Illustrative scenario
Compressors and pumps: condition-based maintenance
Spot bearings and motors deteriorating and plan the repair, instead of waiting for the plant to stop.
This is an illustrative scenario with a hypothetical plant, not an Uptrol customer. The figures are estimates from the assumptions listed below, not achieved results.
- Industry
- Mechanical engineering, metalworking
- Assumed size
- 8 compressors and pumps serving the whole plant
- Scope
- Predictive maintenance, asset records
- Estimated rollout time
- 4–8 weeks
Estimated benefits
8–16 hoursLine downtime avoided per year
Headline estimate70–140 million VNDLosses avoided per year
8Assets monitored continuously
See how we calculated
Assumptions
| Assets monitored | 8 |
| Sudden failures avoided per year | 1–2 |
| Line downtime per failure | 8 hours |
| Loss per hour of line downtime (assumed) | 5 million VND |
| Extra cost of an urgent repair compared with a planned one | 30 million VND |
Calculation
- 1–2 failures × 8 hours = 8–16 hours
- 1–2 failures × (8 hours × 5 million VND/hour + 30 million VND) = 70–140 million VND
- 8 = 8
Failures avoided depend on each asset’s real failure history; use the plant’s repair records of the last 1–2 years to re-estimate.
Context
The hypothetical plant runs most machines on compressed air. When a main compressor or pump fails suddenly, several lines wait for the repair.
Maintenance follows a fixed schedule and the ears of experienced technicians.
What Uptrol deploys
- Vibration and temperature sensors on bearings and motors; current measured at the board
- A baseline of each asset’s normal condition over the first weeks
- Threshold and trend alerts, graded for the maintenance team
- Fault and repair history per asset in Uptrol Thiết bị
Architecture
- 01Vibration and temperature sensors (Modbus/wireless) and current meters
- 02Gateway: periodic reads, vibration indicators, buffering
- 03Uptrol platform: trends, thresholds, alerts
- 04Work orders and asset records
Steps
- 01Pick assets and pointsStart with assets whose failure stops several lines.
- 02Fit sensorsDuring scheduled maintenance, without stopping production.
- 03Record a baselineWatch for a few weeks to get each asset’s baseline and set first thresholds.
- 04Alerts and processLink alerts to owners and work orders; review thresholds regularly.
Related solution: Predictive maintenance · Related software: Uptrol Assets