2,000 power assets use predictive software to foresee failures; ROI is 6-9 months

Predictive software sees failures before they happen, protecting 2,000 power assets globally, says SmartSignal, with typical return on investment of 6-9 months.


Chicago, ILSmartSignal Plant Availability and Performance Solution (APS) predicts, diagnoses, and prioritizes equipment failures; it identifies and resolves minor issues before they grow into major problems.

DTE Energy (Detroit

SmartSignal says that it works with each plant to configure a solution to fit its unique combination of people, process, and technology. Every plant, no matter what its staffing and culture, to easily deploy SmartSignal Plant APS and quickly achieve measureable ROI—often within a matter of weeks, because of the flexibility of the offering, the company says.
“SmartSignal Plant Availability and Performance Solution has proven beneficial to us in several ways,” says Mike Bennett, operations manager at Mirant Dickerson, a Washington, DC-area power plant that installed SmartSignal Plant APS in March 2007. “First, the quick notifications we receive have enabled us to plan downtime and prevent equipment failures. Second, the weekly item reporting has enabled us to improve plant work orders and plan corrective maintenance. Third, when we run into a performance issue, we’ll call the SmartSignal team to explore the model and help us identify abnormal trends.”
Over the last year, SmartSignal has worked with clients to eliminate thousands of rotating and non-rotating equipment failures. In the process of driving down costs and improving safety, plants employing SmartSignal Plant APS have:
• Achieved availability gains of 1% to 5%;
• Reduced unplanned maintenance by 5%
• Improved heat rate by a 0.25% to 0.5%.
Beyond these benefits, says
How it works: SmartSignal advanced asset analyticsems that mesh closely with a plant’s O&M processes.
Through its Internet collaboration features, SmartSignal works with plant personnel until the problems are investigated and resolved. SmartSignal Plant APS provides the intelligence and guidance needed to predict, diagnose, and prioritize developing failures even before traditional, often difficult-to-maintain, condition-based monitoring tools detect them—which provides plants with critical lead time.
Also read:

Get smart with controls

Control Engineering about DTE Energy application. SmartSignal has information about other applications of predictive technologies .
Control Engineering provides other stories on predictive maintenance .
– Edited by  Mark T. Hoske , editor in chief
Control Engineering News Desk
Register here and scroll down to select your choice of eNewsletters free .

No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2013 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
A cool solution: Collaboration, chemistry leads to foundry coat product development; See the 2015 Product of the Year Finalists
Raising the standard: What's new with NFPA 70E; A global view of manufacturing; Maintenance data; Fit bearings properly
Sister act: Building on their father's legacy, a new generation moves Bales Metal Surface Solutions forward; Meet the 2015 Engineering Leaders Under 40
Cyber security cost-efficient for industrial control systems; Extracting full value from operational data; Managing cyber security risks
Drilling for Big Data: Managing the flow of information; Big data drilldown series: Challenge and opportunity; OT to IT: Creating a circle of improvement; Industry loses best workers, again
Pipeline vulnerabilities? Securing hydrocarbon transit; Predictive analytics hit the mainstream; Dirty pipelines decrease flow, production—pig your line; Ensuring pipeline physical and cyber security
Upgrading secondary control systems; Keeping enclosures conditioned; Diagnostics increase equipment uptime; Mechatronics simplifies machine design
Designing positive-energy buildings; Ensuring power quality; Complying with NFPA 110; Minimizing arc flash hazards
Building high availability into industrial computers; Of key metrics and myth busting; The truth about five common VFD myths

Annual Salary Survey

After almost a decade of uncertainty, the confidence of plant floor managers is soaring. Even with a number of challenges and while implementing new technologies, there is a renewed sense of optimism among plant managers about their business and their future.

The respondents to the 2014 Plant Engineering Salary Survey come from throughout the U.S. and serve a variety of industries, but they are uniform in their optimism about manufacturing. This year’s survey found 79% consider manufacturing a secure career. That’s up from 75% in 2013 and significantly higher than the 63% figure when Plant Engineering first started asking that question a decade ago.

Read more: 2014 Salary Survey: Confidence rises amid the challenges

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.