1. Implementation of Condition
Monitoring
By : Uttam Kumar Misra (MIE)
(Condition Monitoring )

2. What is CBM?
• CBM is a philosophy of managing changes in
Maintenance strategy.

3. “The ultimate objective of a CBM
program is to ensure the availability
of the machine for safe and reliable
operation during its useful life at
optimum maintenance cost”

4. Why CBM is required
• Quality
CBM improves the QUALITATIVE
availability of equipment due to enhanced
monitoring of the same.
Or
CBM ensures the Reliable performance of the
equipment due to enhanced monitoring of the
same.

5. Why CBM is required
(contd…)
• Cost Benefits
Extended PM frequencies, lesser job-contracts.
Minimum equipment damage/repairs.
Reduced over time.
Minimum oil use and disposal.
Less inventory through reliability enhancement.
Indirect cost-Less part loading due to equipment outage

6. Why CBM is required
(contd…)
• Time Factor
 Reduced down time of equipment through
scheduled Vs unscheduled repairs.
High Mean-time-difference between outages.


7. An approach to Best Condition
Monitoring Practices
Factors affecting Industrial applications
Where downtime cost is predominantly high
Where a safety risk is particularly likely to arise from
the breakdown of the machinery.
Where accurate and advanced planning of
maintenance is essential.
Where plant/equipment is of recent design & may
have residual development problems

8. Where operators cannot be expected to detect
faults in expensive equipment whose
breakdown may result in serious damage.
Where instruments or other equipment 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.

9. Pertinent Indexes
Potential gross savings by applying condition
monitoring to the industry would be about
Some% of the added value output.
Average annual maintenance expenditure on
plant & machinery to Average annual capital
invested in plant & machinery is about 80%.
Overall Equipment Effectiveness (%) =
Availability X Machine Efficiency X Quality Output
(>95%)

10. Percentage forced outages unit wise – Cost
wise & Total downtime wise
Plant load factor
Supply frequency
Comparison of pertinent failures – Frequency
wise (repetitive type & non-repetitive type) and
Total downtime wise (repetitive type & non-
repetitive type).
Availability-1%Higher availability performance
(95% – 99%) for an investment of xx USD in a
plant would accrue savings of yy USD

11. Technologies being used for CBM:
1. Vibration Analysis
2. Ultrasonic and Acoustic Emission
3. Thermography
4. Dissolved Gas Analysis
5. Oil Analysis
6. Noise And Acoustics

12. Technologies being used:
7. Wear Debris Analysis
8. Corrosion
9. Shock Pulse
10. Appearance And Odor
11. Level Leakage And Flow
12. Power Performance And Efficiency

13. Technologies being used:
13. Steady State(Speed , Temperature etc)
14. Electric Motor (Air gap, Power ckt fault)

14. Machines Covered Under Vibration
Technology:
Equipment Frequency
Blower, Wter Pump,
……………………..etc
Every Month

15. Vibration technology successful
implementation steps
• Plant :
• Area:
• Floor plans and maps:
• Total machine :
• Machine identification:
• Machine diagram:
• Machine information data sheet :
• Types of Machine:
• Criticality of each piece of machine:
• Measurement point:
• Contract information for resources:

16. • Transport:
• Vibration instrument:
• Supporting instrument :
• Hardware and Software:
• Man power:
• Safety:
• Frequency of measurement:
• Total workload and scheduling:
• Establish CBM/PM work order for collecting all possible
information regarding machine:
• CBM Checklist:
• Different level of meeting:
• Reporting:
• Detailed analysis report:

17. • Daily report:
• Weekly report:
• Monthly report:
• Critical/unsatisfactory equipment reporting:
• Stabilizations of system:
• Establish maintenance manpower training
• Documentation
• KPI

