What is condition-based monitoring?
Condition-based monitoring (CBM) is a maintenance strategy that uses real-time data to assess equipment health and determine when maintenance is needed.. Instead of relying on fixed schedules or waiting for equipment to fail, CBM uses sensors and data analysis to detect early signs of deterioration or potential malfunction.
Condition monitoring techniques are used to evaluate machine health and performance according to condition-based parameters. Many manufacturing businesses rely on condition-based monitoring techniques in order to detect deviations from normal operating conditions. Condition monitoring systems are often built into broader asset management programs and integrated with other tech platforms.
The importance of condition-based monitoring
Condition monitoring is important because it provides you with a clear and continuous process for measuring the health and performance of your critical business assets in real time. This, in turn, gives you the power to perform preventive maintenance and more advanced types of maintenance like predictive maintenance which aim to stop potential failures from occurring.
In the manufacturing sector, critical business assets usually include equipment, machinery, and industrial facilities. The productivity of your business depends on the functionality of these assets. Keeping assets functional in the long term requires routine maintenance and close performance monitoring.
What’s the difference between condition-based monitoring and maintenance programs?
Condition-based monitoring refers specifically to the process of monitoring the condition of equipment using various techniques (e.g., vibration analysis, oil analysis, etc.). It’s about collecting and analyzing data to understand the real-time health of assets.
Condition-based maintenance (CBM) focuses on data collection and analysis, while condition-based maintenance (CBM) applies that data to schedule and perform maintenance activities.
A CBM program includes:
- Data collection: Collect data through sensors and other monitoring techniques.
- Data analysis: Interpret the data to identify trends and potential issues.
- Decision-making: Determine the appropriate maintenance actions based on the data analysis.
- Maintenance execution: Carry out the necessary maintenance tasks (e.g., repairs, replacements, adjustments).
- Continuous improvement: Evaluate the effectiveness of the CBM program and make adjustments as needed.
Condition-based monitoring is a tool used within a condition-based maintenance program. The program provides the framework for how the monitoring data is used to make informed maintenance decisions.
While monitoring is crucial, it’s only one part of a comprehensive CBM program. The program ensures that the monitoring data is effectively used to optimize maintenance activities, prevent failures, and improve overall asset reliability.
Benefits of monitoring critical business assets
Conducting real-time or high-frequency monitoring of critical assets allows you to:
- Identify performance issues before they can escalate into costly problems and equipment failures. By continuously monitoring equipment, you can detect subtle changes and anomalies that may indicate impending problems. This allows for proactive intervention to address issues before they lead to breakdowns, production disruptions, or costly repairs. For example, monitoring vibration levels in rotating equipment can reveal early signs of bearing wear, enabling timely replacement and preventing catastrophic failure. This proactive approach can significantly reduce maintenance costs and improve overall operational efficiency.
- Optimize asset performance and extend equipment lifespan through preventive maintenance and repairs. Continuous or periodic monitoring provides valuable insights into asset health and performance trends. This data can be used to optimize maintenance schedules, ensuring that interventions are performed only when necessary. By addressing minor issues early on, you can prevent them from escalating into major problems, extending the lifespan of your equipment and maximizing its return on investment. Additionally, tracking key metrics such as Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR) can help you assess the effectiveness of your maintenance management strategy and identify areas for improvement.
- Ensure compliance with regulatory standards and safety protocols while mitigating the risks associated with accidents or malfunctions. Many industries have strict safety and environmental regulations that require continuous monitoring of critical equipment and assets. Real-time monitoring helps you comply with these standards and proactively identify potential hazards. For instance, monitoring pressure levels in pipelines can help prevent leaks and ensure the safety of personnel and the environment.
Industries that depend on condition monitoring systems
Effective asset monitoring is essential for ensuring operational efficiency, safety, and sustainability across various industries. But in certain industries, the consequences of asset failure can be particularly severe. For instance:
- In manufacturing, machine failures can halt production lines, cause unplanned downtime, and lead to significant financial losses.
- In transportation, failure to monitor the condition of traffic lights, signage, and electrical equipment can result in accidents, injuries, and property damage.
- In the energy sector, unmonitored infrastructure like deteriorating pipelines or aging power plants can lead to environmental disasters and widespread disruption of services.
Types of condition-based monitoring techniques
There are various types of condition monitoring techniques. Each measures a specific condition parameter. The following are among the leading condition monitoring techniques used in manufacturing, production, and industrial operations:
1. Vibration analysis
Vibration analysis is used to measure the vibration levels in rotating machinery. When vibration patterns change, this may be an indication of equipment misalignment, imbalances, or component deterioration.
- How it works: With vibration monitoring, sensors are placed on or near rotating equipment in order to measure vibrations at various axis points. The vibration sensors analyze amplitude, frequency, and waveform in order to detect abnormal patterns. With the help of Internet of Things (IoT) technology, these patterns can identify potential faults or measure equipment deterioration.
