Condition Monitoring

About Condition Monitoring

Condition monitoring (CM) is a maintenance approach that predicts machine health and safety through the combination of machine sensor data that measures vibration and other parameters (in real-time) with state-of-the-art machine monitoring software.

The proactive nature of condition monitoring is an innovative step forward on several levels for some manufacturers. Plant personnel are safer and thus, we are all collectively safer. Condition monitoring also eliminates unnecessary and wasted costs associated with over-maintaining healthy machines based on the static metric of operating hours alone.

Popular Products

• Hikmicro AI56 Acoustic Imaging Camera: Renowned for its advanced sensitivity, detailed imaging, and user-friendly interface, making it ideal for detecting leaks, electrical discharges, and mechanical faults in various industrial applications.

• Fluke ii900 Acoustic Industrial Imager: An advanced tool for detecting leaks in compressed air, gas, steam, and vacuum systems. It features a 7-inch LCD touchscreen overlaying a SoundMap™, allowing for quick and accurate detection, improving energy efficiency and reducing maintenance costs.

• UE Systems Ultraprobe® 3000 Ultrasonic Inspection System: Digital tool for detecting faults like compressed air leaks, failing steam traps, and electrical discharges, compatible with Ultratrend DMS software for detailed reports, and ideal for energy conservation programs.

• Beha-Amprobe ULD-400-TE Ultrasonic Transmitter: Uses ultrasonic signals to detect leaks in unpressurised systems, such as automobile windshields, gas tanks, and building windows and doors, ensuring accurate pinpointing, enhancing maintenance efficiency and safety.

• TPI 9070 Smart Vibration & Bearing Condition Analyser: User-friendly tool for industrial settings, enabling the monitoring and analysis of machine vibrations to identify issues like unbalance, misalignment, and looseness. It features a full-colour OLED display, built-in band filters, and an IP67-rated case for durability.

• FLIR SV87-Kit Vibration Monitoring Solution: A wireless system monitors temperature and vibration data for industrial equipment, transmitting real-time data to mobile devices or PCs via a remote gateway, enabling maintenance teams to make informed decisions without manual inspections.

• UNI-T UT372 Non-Contact Tachometer: Measures the rotational speed of machinery without direct contact, covering four ranges (10 to 99,999 RPM). It offers data hold, MAX/MIN/AVG modes, and auto power-down for energy efficiency. Its USB interface allows easy data transfer to a PC, making it useful in industrial and maintenance applications.

• Testo 465 Non-Contact Tachometer: One-handed device for measuring RPM of rotating parts like fans and shafts. It uses an LED optical sensor, a visible red beam, and reflective markers for accuracy. It has a two-button operation, saves minimum, maximum, and mean values, and is protected with a SoftCase protective cover.

FAQs

• What is condition monitoring?
  Condition monitoring is a predictive maintenance technique that tracks the health of machinery in real-time by monitoring parameters like vibration, temperature, and pressure. This approach helps detect early signs of potential issues, allowing for timely maintenance to prevent equipment failure, reduce downtime, and extend asset lifespan.

• How does condition monitoring work?
  Condition monitoring involves using sensors and data analysis tools to measure various parameters of machinery, such as vibration, temperature, and oil quality. By continuously collecting and analyzing this data, maintenance teams can detect deviations from normal operating conditions, indicating potential problems.

• Why is condition monitoring important?
  It helps identify potential equipment failures before they occur, allowing for timely maintenance. This proactive approach minimizes unplanned downtime, reduces repair costs, and extends the lifespan of machinery. Additionally, it enhances safety by preventing catastrophic failures and improves overall operational efficiency.

• What are the different types of condition monitoring techniques?
  Techniques include vibration analysis for detecting imbalances, thermography for spotting heat anomalies, oil analysis for checking lubricant contamination, ultrasound testing for finding leaks and electrical discharges, and electrical monitoring for tracking electrical issues.

• How does online condition monitoring differ from handheld monitoring?
  Online condition monitoring uses fixed sensors for continuous, real-time data collection and automated alerts, while handheld monitoring involves periodic checks with portable devices, providing condition snapshots at specific intervals.

• What is the difference between condition monitoring and predictive maintenance?
  Condition monitoring tracks machinery’s current state, while predictive maintenance uses this data to forecast failures and schedule timely maintenance. Essentially, condition monitoring provides data, and predictive maintenance plans actions based on it.

• What tools are used in condition monitoring?
  Tools include acoustic imaging cameras for detecting sound anomalies, ultrasonic leak detectors for identifying leaks, vibration testers for measuring machine vibrations, and tachometers for tracking the RPM of rotating machinery.

• How can condition monitoring reduce maintenance costs?
  Condition monitoring reduces maintenance costs by identifying potential issues early, allowing for timely repairs before they escalate into major problems. This proactive approach minimizes unplanned downtime, extends equipment lifespan, and reduces the need for costly emergency repairs. Additionally, it optimizes maintenance schedules, ensuring resources are used efficiently.

• What is an example of condition monitoring in practice?
  A practical example of condition monitoring is the use of vibration analysis on rotating equipment like turbines. By continuously monitoring vibration levels with sensors, maintenance teams can detect abnormalities such as imbalances or misalignments early on. This proactive detection allows for timely interventions, preventing major failures and reducing downtime.

• What challenges are associated with implementing condition monitoring?
  Implementing condition monitoring faces challenges such as high initial costs for equipment and software, managing large data volumes, and training personnel to use the systems effectively. Additionally, integrating these systems with existing maintenance practices requires significant adjustments.

• How often should condition monitoring be performed?
  The frequency of condition monitoring depends on the criticality and usage of the equipment. For high-risk machinery, continuous monitoring is ideal. For less critical equipment, periodic checks, such as weekly or monthly, may suffice. The goal is to balance the need for timely data with the resources available for monitoring.

• What data is collected during condition monitoring?
  During condition monitoring, data collected includes vibration levels, temperature readings, oil quality, acoustic emissions, and electrical parameters. This data helps in identifying potential issues and maintaining optimal equipment performance.