Condition Monitoring System

1. What is a condition monitoring system?

❖ A condition monitoring system (CMS) is a maintenance approach for

forecasting the health of equipment or machines along with sensor

data to measure vibration and related parameters with upgraded
machine monitoring software.

❖ The dynamic nature of the condition monitoring system is a

revolutionary step ahead on various levels for most manufacturing

authorities.

❖ This condition monitoring system permits or allows the plant

operators to remotely monitor and control the health of each and

every piece of machinery equipment.

❖ This system offers an integrated, plant view of every mechanical

operation.
❖ This system releases an alert signal if there is any error or change in

machine health detected to enable the plant operators to look at the

plant situation and to take required corrective actions.

❖ This system is treated as the heart and soul of all process industries

and power plants.

❖ Digitalization is the key to unlocking the huge amount of

unexploited information embedded in plant operations.

❖ Connecting the data, insights, and self-learning models across your

entire process plant operation to increase capital efficiency and

profitability, decrease unexpected costs, and better allocate
valuable resources.

❖ Generally, the equipment or plant failures or errors are unexpected

and are not time bases.

❖ Equipment failures are considerable total loss of production for

many assets worth tens of thousands to millions per day.

❖ Every process industry tends to focus on larger or more expensive

machines to make more profit and money.

❖ The maintenance costs for plant equipment appear fair and

moderate viewed on a per asset basis.

❖ But when viewed for hundreds of assets in a typical plant the

maintenance costs can be noticeable.

❖ Reduction of maintenance costs through effective condition

monitoring systems makes a large impact on plant profitability

❖ A condition monitoring system is a planning tool that makes

awareness in planning and managing the plant asset and allows for
prior maintenance of a functional failure
 ❖ The traditional or direct maintenance costs can be easily predicted

and managed. But hidden or indirect

❖ Indirect (hidden) maintenance costs are expensive and stealthy and

can result up to 5X higher.

❖ Reducing these hidden costs is mandatory.

❖ To reduce these hidden costs the plant shifts from a traditional

approach to a dynamic reliability-based approach.

What are different types of condition monitoring systems

available for pumps and motors?
Various types of condition monitoring systems available for pumps
and motors

1. Vibration analysis and diagnostics:

❖ This is one of the most well-known predictive maintenance methods.

❖ Vibration analysis can detect misalignments and imbalances.

❖ This technique includes shock pulse analysis for rotors, ultrasonic

analysis to detect leaks, and time waveform analysis for machines

having X & Y probes

❖ The vibration frequency of the rotating part of a device determines

the operating status of the device.

❖ If any changes in normal operation are detected this accounts for

degradation.

2. Lubricant oil analysis

❖ This analysis applies to machine oils, lubricants, and fluids.

 ❖ This indicates wear, overheating, contamination, and higher iron

levels like dirt and grit.

❖ This analysis will reduce gearbox damage by 50% and bearing

damage by 75% by avoiding contamination.

❖ If any waste is found in the machine lubricant, this indicates

material loss from the corroding component.

❖ Analysing the waste or junk detected helps to identify the defective

part for repair and replacement.

3. Acoustic emission.

❖ All parts of the rotating device will generate some kind of sound or

noise by the nature of their motion.

❖ High-frequency emission changes indicate various faults.

4. Infrared thermography

❖ This shows the heat and radiation patterns in machines

❖ Any change in temperature at various spots indicates failure, a heat

point on the machine indicates the failure or degradation of a

bearing.

❖ While a cool spot on a building can be a pipe leakage.

❖ Overheating in electrical machines, pipe leakage, and weakness in a

pressurized container.

❖ This thermography will reduce risk, prevent failures, and decrease

costs and losses.

5. Motor circuit analysis

❖ Motor circuit analysis is used to analyze the working condition of an

electric motor’s rotors, coupling, or belt.

❖ Motor circuit analysis improves the efficiency of equipment by 10-

15%. by reducing energy costs

6. Ultrasonic monitoring

❖ It is cost-effective when applied together with vibration analysis.

❖ It uses high-frequency sound waves for leakage detection, and

cavitation.

❖ This monitoring system reduces inspections by 30%.

7. Radiography

❖ Radiography includes analysis of radiation and neutron radiography.

❖ It is a very rigorous method of non-destructive testing.

❖ It allows the plant operator to inspect internal defects, such as

corrosion effects in mold or forge parts and in welding defects.

❖ This radiography has a major advantage in that this can be used for

various types of materials, and allows for operator protection.

8. Electromagnetic measurement

❖ An electromagnetic measurement system measures distortions in a

magnetic field to spot cracks, dents, corrosion, weaknesses, and

other defects.

❖ Eddy-current testing (ECT) is the well-known method of

electromagnetic monitoring to measure magnetic distortions,

 ❖ This testing is used in the petrochemical industry to detect tight

cracks.

What are the benefits of a Condition Monitoring System?

❖ Minimizes downtime

❖ Reduces maintenance costs and hidden costs

❖ This eliminates unnecessary and wasted expenses associated with

maintaining machine health based on the static metric of operating

hours alone.

❖ This condition monitoring system is considered an accurate and true

maintenance tool for every industrial process equipment.

❖ This condition monitoring system benefits much more in terms of

financial, and operational safety of the plant.

❖ The plant that offers these systems realizes minimum risk and high

rewards with great efficiency because these are highly reliable and
proved as extremely effective across multiple manufacturing
industries.

❖ Increases plant and operator safety.

How to get started for conditioning monitoring of the system?

Step one: Installation of the hardware required.
1. Installation of hardware such as monitoring sensors on serviceable
assets including

❖ Rotating machinery like turbines, compressors, pumps, and motors.

❖ Stationary assets like boilers, heat exchangers, and mills.

2. The plant team works with the vendor installation team to re-
assemble or modify machines as required, and to ensure the
appropriate installation of monitoring instrumentation.

Step two: Measurement and collection of data

The sensors after installation must start to measure the following
machine elements
1. Vibration and position: This indicates the dynamic and static motion
of the machine case or rotor.
2. Rotor speed: during rotation analyzes vibration data and
determination of malfunctions that occur in the machine. The
vibration frequencies of the machine reflect direct multiples of the
rotating speed.
3. Temperature: The temperature of radial and thrust bearings, lube
oil, stator windings, and steam temperatures of the machine can be
measured by sensors such as RTDs and Thermocouples measures.

Step three: Monitoring of installed machines

1. Trained operators for maintenance are alerted and irregularity in the
system is detected and the data provided is used to determine the
requirement of immediate attention.
2. This data from process sensors is sent to centralized monitoring
software for evaluation and diagnostics
What are common examples included in condition-based
monitoring systems?
Some common examples of condition monitoring systems include
vibration, oil, and temperature.

❖ Monitoring and analysis of Vibration.

❖ Tracking and measurement of Temperature.

❖ Analysis of lubrication and cooling oil.

What are the elements of a condition monitoring system?

The Condition Monitoring system consists of five key elements:

❖ Site Assessment.

❖ Fleet management.

❖ Equipment Inspections.

❖ Preventative Maintenance.

❖ Fluid Sampling & Analysis.

Why is condition monitoring used?

❖ The condition monitoring system allows for scheduled maintenance.

❖ It takes appropriate actions to prevent equipment damage and

avoid its consequences.

❖ Condition monitoring has unique benefits that may reduce the life

span and address before the equipment's major failure

What are the elements of a condition monitoring system?

Elements of the Condition Monitoring system

● Steam Turbine.

● Thrust Bearing.

● Compressor.

● Turbines.

● Major Component.

● Rotating Equipment.

● Shutdown.