- Benefits
- Detect potential faults and anticipate equipment failures before they occur
- Improve equipment performance and reliability
- Plan ahead for cost-effective, condition-based maintenance
- Common uses
- Performance analysis for equipment with rotating components such as pumps, turbines, electric motors, and compressors
- Condition monitoring in industries like Aerospace, Automotive, and Manufacturing
2. Oil analysis
Oil analysis is used to evaluate lubricating oil samples for signs of contamination, wear, and corrosion. This non-invasive technique can provide insights into the condition of components such as bearings, gears, and hydraulic systems.
- How it works: With oil analysis, samples are collected directly from operational machinery and equipment for assessment in a laboratory setting. Analysis will typically include several layers of assessment including spectroscopy, chromatography, and particle counting. These methods are used to assess viscosity and identify contaminants, particles, metals, and other indicators that equipment may be deteriorating or in need of maintenance.
- Benefits
- Detect equipment wear and component degradation before breakdown
- Extend the lifespan of your equipment through preventive maintenance
- Reduce the occurrence of unplanned downtime
- Common uses
- Assessing the condition of engines, gearboxes, and hydraulic systems
- Monitoring oil quality in Automotive, Marine, and Industrial applications
3. Thermography
Thermography is used to detect abnormal temperature variations in equipment. Thermal cameras can identify changes in temperature, which may be an indication of overheating, lubrication issues, or mechanical problems.
- How it works: With thermography, thermal cameras are used to detect infrared radiation emitted by objects. This radiation is converted into visible images representing surface temperatures. Infrared thermography makes it easier for observers to spot abnormal temperature patterns, which may point to issues with equipment or help predict potential equipment failure.
- Benefits
- Inspect equipment using non-invasive imaging
- Detect overheating components before they cause equipment malfunction
- Improve safety and mitigate the risk of accident or injury due to malfunction
- Common uses
- Inspection of electrical systems and mechanical equipment for loose connections, insulation defects, pipe leaks, misalignment, and more
- Condition monitoring in the Power Generation, Oil & Gas, Defense & Aerospace, and Automotive industries, among others
4. Acoustic analysis
Acoustic analysis is used to capture the sound waves generated by your machinery or equipment. Microphones or acoustic sensors may be used to detect changes in sound patterns, which can indicate abnormal equipment function.
- How it works: With acoustic analysis, sensors are used to capture the sound waves produced by machinery during operation. Acoustic analysis usually also includes advanced signal processing, which is used to distinguish between normal and abnormal operating sounds. Shifts in the frequency, intensity, or pattern of sound may point to potential faults or impending equipment failure.
- Benefits
- Detect mechanical issues such as gear damage before equipment fails.
- Monitor inaccessible or hazardous equipment remotely
- Implement at low cost and with quick turnaround time
- Common uses
- Detection of leaks and anomalies in pipelines and fluid systems
- Assessment of mechanical components in Chemical Processing, Power Generation, Oil & Gas refineries, and other operations dealing with hazardous materials
5. Electrical monitoring
Electrical monitoring is used to provide continuous, real-time analysis of critical electrical parameters including voltage, current, and induction. Electrical monitoring can detect changes in these parameters, which may be an indication of electrical overload, equipment degradation, and other serious safety and fire hazards.
- How it works: Sensors and meters are placed on electrical panels and other equipment. These sensors produce data about your equipment’s power signature analysis (i.e. voltage and current) along with other parameters like induction (electricity generation via magnetic field interaction), capacitance (the ability to store an electric charge), and insulation condition. This performance data can then be analyzed to detect deviations from normal operating conditions, which may be an indication of faults or inefficiencies in electrical systems.
- Benefits
- Detect electrical faults and potential hazards before they can pose a safety threat
- Optimize the energy consumption and efficiency of your equipment
- Improve the reliability and uptime of your electrical systems
- Common uses
- Monitoring of power distribution systems, switchgear, and transformers
- Condition monitoring across all industries including Chemical Processing, Mining & Materials, Energy, Building, and much more
How to establish a condition-based monitoring program
Establishing a condition-based monitoring (CBM) program requires a structured approach and careful consideration of your operation’s goals and needs. Your business can implement a condition-based monitoring program by following the six steps listed below:
- Prioritize the assets you want to monitor with a focus on equipment that is costly to replace and critical to your productivity.
- Identify all known and probable failure modes for selected assets.
- Select compatible condition monitoring systems and techniques in response to the probable failure modes identified above.
- Define baseline limits for chosen CBM solutions so that the system can warn you when monitored equipment is beginning to deteriorate with enough time to perform corrective actions.
- Establish the CBM program by defining tasks and delegating responsibilities to your maintenance team with an emphasis on collecting and recording measurements.
- Analyze the data, plot out trends, and schedule maintenance work accordingly.
By following these steps, you can establish a robust condition-based monitoring program in order to improve asset health, reduce unplanned downtime, and optimize preventive and proactive maintenance programs.
But you should keep in mind that some condition monitoring sensors and solutions are easier to implement than others. Before diving into implementation, you should have a complete understanding of the resources and costs needed to implement each condition monitoring solution, and a clear sense of the solution that best fits your maintenance needs.
Need help transitioning from reactive maintenance to more proactive, data-based strategies? Download our free guide to start seeing the benefits of better maintenance plans and schedules.