CONDITION MONITORING

Condition monitoring (CM) is the process of monitoring a particular condition in machinery

(such as vibration, temperature, etc) to identify changes that could indicate a developing fault.
It is a major part of predictive maintenance as implementing condition monitoring allows for
maintenance to be scheduled and preventive actions taken to prevent further failure and
subsequent unplanned downtime.

Condition monitoring techniques are used on a range of equipment, including rotating

machinery, auxiliary systems and parts such as compressors, pumps, motors and presses.

Traditional condition monitoring was mainly based around vibration analysis, but more
modern, innovative techniques use sensors to measure different parameters in real time and
can send an alert when a change is detected.

How does it Work?

There was a time when condition monitoring as carried out by an engineer holding a wooden
stick against a machine and feeling the vibrations to check if the equipment was running
correctly. However, this has developed considerably with the use of digital technology, the
Internet and advanced maintenance techniques (AMTs).

Modern ongoing real time monitoring means that engineers can schedule planned
maintenance as required, rather than simply scheduling maintenance for a fixed date (i.e.
every six months). This allows maintenance to be scheduled at a more efficient time, as and
when required, leading to less downtime.

Condition monitoring can also prevent other components in a machine from failing as a
knock-on effect from one part breaking down. This use of predictive maintenance is a great
advancement from reactive maintenance, which involved running a machine to failure and
then replacing either it or its components. This heightens efficiency and removes unexpected
downtimes from a work schedule as well as minimising inspection procedures (You can find
out more about corrective, preventive and predictive maintenance here).

Condition monitoring can be broadly broken down into three steps:

1. Install the Monitoring System

The first step in condition monitoring is to install the monitoring system hardware onto your
serviceable equipment. This may require some retrofitting or modification of your existing
assets, with different items of equipment requiring different approaches or instrumentation.

2. Baseline Data Measurement

With the monitoring system installed, you can begin to measure the performance of your
equipment. The data collected can include vibration, rotor speed, temperature, and process
sensor data. This will give you a baseline against which you can monitor your equipment
against its optimum operating conditions going forward.

3. Ongoing Monitoring

The system can now monitor your systems using sensors and condition monitoring software
that will evaluate performance and provide diagnostics. The system can also send out an alert
when an operational abnormality is detected and assess the data to determine if immediate
action is required or if the machine can operate for a while longer while maintenance is
scheduled.

Condition Monitoring and The Internet of Things

The Internet of Things (IoT) is set to change condition monitoring as devices are able to
connect and communicate with each other. This means that connected smart machines in
different locations can communicate with each other to provide a joined-up comparison
between systems.

This additional data will help engineers to make informed decisions about their machinery
and any maintenance requirements. It can also improve diagnostic efficiency as the time it
takes to carry out thermographic or vibration monitoring on one machine can now be used to
test several machines simultaneously.

Connecting machines in this way can offer comparable data analysis of an entire production
process regardless of whether the machines are carrying out similar tasks or not. As soon as a
change in running levels is detected across the chain of production, operators can assess
where the problems may be and act upon imminent faults.

Types
Several different monitoring techniques can be used to evaluate the condition of your
equipment. These include monitoring using sensors along with more physical techniques,
such as checking for contaminants in machine oils.

While the different methods may indicate the same fault, they are best used together to
deliver an overall picture of a machine’s operation. Each type of condition monitoring covers
a range of different techniques to achieve them.

Condition monitoring types include:

Electrical Monitoring

Electrical monitoring involves the use of the principles of deviation in electrical parameters
to find defects or faults. These parameters include capacitance, frequency response,
induction, pulse response and resistance to locate potential issues. This method uses the
measurement of degradation trends to determine whether action is required to prevent system
failure.
Techniques include:

 Alternating current field measurement (ACFM)

 Battery impedance testing
 High potential testing
 Megohmmeter testing
 Motor circuit analysis
 Power signature analysis
 Surge testing

Electromagnetic Measurement

This type of condition monitoring identifies cracks, corrosion, weaknesses and other defects
by measuring field distortions and eddy current changes. Magnetic fields are applied to
surface walls and, as they interfere with one another, they create patterns which can be used
to identify deterioration in material quality and surface features. Also of use in tubing,
electromagnetic testing shows defects as disturbances that can be measured and analysed.

Techniques include:

 Magnetic particle inspection

 Magnetic flux leakage
 Metal magnetic memory method
 Pulsed eddy currents
 Remote and near field eddy current
 Saturated low-frequency eddy currents
 Other eddy current testing

Laser Interferometry

Laser interferometry uses a highly accurate, laser-generated wavelength of light to measure

changes in wave displacement. Based on the interference in light waves generated by a laser,
it is used to locate subsurface and surface defects in materials including composites. It works
by capturing and measuring the interference patterns using an interferometer. These patterns
can show differences in material characteristics such as the presence of corrosion, cavities or
surface defects in the material.

