|Principles||Examination and data collection on machinery, or an entire system using various sensors (accelerometers, proximity probes, LVDT’s, strain gauges, etc), Infrared Thermography, and other methods depending on the process. The data is obtained through scheduled and/or continuous data collection, and this information can then be used to identify trends or patterns that identify issues with the machinery/system. Any changes made to a system or piece of machinery can also be tracked using condition monitoring in conjunction with historical data. |
Vibration Analysis, Infrared Thermography (IR), Ultrasound (UE), and Motor Current Analysis (MCA) are typical methods of analysis used.
|How is it used and for what purpose?|
|Condition monitoring is used to obtain useful information on a piece of equipment or process regarding ‘typical’ and ‘upset’ values for vibration, strain, temperature, noise, etc. Decisions can then be made as to whether these levels are at an acceptable level or if further investigation and/or repair is required. |
Condition monitoring can be used in all industries including petrochemical, pulp and paper, power generation and the automotive industry.
Condition monitoring is a major component of an effective maintenance program, but it can also be used in Root Cause Analysis and to aid in the selection of new or upgraded equipment.
|Applicable Codes and Standards|
|The codes referenced are dependent on the industry, type of equipment and type of monitoring equipment used, but can include: ASTM, ASME, ISO|
CMVA, Vibration Institute
|Form of report|
|A database of information collected is typical and proves valuable to the facility as a reliable source of historical data on all equipment included in the monitoring program. This information can prove to be invaluable during upset or when upgrades are being considered (using the data collected from condition monitoring, trends in vibration increase, for example can be seen and equipment can then be prioritized for maintenance shuts). |
Weekly or monthly reports identifying any increasing trends or outliers in the data collected are also typical.
|Condition monitoring is a very important part of a predictive maintenance program and allows for minimum unplanned outage time and optimization of scheduled maintenance – completing repairs at the most cost effective point and schedule|
|Limitations||Strict procedures must be in place during data collection (settings on equipment, specific locations tested, etc) in order to obtain accurate data. Experienced analysts with multiple technologies are required to raise success rate.|
|Alternatives||Interval Based repair or replacement (more costly), Run to failure (unplanned repairs and replacements required).|
|Technician certification||Condition Monitoring Specialist, Vibration Specialist, Reliability Engineer|
IR certification, UE Certification, Machinery Lubrication Technician
|Rope access applicable? ||Limited|