What Is Condition Monitoring?

What Is Condition Monitoring?

Condition monitoring (CM) is a maintenance approach that predicts machine health and safety by way of the mix of machine sensor data that measures vibration and different parameters (in real-time) with state-of-the-art machine monitoring software. This approach enables plant upkeep technicians to remotely monitor the health of each individual piece of machinery and also gives a holistic, plant-wide view of mechanical operations. Condition monitoring software sends an alert whenever a change is detected in machine health, enabling your upkeep technicians to instantly assess the situation and determine if corrective action is required.

Benefits of condition monitoring
The proactive nature of condition monitoring is an progressive step forward on several ranges for some manufacturers. First, plant personnel are safer and thus, we're all collectively safer. Second, plant managers can stop unplanned downtime because of machine failure while simultaneously making probably the most of planned upkeep downtime by servicing a number of machines and addressing all known problems on the similar time. Additional, condition monitoring also eliminates pointless—and wasted—prices associated with over sustaining healthy machines primarily based on the static metric of operating hours alone.

Though condition monitoring is a tried and true industrial upkeep tool, it is only just starting to be leveraged successfully in a wider array of manufacturing industries. At the moment’s condition monitoring systems can do a lot more for us—financially, operationally, and most importantly, from a safety perspective. Right now’s condition monitoring options are highly reliable and have been proven extraordinarily effective throughout a number of manufacturing industries. Thus, for producers who addecide condition primarily based maintenance strategies, the risk is low and the reward is high.

Methods to get started
In case you are concerned with learning more about condition monitoring and building a proactive predictive maintenance plan in your plant, here's a quick "get started" outline and next steps to guide your path forward.

The 1st step: Set up the hardware
Step one is the set up of monitoring sensors on serviceable assets together with rotating machinery (generators, compressors, pumps, motors, fans) and stationary assets (boilers, heat exchangers). Plant managers work with the vendor set up crew to retrofit or modify machines as needed to make sure the appropriate set up of monitoring instrumentation. Completely different assets require different approaches. Not all assets are created equal, and as such, a variety of condition monitoring products and approaches are required.

Step two: Measure your data
Once put in, sensors can immediately start to measure the following machine elements:

Vibration and position – Indications of dynamic and static motion of the rotor or machine case.
Rotor speed – An vital part of analyzing vibration data and determining 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.
Operating process sensors – these are typically already installed at the machine OEM stage or as a part of the process control system. Valuable data from these sensors combines with the dedicated condition monitoring sensors to provide machine working context enabling a complete picture of how the machine is performing its supposed function.
Step three: Monitor your machines
Data is transmitted from put in condition monitoring and process sensors to a centralized condition monitoring software system for evaluation and diagnostics. Trained maintenance technicians are alerted anytime an abnormality is detected and use data provided to find out if the machine requires instant attention.

Anticipating machine failures before they happen, permits you to catalyze improvements that create positive ripple effects for your 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, often worth tens of 1000's to thousands and thousands per day. Often industries are inclined to deal with the bigger, more expensive machines on the expense of ignoring the smaller supporting machines. Focusing on the machines that "make the cash" is essential however so too is concentrate on those machines without which the money making machine can’t operate.

Improve safety - Relying solely readily available-held devices for monitoring machine health can expose factory workers to pointless risks in our highly automated factories. Additional, occasional catastrophic breakdowns as a result of upkeep gaps can improve worker exposure to hazardous conditions and potential environmental disasters.

Reduce maintenance prices- When seen on a per-asset basis, maintenance prices for plant-wide assets can seem modest. However, when seen collectively throughout the dozens, hundreds, or even hundreds of assets in a typical plant, these costs will be appreciable. Reducing the upkeep costs on each asset by means of efficient condition monitoring—even by a mere 10%—has a large impact on plant profitability. Condition Monitoring is a planning instrument that enables more efficient insight in planning and asset administration, permitting upkeep to be finished in advance of a functional failure.

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

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