Techniques include:

 Digital holography
 Electronic speckle pattern interferometry
 Holographic interferometry
 Laser shearography
 Laser ultrasonics
 Strain mapping

Motor Circuit Analysis

MCA, or motor circuit analysis consists of a range of computerised tests on an electric motor
to determine its condition and if there any possible sources of potential failure. MCA tests
focus on electrical imbalances and degradation of insulation, which are the main causes of
motor failure. The tests are usually split into voltage-based or current-based tests and include
go/no-go tests and those that need to be tracked over time to determine failure development.

Inspections include:

 Air gap
 Insulation
 Online and offline testing regimes
 Power circuit/current signature
 Power quality
 Rotor
 Stator

Oil Analysis / Tribology

As machines wear out or overheat, contaminants are deposited into lubricating oils,
equipment fluids and other operating liquids. This technique collects and tests these oils,
fluids and lubricants to reveal the presence of any contaminants in order to interpret how
close a machine may be to failing.

Techniques include:

 Dielectric strength testing

 Ferrography
 Fourier transform infrared spectroscopy
 ICP / atomic emissions spectroscopy
 Microbial analysis
 Particle quantification index (to check iron content)
 Potentiometric titration/total acid number and total base number
 Presence of water tests
 Sediment tests
 Ultraviolet spectroscopy
 Viscosity/kinematic viscosity testing

Performance Monitoring /Process Variable and Performance Trending

/Observation and Surveillance

This most traditional type of condition monitoring involves visual inspections and the use of
an engineer’s physical senses to judge how a machine is functioning. Used in conjunction
with output tracking and manufacturing performance measurements allows an engineer to
identify any deviations from the expected results, which could indicate a problem with the
equipment. These types of inspection are still valuable today, especially when more advanced
technological tests are not possible, although they are reliant on a degree of experience,
record-keeping and expert interpretation.

Techniques include:

 Audio inspection
 Downtime analysis
  Flow rates
 Output or performance trends
 Pressure
 Temperature
 Touch inspection
 Visual inspection

Radiography/Radiation Analysis/Neutron Radiography

Some of the more thorough non-destructive testing methods, these types of condition
monitoring use radiation imaging to find internal defects in equipment or parts. These
methods are based on the differential absorption or radiation through a material, since
corroded areas and flaws absorb differing amounts of radiation to unaffected areas. The
absorption rates can be measured and analysed to find any defects and these techniques are
also used to insect castings, sintered parts and weldments.

Techniques include:

 Computed radiography
 Computed tomography (CT)
 Direct radiography
 Neutron backscatter
 Neutron radiography
 Positive material identification (PMI)

Thermography/Temperature Measurements/Infrared Thermography

Machinery and parts tend to heat up as failures develop, indicating misalignments,

imbalances, poor lubrication, worn components, mechanical stress, or electrical overheating.
Thermography can identify such thermal anomalies by capturing images of the thermal
radiation patterns emitted from equipment, allowing the use of data collection and analysis to
identify potential failures or part degradation. This type of condition monitoring is used to
identify issues such as overheated electrical connections, pipe leaks or pressure vessel
weaknesses.

Techniques include:

 Comparative thermography
 Comparative qualitative thermography
 Comparative quantitative thermography
 Lock-in thermometry
 Pulse phase thermometry
 Pulse thermometry
 Temperature-related colour changing fluids
 Temperature-related colour changing paint stickers

Ultrasonic Monitoring/Acoustic Analysis/Airborne Ultrasonic Monitoring

Ultrasonic monitoring techniques use high-frequency sound waves to detect part defects
including leaks, part seating and cavities. Used for equipment, bearings and rotating parts,
these methods can detect tiny changes in friction forces that may otherwise be missed using
techniques like vibration analysis. These monitoring methods can offer an early warning
system for machine part deterioration that may otherwise have been masked by ambient plant
noise and temperature.

Techniques include:

 Acoustic emission testing

 Acoustic ranging
 Airborne ultrasonics
 Automatic and continuous ultrasonic inspection
 Backwall echo attenuation
 Dry-coupled ultrasonic testing
 Internal rotating inspection
 Long-range ultrasonic testing
 Phased array testing
 Time-of-flight diffraction
 Ultrasonic backscatter technique
 Ultrasonic thickness and gauging

Vibration Analysis/Dynamic Monitoring

Wear on machine parts, bearings, rotors or shafts can cause them to vibrate in unusual
patterns that can be monitored, recorded and analysed. These vibration patterns can be used
to identify defects and potential failures, including those due to misalignments, imbalances or
even design flaws. Of course, technology has advanced since the days of holding a wooden
stick against a machine (as mentioned above) but the theory remains much the same!

