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Condition Monitoring

Condition monitoring is the process of monitoring equipment health through simple measurements like vibration, current draw, and outlet flow. These measurements are trended over time and compared to known standards or the machine's historical values. Abnormal readings may indicate deteriorating condition and need for maintenance. Vibration is often the most useful measurement parameter and can be measured as part of routine preventive maintenance to introduce condition-based aspects. The key is keeping the monitoring process simple through easy-to-interpret measurements that are trended over time.

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Kashif Muhammad
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228 views3 pages

Condition Monitoring

Condition monitoring is the process of monitoring equipment health through simple measurements like vibration, current draw, and outlet flow. These measurements are trended over time and compared to known standards or the machine's historical values. Abnormal readings may indicate deteriorating condition and need for maintenance. Vibration is often the most useful measurement parameter and can be measured as part of routine preventive maintenance to introduce condition-based aspects. The key is keeping the monitoring process simple through easy-to-interpret measurements that are trended over time.

Uploaded by

Kashif Muhammad
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Starting a Condition monitoring

program and keeping it simple.


Condition Based Maintenance has been defined as:
Maintenance based on the condition of an asset.
Asset: An item of value.
Condition: The state of an item.

Condition Monitoring is the art of monitoring your equipments health by taking


simple measurements of the machines performance. Much the same way a
Doctor will check (measure) your health by checking your pulse, temperature,
blood pressure etc.
If these measures are abnormal the doctor may suggest that they continue to take
measurements but maybe more often. Or based on the first set of readings he
may recommend some process changes such as, better diet, more rest etc. He
bases his decisions on known values or a standard, on scientific research, or
experience from training. Thankfully the medical profession has a good
understanding of what is normal and what is not.

Extraction's from ISO 10816-3


You can also compare
Industrial machines with power above 15kW and
measurements to a known
nominal speeds between120 -15000 r/min
standard such as a bearing
chart for instance or the ISO Unit Group 1 and 3 Group 2 and 4
standard for vibration. You can
mm/s Rigid Flexible Rigid Flexible
use the equipment
manufacturer’s specification, or 0-1.4
the history record of the piece of 1.4-2.3
equipment itself as a
2.3-2.8
comparison.
2.8-3.5

3.5-4.5

4.5-7.1

7.1-11

11--
If you were measuring the current draw and the outlet flow of a pump and could see
that the draw was increasing yet the outlet flow was decreasing, as compared to the
measurements you had taken over the previous months, you would be right in
assuming that the condition was deteriorating and that some maintenance was due
for the pump, assuming of course that all the other variables had stayed the same
such as the material the pump was pumping was the same etc.
Flow and current cannot be measured on all the machines so you have to choose a
measurement parameter that is more suitable for the majority of your equipment.
Which technology you use will depend on the equipment you have. However
vibration measurement is the most versatile and gives the most information which is
why it is the most used measurement parameter.

Remember, what we are trying to do is to take a simple measurement such


as vibration and monitor (watch) the value. We can then react to any
changes. The easy way to do this is by trending the measured value. We are
trying to keep it a simple process. This is not vibration analysis. Vibration
analysis is too time consuming and requires expert interpretation. However if
the trend is climbing we can choose to bring in the expert.
We, on the other hand, are looking for a simple number that we can trend over time; a
number that can tell us that one (1) is good and two (2) is bad. We all know that to
control a process we must measure it. One of maintenances most important processes
is its Preventive Maintenance program (PM’S). By adding measurement we add more
control. This is a great opportunity to combine these two programs together.
I believe that the way we do PM’s has changed. We now use detection instruments
during the process. By using simple instrument such as ultrasonics or vibration
monitoring we can unobtrusively monitor our equipment as part of the PM. I guess you
can call it Condition Based Maintenance. But to me it’s still a calendar based PM the
fact that I now use ultrasonics to listen to the machine instead of a screw driver doesn’t
change what I am doing. The change is the technology that I use.
Whether we call it Preventive Maintenance or Condition Based Maintenance I don’t
think it’s important. What’s important is that it is done on schedule, that it is fully
comprehensive and most importantly condition measurements are taken before and
after the PM or work has been completed.

I would have a PM
technician as the owner
of this process. I would
not use him to complete Using simple software
any of the work that was you can create a
deemed necessary but route and trend the
he would be responsible vibration results.
to commission the
machine back into
service as well as to
take and trend the
measurements.

He can then compare the measurement results to the last PM measurement, as well as to the
measurement he took when the machine was on line etc. If there is a change in the result he can
ask the question why there is a difference. This is very important because if he keeps asking why
and looking for the answers such as shaft alignment, balancing etc. he is on the path of machinery
reliability improvement.

It is a fact that well trained, conscientious, proactive employees prevent more equipment failures
than any maintenance strategy. Give them the training and the measurement tools to help them do
this.

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