What is Condition Monitoring?

Condition monitoring (CM) is a maintenance approach that predicts machine health and safety by way of the combination of machine sensor data that measures vibration and different parameters (in real-time) with state-of-the-artwork machine monitoring software. This approach enables plant upkeep technicians to remotely monitor the health of every particular person piece of machinery and likewise provides a holistic, plant-wide view of mechanical operations. Condition monitoring software sends an alert every time a change is detected in machine health, enabling your maintenance technicians to immediately assess the situation and determine if corrective action is required.

Benefits of condition monitoring
The proactive nature of condition monitoring is an revolutionary step forward on a number of ranges for some manufacturers. First, plant personnel are safer and thus, we are all collectively safer. Second, plant managers can prevent unplanned downtime attributable to machine failure while concurrently making probably the most of planned upkeep downtime by servicing a number of machines and addressing all known problems on the same time. Further, condition monitoring also eliminates unnecessary—and wasted—prices associated with over sustaining healthy machines primarily based on the static metric of working hours alone.

Although condition monitoring is a tried and true industrial upkeep device, it is only just beginning to be leveraged successfully in a wider array of producing industries. In the present day’s condition monitoring systems can do a lot more for us—financially, operationally, and most importantly, from a safety perspective. In the present day’s condition monitoring options are highly reliable and have been proven extraordinarily effective across multiple manufacturing industries. Thus, for manufacturers who adopt condition based maintenance techniques, the risk is low and the reward is high.

The best way to get started
If you are excited about learning more about condition monitoring and building a proactive predictive upkeep plan on your plant, here is a quick “get started” define and next steps to guide your path forward.

The first step: Set up the hardware
The first step is the installation of monitoring sensors on serviceable assets together with rotating machinery (turbines, compressors, pumps, motors, fans) and stationary assets (boilers, heat exchangers). Plant managers work with the seller installation workforce to retrofit or modify machines as wanted to ensure the appropriate set up of monitoring instrumentation. Totally different assets require different approaches. Not all assets are created equal, and as such, a wide range of condition monitoring products and approaches are required.

Step two: Measure your data
Once installed, sensors can instantly start to measure the following machine parts:

Vibration and position – Indications of dynamic and static motion of the rotor or machine case.
Rotor speed – An important a part of analyzing vibration data and figuring out machine malfunctions. Machine vibration frequencies can show up as direct multiples or sub-multiples of the rotative speed of the machine.
Temperature – RTD’s and Thermocouples measure the temperature of the machine’s radial and thrust bearings, lube oil, stator windings, and steam temperatures.
Working process sensors – these are typically already installed at the machine OEM degree or as a part of the process management system. Valuable data from these sensors combines with the dedicated condition monitoring sensors to provide machine working context enabling a complete image of how the machine is performing its meant function.
Step three: Monitor your machines
Data is transmitted from installed condition monitoring and process sensors to a centralized condition monitoring software system for analysis and diagnostics. Trained upkeep technicians are alerted anytime an abnormality is detected and use data provided to determine if the machine requires immediate attention.

Anticipating machine failures earlier than they occur, means that you can catalyze improvements that create positive ripple effects for the entire enterprise, akin to:

Minimize downtime, Maximize production ninety% of failures are NOT time-based. For many assets, failure can imply a substantial or total loss of production, typically value tens of hundreds to hundreds of thousands per day. Usually industries are likely to focus on the larger, more expensive machines at the expense of ignoring the smaller supporting machines. Specializing in the machines that “make the cash” is essential however so too is give attention to these machines without which the cash making machine can’t operate.

Improve safety – Relying completely available-held gadgets for monitoring machine health can expose factory workers to pointless risks in our highly automated factories. Further, occasional catastrophic breakdowns as a result of upkeep gaps can increase worker publicity to hazardous conditions and potential environmental disasters.

Reduce maintenance costs- When viewed on a per-asset foundation, upkeep prices for plant-wide assets can appear modest. However, when seen collectively across the handfuls, hundreds, or even 1000’s of assets in a typical plant, these costs could be appreciable. Reducing the upkeep prices on every asset by efficient condition monitoring—even by a mere 10%—has a big impact on plant profitability. Condition Monitoring is a planning software that allows more efficient perception in planning and asset management, allowing upkeep to be performed in advance of a functional failure.

Reduce hidden costs – Direct (traditional) upkeep prices are predictable and handleable. Indirect (hidden) upkeep prices, each stealthy and steep, can accrue to be as much as 5X higher. For a lot of plants, reducing these hidden costs is a mandate that requires us to shift from the traditional reactive approach (“fix it when it breaks”) to a proactive, reliability-based approach.

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