Key points
Heat exchanger upkeep is a mission-critical concern for many facilities. When this equipment fails, so will the infrastructure it’s supposed to cool before long. At the same time, regular repair and maintenance can be costly and time-consuming.
Predictive maintenance (PdM) offers an answer. This method employs Internet of Things (IoT) devices to track a heat exchanger’s condition in real time. Instead of running to failure or following a set schedule, technicians repair equipment when these devices alert them of an issue. It’s a fairly complex but promising solution that could be the future of heat exchanger upkeep.
Benefits of PdM for Heat Exchangers
PdM is relatively expensive and challenging to implement compared to alternative methods. However, the benefits far outweigh these obstacles if manufacturers execute it properly.
Maximised Heat Exchanger Performance
The most obvious advantage of PdM for heat exchangers is that it’s more effective at keeping this equipment in top condition. Some facilities have seen up to 20% increases in productivity and virtually eliminated breakdowns through this method. That’s because PdM lets manufacturers address issues before they’re outwardly noticeable.
In the context of heat exchangers, PdM solutions can monitor fouling within a system. This real-time insight lets maintenance personnel remove buildup before it causes other issues. As a result, the exchanger lasts longer and performs at its peak for extended stretches.
Less Downtime
Similarly, PdM reduces maintenance-related downtime. Some of these savings come from preventing breakdowns. However, PdM also minimises downtime from unnecessary repairs, as many preventive fixes don’t add value because equipment issues rarely happen on a consistent schedule.
PdM’s early warnings ensure manufacturers address issues while they’re still small. As a result, each repair doesn’t take as long, further reducing downtime. Considering a heat exchanger can last up to 20 years, these savings add up to substantial uptime improvements over its service life.
Reduced Maintenance Costs
Despite being more expensive initially, PdM also reduces long-term repair costs. Much of this cost reduction stems from addressing maintenance concerns before they cause malfunctions. Heat exchanger issues quickly become more expensive as they persist since decreased performance affects other machinery. Because PdM fixes errors earlier, it prevents these outcomes.
PdM also carries lower personnel costs, as repairs are fewer and further between than conventional preventive care. Similarly, manufacturers will experience fewer losses from downtime or decreased productivity in the heat exchanger and the equipment it protects. Over time, these savings more than compensate for PdM’s upfront costs.
Ongoing Improvement Opportunities
As a data-centric solution, PdM can also make it easier to implement ongoing improvements. This repair strategy is only possible with extensive analysis of real-time data. That same analysis can reveal larger heat exchanger operational trends, suggesting where and how the system can improve.
A heat exchanger’s maintenance sensors may detect fouling occurring with increasing frequency, indicating an error somewhere else. These trends will also reveal when replacing the exchanger is more cost-effective than continuing to repair it. Alternatively, sensors may show that moisture in the equipment hinders the cooling system’s efficacy. The facility could then switch to dry steam, which contains just 5% moisture, to minimise these errors.
Credit: unsplash.com Predictive maintenance results in fewer repairs, reducing downtime and labour costs.
Implementing PdM for Heat Exchangers Effectively
Predictive maintenance results in fewer repairs, reducing downtime and labour costs.
Of course, no system is perfect. PdM has unique challenges, including the potential for false positives, which have resulted in increased downtime in some organisations. Given how critical heat exchangers are, it’s important to implement this technology carefully to avoid missteps and ensure a strong return on investment.
There are three related reasons PdM projects fail — facilities have machines of varying ages with differing needs, there are thousands of them and this combination creates overwhelming data volumes. PdM algorithms need lots of data to work, but it can be challenging to manage if there's too much.
The key is to start small with the process that has the most to gain. Given their criticality and frequent maintenance needs, heat exchangers are an excellent starting point for many facilities. Don't just apply PdM to heat exchangers but to one specific system.
Next, businesses must collect enough data. This includes real-time readings from IoT sensors and supplementary information like OEM-recommended practices and repair cost factors. This broader data scope will minimise false positive risks and enable more reliable alerts.
Take detailed notes on this initial PdM rollout and any issues. This information will inform more effective PdM projects when expanding it to other heat exchangers.
Heat Exchangers Need Predictive Maintenance
Fouling and other issues mean heat exchangers have more regular maintenance requirements than other industrial equipment. This regularity of repair and the importance of these systems make them the perfect use case for predictive maintenance.
PdM can be complicated, but if manufacturers approach it carefully and address common pitfalls, the benefits are astounding. As more organisations catch on to this potential, PdM will become the new standard, transforming heat exchanger operations for good.
