Condition Based monitoring

By,
Priyesh Nair
Contents:
1. Maintenance Objectives

2. Maintenance Classification

3. Predictive Maintenance & CBM

4. Comparison of Machine to Human

5. Advantages & Necessity of CBM

6. Techniques & Frequency of CBM

7. Flow Chart of Implementation

8. Implementation

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1. Maintenance Objectives:

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2. Maintenance Classification:
Entire maintenance can be broken down into sub categories which is as follows:

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3. Predictive Maintenance:
As the name implies it involves the prediction of the failure
before it occurs, identifying the root cause for those failure
symptoms and eliminating those causes before the y result
in extensive damage of equipment.
Type of maintenance performed continuously or at
regular intervals according to the requirements to
diagnose a condition and monitor a condition or system.
Also known as Condition Based Monitoring.

Condition Based Monitoring:

The ultimate objective of CBM program is to ensure the
availability of the equipment for safe and reliable
operation during its useful life at optimum maintenance
cost.
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 4. Comparison of Machine to Human
oPredictive Of M/C Is As Doctor Care Human
FOR HUMAN:
HEARTBEAT READING----TEMPRATURE-----BLOOD TEST---------CARDIOGRAPH

FOR M/C:
VIBRATION-----------------THERMOGRAPHY--------M/C OIL TEST------FFT SIGNATURE

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 An approach to best Condition Monitoring
Practices
Factors Affecting Industrial Appliances:
Where downtime cost is predominantly high.
Where a safety risk is particularly likely to arise from the breakdown of
machinery.
Where accurate and advanced planning of maintenance is essential.
Where plant/equipment is of recent design and may have residual
development problems
Where operators cannot be expected to detect faults in expensive
equipment whose breakdown may result in serious damage.
Where instruments or other equipments required for condition
monitoring can be used or is already being used
Where the manufacturer can offer a condition monitoring service to
users of its equipment

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 5. Advantages of CBM:
Allows planned maintenance rather than breakdown
maintenance.
Production can be modified to extend unit life.
Cause of failure can be analyzed.
Permits for maintenance can be planned.
Manpower/Spares can be arranged well in advance.
Modifications can be planned.

Necessity for CBM:

Cost Benefits Time Benefits
Minimum equipment damage/repairs Reduced downtime of equipment
Minimal oil use and disposal through scheduled vs unscheduled
repairs
Less use of inventory items through Reduced Mean Time To Repair
reliability enhancement
Indirect cost-less part loading due to High Mean Time Between Failures
equipment outage differences.
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 6. Techniques for monitoring CBM:
Vibration Analysis
Thermography
Motor Current Signature Analysis
Oil Analysis
Wear Debris Analysis

Frequency of implementation:
S.No. Method Frequency
1. Vibration Analysis Monthly
2. Thermography Quarterly
3. Motor Current Signature Analysis Quarterly
4. Oil Analysis Monthly
5. Wear Debris Analysis On need basis
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 7. Flow Chart of Implementation:

Identify Measurement
Scheduling and
equipment and
Planning Scheduled Data Entry
CBM technique Unscheduled

Exception Report
Abnormal
for corrective Analysis
Reading
action

Corrective Normal
Action by Reading
Department

Report
Feedback from Re- Generation and
Department measurement circulation
Data Entry to
History
Sheets/Softwares
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 8. Implementation:
The CBM methods are implemented based on the equipments that
needs assessment.

S.No. Technique Equipment

1. Vibration Analysis Rotating and reciprocating equipments
All Electrical PCC, MCC, switchyards
2. Thermography
etc.
Motor Current Signature
3. All Terminal Boxes
Analysis
All type of Hydraulic and lubricating
4. Oil Analysis
oils
All type of Hydraulic and lubricating
5. Wear Debris Analysis
oils

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Priyesh Nair