Condition monitoring (CM) is a upkeep approach that predicts machine health and safety via the mix 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 maintenance technicians to remotely monitor the health of every individual piece of machinery and also gives a holistic, plant-wide view of mechanical operations. Condition monitoring software sends an alert each time a change is detected in machine health, enabling your upkeep technicians to instantly assess the situation and decide if corrective action is required.
Benefits of condition monitoring
The proactive nature of condition monitoring is an revolutionary step forward on a number of levels for some manufacturers. First, plant personnel are safer and thus, we’re all collectively safer. Second, plant managers can prevent unplanned downtime as a consequence of machine failure while concurrently making the most of planned maintenance downtime by servicing a number of machines and addressing all known problems on the identical time. Further, condition monitoring also eliminates unnecessary—and wasted—prices associated with over maintaining healthy machines primarily based on the static metric of operating hours alone.
Although condition monitoring is a tried and true industrial upkeep software, it is only just starting to be leveraged successfully in a wider array of producing industries. At this time’s condition monitoring systems can do a lot more for us—financially, operationally, and most importantly, from a safety perspective. In the present day’s condition monitoring solutions are highly reliable and have been proven extremely efficient across a number of manufacturing industries. Thus, for manufacturers who addecide condition primarily based maintenance techniques, the risk is low and the reward is high.
How one can get started
In case you are eager about learning more about condition monitoring and building a proactive predictive upkeep plan on your plant, here is a quick “get started” define and next steps to guide your path forward.
The 1st step: Install the hardware
Step one is the set up of monitoring sensors on serviceable assets including rotating machinery (turbines, compressors, pumps, motors, fans) and stationary assets (boilers, heat exchangers). Plant managers work with the vendor set up group to retrofit or modify machines as needed to ensure the appropriate installation of monitoring instrumentation. Different assets require totally different approaches. Not all assets are created equal, and as such, a wide range of condition monitoring products and approaches are required.
Step two: Measure your data
As soon as put in, sensors can immediately begin to measure the next machine parts:
Vibration and position – Indications of dynamic and static motion of the rotor or machine case.
Rotor pace – An essential a 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 speed 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 installed on the machine OEM stage or as a part of the process control system. Valuable data from these sensors combines with the dedicated condition monitoring sensors to provide machine working context enabling a whole picture of how the machine is performing its intended function.
Step three: Monitor your machines
Data is transmitted from installed 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 before they occur, lets you catalyze improvements that create positive ripple effects for the complete enterprise, akin to:
Reduce downtime, Maximize production ninety% of failures are NOT time-based. For a lot of assets, failure can imply a considerable or total lack of production, often worth tens of thousands to hundreds of thousands per day. Often industries are inclined to give attention to the larger, more costly machines on the expense of ignoring the smaller supporting machines. Specializing in the machines that “make the money” is important however so too is concentrate on those machines without which the money making machine can’t operate.
Increase safety – Relying solely available-held devices for monitoring machine health can expose factory workers to pointless risks in our highly automated factories. Further, occasional catastrophic breakdowns on account of upkeep gaps can improve worker publicity to hazardous conditions and potential environmental disasters.
Reduce maintenance prices- When considered on a per-asset foundation, maintenance prices for plant-wide assets can seem modest. Nonetheless, when seen collectively across the dozens, hundreds, and even hundreds of assets in a typical plant, these prices can be appreciable. Reducing the upkeep prices on each asset via efficient condition monitoring—even by a mere 10%—has a large impact on plant profitability. Condition Monitoring is a planning tool that enables more efficient insight in planning and asset management, allowing upkeep to be executed in advance of a functional failure.
Reduce hidden costs – Direct (traditional) upkeep costs are predictable and handleable. Indirect (hidden) upkeep prices, both stealthy and steep, can accrue to be as much as 5X higher. For a lot of 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 mostly approach.