18. • Book-keeping-Whether a program is performed in house or contracted out, it is
essential that adequate prepared and maintained it is recommended that a notebook
is prepared which includes, limited to section concerning.
• Floor plans and maps- It is critical that personnel are able to find and identify the
equipment monitored. These are also invaluable in establishing the routes .and it
will be helpful when new personnel join the program.
• Machine diagram- A picture is worth a thousand words
• Machine information data sheets- When analyzing the data it is very helpful to
have as information about the machine at hand as a possible.
• A schedule for obtaining route data- Making the task more manageable and
setting of goals
• Contact information for resource's- that have provided or can provide pertinent
information,manufacturer,part supplier,operators,supervisors name and extensions.
• Outlines of procedures-this include everything from how to collect data to the
parameter being used in the spectrum analyzer, to method and guide and report on
the data. As these items may change from time to time and from machine to be
documented.
• Summary of case history -When a problem is identified the report should be
cataloged it may be benefited from again at a later date .
• Cost analysis information - What would have happened had the problem not been

19. • AMS suite for vibration technology includes
• Data base creation
• Route creation
• Data collection
• Data communication
• Analysis
• Reporting

20. • Analysis parameter Set
• F max:
• Waveform length:
• Resolution-:
• Averaging mode-:
• Filtering-:
• Alarm limit set:
• Machine vibration Severities:
• Sampling rate:
• Bandwidth:
• Overlap:
• Fault frequency set:

21. SOUND LEVEL MEASUREMENT
• Measurement every six month, is as per the safety
requirement.
• Turbine floor, Compressor house, pump house,
• etc

22. THERMOGRAPHY:
Sl. No. Area Description Frequency
1. Furnace wall Quarterly
2 etc
3.
4.

23. DISSOLVED GAS ANALYSIS
• Oil samples from transformers are being regularly
sent to Analyse
• Whenever the level of dissolved gases is more than
the norms the frequency of DGA is increased.

24. OIL ANALYSIS
• Being done regular interval
• Primarily the analysis includes moisture content,
viscosity, Total acid number, Mechanical impurities,
PQ index etc.
• On observation of any abnormalities detailed
analysis of sample will be done by WEAR DEBRIS
ANLYSER.

25. OIL ANALYSIS:
Sl.No. Equipment Frequency
1. Hydraulic oil Half yearly
2. etc
3.
4.
5.
6.

26. Selecting level of CM activity –
Practices
The complete Plant – Plants of high product demand
or major strategic significance.
Key Machines Only – Applicable to large industries.
A few critical components of key machines – Widely
applicable to industry.(A few critical components are
selected based on the past failure experience &
monitored for known failure modes using appropriate
techniques.

27. Selecting Machines for Monitoring
Selecting machines on the basis of
Loss of productive earning capacity
Failure damage potential
Safety

28. Selecting Components for Monitoring
Selecting components on basis of
Criticality in terms of machine reliability
High performance duty
Long replacement / delivery time
Have lower life than the rest of the machine

29. Component to be
Monitored
Possible general monitoring method
Visual Behavi
our
Vibrati
on
Wear
Debris
Stationary
components:
Castings
Mountings &
foundations
Tanks & containers
Pressure vessels
Pipes
Heat exchangers
Screens and
separators
Stator Blades
SELECTING METHODS OF MONITORING

30. Rotating
components
Shafts
Machine rotors
Turbine blades
Impellors and
propellers
Wheels
Gears
Chain drives
Flexible couplings
Pulleys and belts
Governors

31. Reciprocating
components
Pistons
Linkages & levers
Cams & tappets
Valves
Cables & chains
Bellows
Diaphragms
Springs
Guides & Slides
Splines

32. Friction
components
Breaks
Clutches
Vibration dampers
Bearings
Plain
Rolling
Flexure

33. Seals
Lip
Mechanical
Packed glands
Windback
Labyrinth
Piston rings
Wear resistant
surfaces
Hard
Elastic

34. Manufacturing
tools
Cutting tools
Metal working
tools
Casting and
moulding dies
Working fluids
Hydraulic
Cooling and heat
transfer
Lubricants

35. MACHINE PERFORMANCE MONITORING
Monitoring
method of m/c
performance
Typical example Remarks
Measuring the
quantity of the
output or
variations in the
quantity
Measuring the delivery
from a conveyor or
pumping system
Measurement of the mean
output rate at standard
conditions can indicate the
existence of a problem. If the
delivery fluctuates, the
condition under which it does
this, may indicate the nature of
the problem.
Measuring the
quality of the
output of
variations in the
quality.
Noting accuracy within
tolerance of the output
of machine tools.
Observing pattern
variations in the fabric
produced by textile
machines. Observing
size distribution in the
output from a crushing
This can provide a very
convenient monitoring method
for direct use by machine
operators.
It will indicate the existence of
a problem and with experience
of its interpretation, can
indicate the nature of the
problem as well.

