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Condition Based Maintenance

Condition based maintenance (CBM) is a strategy that uses the actual condition of assets to determine necessary maintenance, rather than performing maintenance on a predetermined schedule. CBM involves monitoring assets for indicators of performance decreases or impending failure through methods like vibration analysis, infrared scans, or oil analysis. Once issues are detected, CBM allows corrective actions to be scheduled at the optimal time to improve reliability and reduce costs compared to preventative maintenance. CBM is effective for critical assets where safety is important, such as aircraft, and is becoming more common as monitoring technology advances.

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243 views5 pages

Condition Based Maintenance

Condition based maintenance (CBM) is a strategy that uses the actual condition of assets to determine necessary maintenance, rather than performing maintenance on a predetermined schedule. CBM involves monitoring assets for indicators of performance decreases or impending failure through methods like vibration analysis, infrared scans, or oil analysis. Once issues are detected, CBM allows corrective actions to be scheduled at the optimal time to improve reliability and reduce costs compared to preventative maintenance. CBM is effective for critical assets where safety is important, such as aircraft, and is becoming more common as monitoring technology advances.

Uploaded by

Saumya Kharya
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Condition Based

Maintenance
MAINTENANCE MANAGEMENT
SAUMYA KHARYA
DFT-VI

CONDITION BASED MAINTENANCE


Condition Based Maintenance (CBM) is a maintenance strategy that uses the
actual condition of the asset to decide what maintenance needs to be done. It
can shortly be described as maintenance when needed.
CBM dictates that maintenance should only be performed when certain
indicators show signs of decreasing performance or upcoming failure.
Checking a machine for these indicators may include non-invasive
measurements, visual inspection, performance data and scheduled tests.
Condition data can be gathered at certain intervals, or continuously (as is done
when a machine has internal sensors).
CBM can be applied to mission critical that incorporate active redundancy and
fault reporting and non-mission critical assets that lack redundancy and fault
reporting.
Unlike in planned scheduled maintenance (PM), where maintenance is performed
based upon predefined scheduled intervals, condition based maintenance is
performed only when it is triggered by asset conditions. Compared with
preventative maintenance, this increases the time between maintenance
tasks, because maintenance is done on an as-needed basis.
The goal of CBM is to spot upcoming equipment failure so maintenance can
be proactively scheduled when it is needed - and not before. Asset conditions
need to trigger maintenance within a long enough period before failure, so work
can be finished before the asset fails or performance falls below the optimal
level.

CBM = COST SAVINGS + HIGHER SYSTEM RELIABILITY


CBM allows preventive and corrective actions to be scheduled at the
optimal time thus reducing the total cost of ownership.
Today, CBM methods are becoming more mature and improvement in technology
are making it easier to gather, store and analyze data for CBM. In particular, CBM
is highly effective where safety and reliability is the paramount concern such as
the aircraft industry, semiconductor manufacturing, Nuclear, Oil and Gas etc.

Value potential
As systems get more costly, and instrumentation and information systems tend
to become cheaper and more reliable, CBM becomes an important tool for
running a plant or factory in an optimal manner. Better operations will lead to
lower production cost and lower use of resources. And lower use of resources
may be one of the most important differentiators in a future where
environmental issues become more important by the day.
A more down to earth scenario where value can be created is by monitoring the
health of your car motor. Rather than changing parts at predefined intervals, the

car itself can tell you when something needs to be changed based on cheap and
simple instrumentation.
It is Department of Defense policy that condition-based maintenance (CBM) be
"implemented to improve maintenance agility and responsiveness, increase
operational availability, and reduce life cycle total ownership costs".

The 3 Phases of Condition Based Maintenance


1. Surveillance - Monitoring the equipment condition to detect developing
problems.
2. Diagnosis - Isolating the root cause of the issue and developing a corrective
plan based on priority, equipment condition and its remaining life.
3. Remedy - Performing the corrective action.

Types of Condition Based Maintenance

Vibration analysis rotating equipment such as compressors, pumps,


motors all exhibit a certain degree of vibration. As they degrade, or fall out of
alignment, the amount of vibration increases. Vibration sensors can be used
to detect when this becomes excessive

Infrared IR cameras can be used to detect high temperature conditions in


energized equipment

Ultrasonic Detection of deep subsurface defects such as boat hull corrosion

Acoustic - Used to detect gas, liquid or vacuum leaks

Oil analysis measure the number and size of particles in a sample to


determine asset wear

Electrical Motor current readings using clamp on ammeters

Operational performance sensors throughout a system to measure


pressure, temperature, flow etc

Data Collection
Data can be collected from the system by two different methods:

Spot readings can be performed at regular intervals using portable


instruments
Sensors can be retrofitted to equipment or installed during manufacture
for continuous data collection

Critical systems that require considerable upfront capital investment, or that


could affect the quality of the product that is produced, need up to the minute
data collection. More expensive systems have built in intelligence to self-monitor
in real time. For example, sensors throughout an aircraft monitor numerous
systems while inflight and on the ground to help identify issues before they

become life threatening. Typically, CBM is not used for non-critical systems and
spot readings suffice.

Advantages of Condition Based Maintenance

CBM is performed while the asset is working, this lowers disruptions to normal
operations

Reduces the cost of asset failures

Improves equipment reliability

Minimizes unscheduled downtime due to catastrophic failure

Minimizes time spent on maintenance

Minimizes overtime costs by scheduling the activities

Minimizes requirement for emergency spare parts

Optimized maintenance intervals (more optimal than manufacturer


recommendations)

Improves worker safety

Reduces the chances of collateral damage to the system

Disadvantages of Condition Based Maintenance

Condition monitoring test equipment is expensive to install, and databases


cost money to analyze

Cost to train staff you need a knowledgeable professional to analyze the


data and perform the work

Fatigue or uniform wear failures are not easily detected with CBM
measurements

Condition sensors may not survive in the operating environment

May require asset modifications to retrofit the system with sensors

Unpredictable maintenance periods

Challenges of Condition Based Maintenance

CBM requires an investment in measuring equipment and staff up-skilling so


the initial costs of implementation can be high.

CBM introduces new techniques to do maintenance, which can be difficult to


implement due to resistance within an organization.

Older equipment can be difficult to retrofit with sensors and monitoring


equipment, or can be difficult to access during production to spot measure.

With CBM in place, it still requires competence to turn performance


information from a system into actionable proactive maintenance items.

Example of Condition Based Maintenance


Motor vehicles come with a manufacturer-recommended interval for oil
replacements. These intervals are based on manufacturers' analysis, years of
performance data and experience. However, this interval is based on an average
or best guess rather than the actual condition of the oil in your specific vehicle.
The idea behind CBM is to replace the oil only when a replacement is needed,
and not on a predetermined schedule.
In the case of industrial equipment, oil analysis can perform an additional
function too. By looking at the type, size and shape of the metal particulates that
are suspended in the oil, the health of the equipment it is lubricating can also be
determined.

REFERENCES
1. http://www.maintenanceassistant.com/condition-based-maintenance/
2. http://en.wikipedia.org/wiki/Condition-based_maintenance

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