Ultimate Condition Monitoring Cheat Sheet: Techniques, Tools & Best Practices

Introduction to Condition Monitoring

Condition monitoring is the process of systematically measuring and tracking the performance and condition of machinery and equipment to identify changes that could indicate developing faults. It serves as the foundation of predictive maintenance strategies, enabling organizations to detect potential failures before they occur.

Why Condition Monitoring Matters:

• Reduces unexpected downtime by up to 45%
• Extends equipment life by 20-40%
• Decreases maintenance costs by 25-30%
• Improves safety by identifying hazardous conditions
• Optimizes spare parts inventory management
• Enhances overall operational efficiency

Core Concepts & Principles

The P-F Curve

The P-F (Potential Failure to Functional Failure) curve illustrates how equipment deteriorates over time:

Key Monitoring Principles

• Baseline Establishment: Document equipment performance when new or after maintenance
• Trending Analysis: Compare current readings against historical data
• Threshold Setting: Define alert and alarm levels for critical parameters
• Criticality Assessment: Prioritize monitoring based on equipment importance
• Root Cause Analysis: Use monitoring data to identify underlying failure mechanisms

Condition Monitoring Implementation Process

1. Program Development

   • Identify critical assets
   • Determine failure modes and monitoring points
   • Select appropriate technologies
   • Establish monitoring frequencies

2. Data Collection

   • Install sensors/monitoring equipment
   • Set up data collection routes
   • Establish measurement protocols
   • Train technicians on proper data collection techniques

3. Data Analysis

   • Compare readings to baseline values
   • Identify anomalies and deviations
   • Determine severity of condition
   • Generate alerts for concerning trends

4. Decision Making

   • Evaluate maintenance needs
   • Plan interventions based on severity
   • Schedule repairs or replacements
   • Document findings for future reference

5. Program Optimization

   • Review effectiveness of monitoring techniques
   • Adjust monitoring frequencies
   • Update alarm thresholds
   • Incorporate new technologies as appropriate

Key Monitoring Techniques & Applications

Vibration Analysis

• Primary Use: Rotating equipment (motors, pumps, fans, gearboxes)
• Detects: Imbalance, misalignment, bearing faults, looseness, resonance
• Equipment: Portable analyzers, online systems, accelerometers
• Typical Frequency: Monthly for critical equipment

Infrared Thermography

• Primary Use: Electrical systems, mechanical equipment, building envelopes
• Detects: Electrical resistance, friction, insulation breakdown, leakage
• Equipment: Infrared cameras, thermal imagers
• Typical Frequency: Quarterly for electrical systems

Oil Analysis

• Primary Use: Lubricated mechanical systems, hydraulic systems
• Detects: Wear particles, contamination, lubricant degradation
• Parameters: Viscosity, particle count, water content, acid number
• Typical Frequency: Quarterly or based on operating hours

Ultrasonic Testing

• Primary Use: Pressure systems, steam traps, electrical systems, mechanical bearings
• Detects: Leaks, electrical arcing, friction, valve operation
• Equipment: Ultrasonic detectors, contact and airborne sensors
• Typical Frequency: Monthly for critical systems

Motor Current Analysis

• Primary Use: Electric motors and driven equipment
• Detects: Electrical issues, power quality, mechanical loading problems
• Parameters: Current signature, power factor, voltage imbalance
• Typical Frequency: Semi-annually or when issues suspected

Performance Monitoring

• Primary Use: Process equipment, HVAC systems, power generation
• Detects: Efficiency loss, flow restrictions, control issues
• Parameters: Flow, pressure, temperature, power consumption
• Typical Frequency: Continuous for critical processes

Comparison of Monitoring Technologies

Common Challenges & Solutions

Data Overload

Challenge: Too much data to analyze effectively Solution: Implement automated analysis systems with smart alarms and focus on critical parameters

False Alarms

Challenge: Excessive alerts causing “alarm fatigue” Solution: Use multi-parameter confirmation, establish proper thresholds, apply statistical analysis

Skilled Personnel Shortage

Challenge: Lack of qualified analysts Solution: Invest in training programs, utilize remote diagnostics services, implement expert systems

Sensor Placement & Selection

Challenge: Improper sensor location affects data quality Solution: Follow manufacturer guidelines, document sensor locations, use expertise of equipment specialists

Cost Justification

Challenge: Difficulty proving ROI for condition monitoring Solution: Document prevented failures, track downtime reduction, calculate savings from extended equipment life

Best Practices & Practical Tips

Equipment Selection

• Focus on critical equipment first (high-value assets, bottleneck equipment)
• Match monitoring technology to failure modes
• Consider equipment accessibility when selecting techniques
• Integrate multiple monitoring technologies for comprehensive coverage

Data Collection

• Collect data under consistent operating conditions when possible
• Document all relevant operating parameters during measurement
• Ensure proper sensor mounting and placement
• Calibrate instruments regularly

Program Management

• Integrate condition monitoring into CMMS/EAM systems
• Document all findings and actions taken
• Create standardized reporting formats
• Establish clear responsibilities for monitoring activities

Analysis & Interpretation

• Compare data to established baselines and trends
• Use multiple technologies to confirm findings
• Consider operating context when analyzing data
• Document and share success stories to build program support

Common Pitfalls to Avoid

• Over-monitoring non-critical equipment
• Under-utilizing collected data
• Failing to act on identified issues
• Using inappropriate technologies for specific applications
• Neglecting training and knowledge transfer

Resources for Further Learning

Industry Standards

• ISO 17359: Condition monitoring and diagnostics of machines
• ISO 13373: Vibration condition monitoring
• ISO 18436: Qualification and certification of personnel

Professional Organizations

• Society for Maintenance & Reliability Professionals (SMRP)
• Vibration Institute
• International Council for Machinery Lubrication (ICML)

Training & Certification

• Vibration Analyst Certification (ISO Category I-IV)
• Certified Reliability Leader (CRL)
• Certified Maintenance & Reliability Professional (CMRP)
• Thermal Imaging Certification
• Lubrication Excellence Certification

Recommended Reading

• “Practical Machinery Vibration Analysis and Predictive Maintenance” by C. Scheffer
• “An Introduction to Predictive Maintenance” by R.K. Mobley
• “Machinery Failure Analysis and Troubleshooting” by H.P. Bloch
• “Root Cause Failure Analysis” by R.J. Latino

Software & Tools

• Computerized Maintenance Management Systems (CMMS)
• Vibration analysis software
• Reliability analytics platforms
• Mobile data collection applications
• IoT-based monitoring solutions