Understanding Condition Monitoring

Devices

Portable balancer & Vibration analyzer Balanset-1A

$2,344.68 Izvorna cijena bila je: $2,344.68.$2,018.20Trenutna cijena je: $2,018.20.

Parts

Vibration sensor

$106.85 Izvorna cijena bila je: $106.85.$83.10Trenutna cijena je: $83.10.

Parts

Optical Sensor (Laser Tachometer)

$147.21 Izvorna cijena bila je: $147.21.$106.85Trenutna cijena je: $106.85.

Devices

Balanset-4

$8,076.37

Parts

Magnetic Stand Insize-60-kgf

$54.61

Parts

Reflective tape

$11.87

Devices

Dynamic balancer “Balanset-1A” OEM

$2,059.75 Izvorna cijena bila je: $2,059.75.$1,780.77Trenutna cijena je: $1,780.77.

Definition: What is Condition Monitoring?

Condition monitoring (CM, also called condition-based monitoring or CBM) is the practice of periodically or continuously measuring and trending equipment operating parameters—primarily vibration, temperature, and performance metrics—to assess equipment health, detect developing faults early, and schedule maintenance based on actual condition rather than fixed time intervals. Condition monitoring enables the transition from reactive (fix after failure) or time-based (scheduled regardless of need) maintenance to predictive maintenance where interventions are optimized based on equipment condition.

Condition monitoring is fundamental to modern reliability-centered maintenance programs, providing the data foundation for condition-based decisions that maximize equipment uptime, reduce maintenance costs, prevent catastrophic failures, and optimize spare parts inventory.

Core Monitoring Technologies

1. Vibration Analysis (Primary)

• Most comprehensive machinery condition indicator
• Detects mechanical defects (unbalance, misalignment, bearing defects)
• Provides early warning (months before failure)
• Standard techniques: FFT, envelope analysis, trending

2. Temperature Monitoring

• Bearing and winding temperatures
• Indicates lubrication problems, overload, cooling issues
• Complements vibration (confirms severity)
• Simple and cost-effective

3. Oil Analysis

• Wear particle analysis
• Contamination detection
• Lubricant degradation assessment
• Early warning of internal wear

4. Thermography

• Infrared imaging of equipment
• Detects hot spots (electrical, mechanical)
• Non-contact surveys
• Electrical and mechanical applications

5. Motor Current Analysis

• Electrical signature analysis
• Detects rotor bar defects, stator problems
• Non-invasive
• Complements vibration for motors

Implementation Approaches

Route-Based Monitoring

• Technician visits equipment on regular route
• Handheld instruments collect data
• Frequency: weekly, monthly, quarterly
• Cost-effective for many machines
• Scalable to large facilities

Online Continuous Monitoring

• Permanently installed sensors and instruments
• Continuous or frequent automatic measurements
• Real-time alarming
• For critical equipment
• Higher cost but maximum protection

Hybrid Approach

• Online for critical equipment
• Route-based for general equipment
• Optimizes cost and coverage
• Most common in practice

Benefits

Operational Benefits

• Increased Uptime: Prevent unplanned failures
• Extended Equipment Life: Timely interventions prevent damage
• Production Continuity: Schedule maintenance during planned outages
• Safety: Prevent catastrophic failures

Economic Benefits

• Reduced Maintenance Costs: Eliminate unnecessary preventive maintenance
• Lower Spare Parts Inventory: Order when needed, not “just in case”
• Prevent Secondary Damage: Early intervention prevents collateral damage
• Optimized Labor: Focus resources on equipment that needs attention

Knowledge Benefits

• Understand equipment failure modes
• Improve designs and specifications
• Build historical knowledge base
• Data-driven decision making

Program Implementation

Equipment Criticality Analysis

• Identify critical equipment (production impact, safety, cost)
• Assign monitoring level based on criticality
• Critical: online monitoring
• Important: monthly routes
• General: quarterly routes or none

Baseline Establishment

• Measure all equipment when healthy
• Establish baseline signature
• Define normal operating parameters
• Foundation for all trending

Alarm Limits

• Set based on baselines and standards
• Alert, alarm, and trip levels
• Equipment-specific rather than generic
• Adjust based on experience

Success Factors

Management Support

• Resource allocation (equipment, personnel, training)
• Long-term commitment (ROI takes time)
• Integration with maintenance strategy

Skilled Personnel

• Training in vibration analysis
• Understanding of machinery
• Diagnostic capabilities
• Continuous learning

Quality Data

• Consistent measurement procedures
• Calibrated instruments
• Proper data management
• Reliable trending

Action on Results

• Must act on CM findings (or program has no value)
• Integration with work order system
• Feedback loop (verify repairs effective)

Condition monitoring transforms maintenance from reactive or scheduled to predictive and optimized. Through systematic measurement, trending, and analysis of equipment condition indicators, CM programs enable early fault detection, planned maintenance timing, and data-driven decisions that maximize equipment reliability and uptime while minimizing maintenance costs in industrial facilities.

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