36. Monitoring
method of m/c
performance
Typical example Remarks
Measuring the
relationship
between the input
and output of the
machine.
Comparing the fuel
consumption and
electrical output of a
diesel generator.
Measuring the distance
traveled per unit of fuel
consumption of a
transport vehicle.
Can indicate the existence of
problem using measurements,
which are often already
recorded for other reasons.
Simultaneous
measurement of
two output
variables, and a
comparison
between them, on
an allowable
operating
envelope
The flow/pressure rise
relationship for a pump.
The temperature
difference/flow
relationship for a heat
exchanger.
The pressure drop/flow
relationship for a
separator.
This method of monitoring
enables the condition of the
machine or plant item to be
determined, independently of
any other changes, which may
have occurred in the system of
which it is a part.

37. COMPONENT BEHAVIOUR MONITORING
Component Function (s) Method of monitoring
component behaviour
Seals (static and
dynamic)
To prevent leakage Detection of leakage by: Smell,
Visual inspection, Snifting, Noise
Structural
components
(casings,
containment
vessels, load
carrying machine
parts).
To remain intact
without progression
of cracks etc.
Strain gauging.
Brittle lacquers
Acoustic emission (listening to
the sound generated by the
strain of materials using a
microphonic transducer attached
to the surface). Crack detection
by magnetic eddy current, and
liquid penetrant methods.

38. Bearings To located shafts as
required, but with the
minimum of resistance
to rotation
The measurement of
shaft location by
proximity transducers.
The measurement of
bearing temperature as
a check on frictional
heat generated by
malfunctions.
Friction components
(brakes, clutches).
To provide controlled
and relatively high
friction with the
minimum of wear and
overheating
Periodical wear
measurement.
Temperature
measurement to detect
general overheating.
Cylinder liners To guide pistons and
provide gas seals with
the piston rings with a
minimum of wear.
Wear detection with
wear sensors.
Temperature
measurement. Blow by
detection by ultrasonic
sound emission.

39. Condition Based Maintenance –
Implementational Steps
Step –1
Establish an inventory of all physical assets
Develop an equipment identification (codification) plan
down to the component level.
Develop an equipment data card ( Location, Make, Model,
Manufacturer, Supplier, Major specs, Drawing Nos.
Foundation details, Major sub assemblies, Bearing details
etc.)
Organise all technical information

40. Step – 2
Develop a process flow chart indicating all equipments
down the line.
 Establish criticality of each piece of equipment (Major
factors to be considered are – Impact on Production, Safety,
Cost of equipment Maintenance requirements-resources,
RAM, & Effect on Quality)
Step – 3
Compile Condition Based Maintenance data for all the
critical equipments (in the first phase) – Techniques
applicable, Measurement parameters applicable standards,
Alarm & Critical Levels

41. Measurement points, frequency etc.
Develop CBM checklists
Step – 4
Establish total workload (manhours)
Schedule CBM activities evenly throughout the year
Step – 5
Incorporate Total Productive Maintenance concepts
(autonomous maintenance, small group activities, one point
lessons, action on major losses, and 5S) to improve
maintenance function.

42. Step – 6
Establish PM/CBM work order (basic document for
collecting all possible information on maintenance
activities and resources.
Collate for data entry
Step – 7
Computerisation of Maintenance function including
its interfacing with spares management and costing
deptt. Computerisation to generate m/c history and
various reoports.

43. Step – 8
Design reporting parameters, indexes, different
levels of reports.
Carry out detailed analysis - RAM, B/d Analysis,
Maintenance Costing, Performance analysis etc.
Feedback to respective groups
Step – 9
Stabilisation of the system
Establish Maintenance manpower
Training

45. THANKS