Why Preventive Maintenance Matters

Preventive maintenance is far more cost-effective than reactive repairs. Studies show that preventive maintenance programs can reduce unplanned downtime by 50-70% and extend equipment life by 20-40%. For critical production equipment like separators, the return on investment is substantial.

Maintenance Schedule Components

A comprehensive preventive maintenance program includes multiple maintenance intervals:

Daily Checks

Operator-performed checks to catch issues early:

• Visual inspection for leaks or unusual conditions
• Monitor vibration levels
• Check operating temperatures
• Review alarm history
• Verify process parameters

Weekly Maintenance

• Clean HMI screens and control panel exteriors
• Check for loose connections
• Review trend data for anomalies
• Verify safety system operation
• Check lubrication levels

Monthly Maintenance

• Calibrate critical sensors
• Inspect electrical connections
• Review and clean filters
• Check VFD parameters and operation
• Verify communication networks
• Update documentation

Quarterly Maintenance

• Comprehensive control system inspection
• PLC program backup and verification
• HMI screen review and updates
• VFD parameter review
• Safety system testing
• Spare parts inventory review

Annual Maintenance

• Complete system inspection
• Mechanical inspection (bearings, seals, bowl)
• Electrical system testing
• Control system optimization
• Performance testing
• Compliance audit

Control System Maintenance

Control system maintenance is critical for reliable separator operation:

PLC Maintenance

• Program backup and version control
• I/O module status verification
• Communication network testing
• Battery replacement (if applicable)
• Firmware updates
• Program optimization review

HMI Maintenance

• Screen backup and documentation
• Touch screen calibration
• Display brightness and contrast adjustment
• Alarm management review
• Trend configuration review
• Software updates

VFD Maintenance

• Parameter backup
• Fault history review
• Cooling fan inspection
• Terminal tightening
• Capacitor health check
• Firmware updates

Mechanical Maintenance

Proper mechanical maintenance extends separator life:

• Bearing inspection and lubrication
• Seal inspection and replacement
• Bowl inspection for wear or damage
• Vibration analysis
• Alignment checks
• Belt or coupling inspection

Predictive Maintenance Technologies

Modern predictive maintenance tools enable condition-based maintenance:

Vibration Monitoring

• Continuous vibration monitoring
• Trend analysis for early fault detection
• Bearing condition assessment
• Imbalance detection

Thermal Imaging

• Electrical connection inspection
• Motor temperature monitoring
• Bearing temperature analysis
• Hot spot identification

Performance Monitoring

• Separation efficiency tracking
• Energy consumption analysis
• Process parameter trending
• Performance degradation detection

Maintenance Documentation

Comprehensive documentation supports effective maintenance:

• Maintenance checklists
• Work procedures
• Spare parts lists
• Maintenance history records
• Calibration certificates
• Test reports

Maintenance Service Contracts

YES-AL offers comprehensive maintenance service contracts:

Service Levels

• Basic: Scheduled inspections and basic maintenance
• Standard: Comprehensive maintenance with priority support
• Premium: Full-service contract with 24/7 support and guaranteed response times

Contract Benefits

• Predictable maintenance costs
• Priority service response
• Discounted parts and labor
• Comprehensive documentation
• Performance reporting