can be prevented
• Maintenance to prevent failures
• Personnel
• Service Teams

Preventive maintenance depends on the sensors that

convert the physical signals into electrical signals and
I will explain this through the following examples:-
1- Oil Pressure Sensor
The main job of an engine oil pressure sensor is to keep
track of the oil pressure in the MACHINE and then transmit
this information straight to the combination meter or the
instrument panel.

If the machine has an electronic control module, then the oil

pressure switch will send this information to the module
where it can be calculated. After it is calculated, the
information gets sent to the combination meter or
instrument panel so that the engine oil pressure warning
light or the oil pressure gauge can be activated.
2- Thermography
Thermography is a method of inspecting electrical and
mechanical equipment by obtaining heat distribution
pictures. This inspection method is based on the fact
that most components in a system show an increase in
temperature when malfunctioning. The increase in
temperature in an electrical circuit could be due to
loose connections or a worn bearing in the case of
mechanical equipment. By observing the heat patterns
in operational system components, faults can be
located and their seriousness evaluated.
The inspection tool used by Thermographers is the Thermal
Imager. These are sophisticated devices which measure the
natural emissions of infrared radiation from a heated object
and produce a thermal picture. Modern Thermal Imagers are
portable with easily operated controls. As physical contact
with the system is not required, inspections can be made
under full operational conditions resulting in no loss of
production or downtime.

Thermography can be used in many faults, such as the

electrical faults shown in the image :-
Usually, a computerized system is used in expensive
machines such as high-capacity electricity generators, which
give signals such as oil shortage, high temperature, voltage
difference, or change of filters.

This is a system that supports the preventive maintenance of

an electric generator so that many sensors are connected to
check the generator in terms of oil, load, current, voltage,
cooling ... and other things.
 This image from the System Book explains what are the
errors and how to solve them

Refrains
1- http://www.irantpm.ir/wp-content/uploads/2008/02/an-introduction-to-predictive-
maintenance.pdf
2- http://www.lirkorea.com/Landinstruments.net%20Website/infrared/downloads/pdf
/thermography_guide.pdf
3- http://s-e-t.ru/techdocs/Manual_DCP-10.pdf

end