FACT SHEET

Methods and benefits of condition

monitoring.

There are many types of condition monitoring (CM) and the parameters that they measure indicating
the mechanical condition of the machinery include;

• Performance
• Bearing Temperature
• Vibration
• Oil Pressure
• Oil Debris

The techniques of CM allow the determination of the health of a piece of plant or machinery. If the
condition is sub-optimal, then CM can help make it possible to determine the causes of any detected
problems. The broad categories of CM techniques include;

• Thermography
• Vibration Analysis
• Tribology

These categories can be further sub-divided into the following techniques used in the industrial and
transportation sectors;

• Acoustic Emission
• Ultrasound Emission
• Infrared Thermography
• Motor Condition Monitoring
• Motor Current Signature Analysis (MCSA)
• Lubricant Analysis
• Vibration Condition Monitoring and Analysis

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FACT SHEET

These techniques can be used singularly or combined depending on the application and
the preferred parameters needed to deliver the best protection against failure and improved
maintenance planning.

The data that CM provides can be used in two ways;

• Trend Monitoring. This involves the continuous and regular measurement and interpretation of
the data. By selection of the most suitable and measureable indication of machine or component
deterioration, it is possible to determine when deterioration will exceed a critical rate by studying
the trend of the data combined with running time.
• Condition Checking. With the machine running a check measurement is taken using a suitable
indicator - oil level, for example – which is then used as a measure of the machine condition at
that time. The effectiveness of this method depends on the frequency of the check measurement
being taken.

CM can provide benefits and savings in four ways;

• By using CM as part of a Predictive Maintenance planning and work control system. This provides
detection of potential failures at an early stage allowing reactive maintenance of damage that
would have led to in-service failure to be undertaken in a planned manner. Through the use of
better risk management and planning, savings can be realised.
• By contributing to elimination of defects in which the underlying causes of persistent and
recurring problems can be identified and actions taken to either change the design, maintenance
or operation to prevent further failures.
• Through the displacement of less cost effective, non-value adding intrusive maintenance tasks
with inspections that can be carried out during machinery operation quickly and easily.
• By combining the above factors to increase reliability and availability leading to higher
production rates without large sums of capital investment.

To gain the maximum benefit from CM it is best for it to form part of a Predictive Maintenance
work system. The most successful outcomes go beyond using CM to predict failures and used the
technology to form part of a reliability focussed defect elimination programme, thereby providing
the maximum return on investment. Additionally, maintenance strategy processes have identified
where predictive maintenance could be used instead of non-value added intrusive maintenance
tasks.

More information at gillsc.com

E support@gillsc.com
T +44 (0)1590 613900 Sensors & Controls