Condition-Based Monitoring Examples
Equipment failure is incredibly frustrating, but it’s just a part of life. Plant managers become accustomed to preventing failures in any way possible, performing regular inspections, and ensuring equipment runs properly. However, preventative measures alone are not enough to avoid malfunctions. Condition-based monitoring (CBM) uses a combination of tools and technology to monitor equipment performance in real-time and accurately predict failures based on fluctuations and irregularities in data.
With the right CBM systems in place, you can drastically reduce downtime and ensure that your machinery functions to the best of its abilities at all times. Here are some examples of CBM techniques that you can use to transform maintenance to your advantage.
Vibration monitoring is the most common type of CBM, and this is because the majority of machines vibrate to some extent. In most cases, a monitoring device is attached to the equipment. As the machine vibrates, the device tracks and analyzes the movement and provides feedback to users. You can tell a lot about the health and overall wellbeing of a piece of equipment by the type and frequency of its vibrations, which is why vibration monitoring is such a widely-used CBM technique.
If your equipment is emitting an unusually high amount of heat, it could signify that something is amiss. Fortunately, with temperature monitoring tools, you can be alerted to temperature issues before they lead to irreparable damage. Though excessive heat can be a warning sign of equipment degradation, it can also signal misalignment within the machine. It’s essential to detect temperature-related problems as early as possible to prevent further damage or even total equipment failure.
Condition-based monitoring can also be used to monitor electrical currents and sound the alarm on disrupted electric flows. Some machines may be receiving too much electricity, while others are running short, but with the right CBM practices in place, you can eliminate many of the issues related to voltage and electric flow. Watching for unusual changes in voltage can be a lifesaver for your equipment.
Sonic and Ultrasonic Monitoring
CBM devices can monitor the sounds emitted by your equipment, listening for unusual changes in vibrations to determine if something is going wrong and where the problem is occurring. Ultrasonic monitoring can reveal both mechanical and electric failures and is a great way to ensure the ongoing performance of your equipment.
Many types of machines require lubrication to keep their parts moving optimally. However, lubricant oil provides another often overlooked benefit — it can give you a good idea of what parts of your machine are functioning correctly and which are starting to wear down. CBM tools can inform you of concerning elements found in the oil, which can indicate problem areas in the equipment. By monitoring the quality of your oil and checking for debris and other signs of malfunction, you can prevent lasting damage to your equipment.
Benefits of CBM
Condition-based monitoring is helpful in several ways. It primarily provides you with real-time data demonstrating the health of your machinery. Reactive measures are acceptable, preventative measures are better, but taking things a step further with CBM technology can ensure even greater success in avoiding malfunctions and downtime. Being able to detect and stop problems in their tracks can help promote the longevity of your equipment.
Unlike regular preventative monitoring, CBM can show you what’s going wrong and why, so that you can do even more to prevent the same issues from occurring down the road. This, in turn, can help you achieve desired outcomes and make data-driven maintenance decisions. Here are a few additional benefits of CBM:
- Reduced failures
- Cost savings due to fewer asset replacements
- Greater management efficiency
- A better understanding of equipment
- Employee safety
- Less downtime
See Trillium’s CBM Tool in Action!
Implementing condition-based monitoring technology can be challenging, especially if you’ve been using more traditional methods for preventing and resolving equipment failures. You may be dismayed by the prospect of having different devices attached to your machines, monitoring activities you aren’t always fully aware of. Knowing what tools to use for different types of monitoring can seem daunting, and many businesses forego CBM altogether for this reason.
Trillium provides the equipment to assist your company with CBM installation. Unlike some other CBM systems, Trillium’s tool is user-friendly and offers easy-to-understand data around the health of your assets. You can easily track your equipment, whether you’re working on-site or remotely, pulling up the data you need when you need it.
Additional features offered by Trillium include a work order dashboard, push notifications, in-app management, training videos, and work order management. Trillium’s team prioritizes efficiency and convenience so that you can get your CBM system up and running as quickly and painlessly as possible. Contact us today to get started!