What’s Condition Monitoring?

Condition monitoring (CM) is a upkeep approach that predicts machine health and safety via the combination 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 in addition affords a holistic, plant-wide view of mechanical operations. Condition monitoring software sends an alert at any time when a change is detected in machine health, enabling your upkeep technicians to right away assess the situation and determine if corrective motion is required.

Benefits of condition monitoring

The proactive nature of condition monitoring is an innovative step forward on a number of ranges for some manufacturers. First, plant personnel are safer and thus, we’re all collectively safer. Second, plant managers can forestall unplanned downtime due to machine failure while concurrently making probably the most of planned upkeep downtime by servicing multiple machines and addressing all known problems on the same time. Further, condition monitoring additionally eliminates pointless—and wasted—costs associated with over sustaining healthy machines based mostly on the static metric of operating hours alone.

Although condition monitoring is a tried and true industrial maintenance tool, it is only just beginning to be leveraged effectively 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. At the moment’s condition monitoring solutions are highly reliable and have been proven extremely efficient across a number of manufacturing industries. Thus, for manufacturers who adchoose condition based upkeep strategies, the risk is low and the reward is high.

The right way to get started

In case you are fascinated about learning more about condition monitoring and building a proactive predictive maintenance plan in your plant, here is a quick “get started” define and subsequent steps to guide your path forward.

Step one: Set up the hardware

The first step 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 staff 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, quite a lot of condition monitoring products and approaches are required.

Step two: Measure your data

As soon as put in, sensors can instantly start to measure the next machine components:

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 figuring out machine malfunctions. Machine vibration frequencies can show up as direct multiples or sub-multiples of the rotative pace 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 put in at the machine OEM level or as part of the process management system. Valuable data from these sensors combines with the dedicated condition monitoring sensors to provide machine working context enabling an entire picture of how the machine is performing its meant 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 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 happen, permits you to catalyze improvements that create positive ripple effects for your complete enterprise, resembling:

Decrease downtime, Maximize production 90% of failures are NOT time-based. For many assets, failure can imply a considerable or total lack of production, usually value tens of thousands to hundreds of thousands per day. Usually industries are inclined to concentrate on the larger, more expensive machines on the expense of ignoring the smaller supporting machines. Focusing on the machines that “make the cash” is important however so too is give attention to those machines without which the cash making machine can’t operate.

Increase safety – Relying completely readily 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 consequence of maintenance gaps can enhance employee publicity to hazardous conditions and potential environmental disasters.

Reduce maintenance costs- When seen on a per-asset foundation, upkeep costs for plant-wide assets can seem modest. Nevertheless, when viewed collectively across the handfuls, hundreds, and even 1000’s of assets in a typical plant, these prices might be appreciable. Reducing the maintenance 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 allows more effective insight in planning and asset management, permitting upkeep to be achieved in advance of a functional failure.

Reduce hidden prices – Direct (traditional) upkeep costs are predictable and manageable. Indirect (hidden) upkeep costs, both stealthy and steep, can accrue to be as much as 5X higher. For many 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-based approach.

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