Techniques include:

 Shock pulse analysis

 Broadband vibration analysis
 Fast fourier transforms
 Power spectral density (PSD)
 Spectrogram/spectrum analysis
 Time waveform analysis
 Ultrasonic analysis

Why it is Important
Condition monitoring is a tried and tested effective maintenance tool that is being used by an
increasing number of industries. Condition monitoring systems provide important benefits
from a financial, operational, and safety perspective.

While condition monitoring solutions may require some investment, these expenses are
returned by preventing costly unplanned downtimes as a result of machine failure, as well as
eliminating the unnecessary maintenance costs associated with scheduling maintenance based
on operating hours rather than actual condition.
When used with connected systems, condition monitoring allows users to make the most of
planned maintenance downtime, servicing multiple machines and addressing all problems
simultaneously.

Proactive condition monitoring is also important from a safety perspective, as the effective
monitoring and maintenance of machinery prevents accidents from occurring.

What are the Advantages?

As touched upon above, condition monitoring offers benefits for maintenance scheduling,
operating costs, reduced downtime and safety. It allows users to determine whether an asset is
likely to break down, what will cause the problem, and when the failure may occur. This
gives owners time to organise maintenance before the failure happens, avoiding unplanned
downtime and allowing repairs to be set for a suitable time in a production schedule.

As such, the advantages of condition monitoring include:

1. Avoid Unplanned Downtime

Avoiding unplanned downtime offers a range of beneficial outcomes for an industrial

environment. By removing unplanned downtimes you prevent unplanned production delays
which can lead to a loss of reputation if orders are not completed on time and the need to pay
overtime to complete a job. In addition, there is no need to pay for an emergency call out to
maintenance staff, which is more expensive than pre-scheduled maintenance.

2. Protect Your Other Assets

A machine failure can cause damage in other systems, compounding the problem further
while also increasing repair or replacement costs. As a result, there will be no need to buy
and store large numbers of replacement assets or parts in case of an unexpected failure.
Instead, you will be forewarned of the need to replace a part and can order it as required in
time for scheduled maintenance.

3. Eliminate Unnecessary Maintenance to Maximise ROI

Using condition monitoring as part of a predictive maintenance programme can increase the
return on investment (ROI) of mechanical assets. Preventive maintenance programmes are set
at regular intervals (i.e. annually) or after a set number of operating hours, irrespective of
whether the maintenance is required or not. Through condition monitoring, it is possible to
eliminate unnecessary maintenance and downtimes by only scheduling repairs when required.
This means that you can get more working value from each machine, reducing the total cost
of ownership and maximising the ROI for your equipment.

4. More Efficient Maintenance

Condition monitoring allows for more efficient maintenance by indicating where a fault may
lie. This means that maintenance engineers do not need to check working components while
locating the fault. This not only saves time and gets your maintenance completed faster, but
also saves the cost of paying a maintenance engineer for wasted time.
5. Improved Safety

Checking and repairing machines before they break safeguards employee safety and helps
ensure safer work practices. Condition monitoring means that owners can plan maintenance
before failure occurs that could pose a threat to employees working nearby.

6. Improved Asset Efficiencies

Condition monitoring can also improvements the efficiency of assets. By having a record of
which parts are running poorly, you can focus efficiency improvement efforts on those
specific parts, thereby improving the overall capabilities of your equipment.

What are the Disadvantages?

Despite the many advantages to be found with condition monitoring, there are also some
drawbacks; particularly related to the initial set-up of condition monitoring systems.

These drawbacks include:

1. Installation Costs

Condition monitoring equipment can be expensive to buy and install. In some instances, the
monitoring systems may even require assets to be modified for retrofitting with sensors.
There may also be additional sensor costs to take account of operating environments, further
increasing the price of installation.

Some asset owners may decide that certain items of equipment are not worth the investment
and prefer to either schedule regular maintenance for easily repairable items or even run to
failure for non-safety critical items.

2. Operational Costs

The ongoing data analysis required for condition monitoring will require either staff training
to implement or the hiring of engineers with the required knowledge and experience. These
will both incur additional costs, although this can often be offset by the many financial
benefits of condition monitoring (as shown above).

3. Unpredictable Maintenance Scheduling

While condition monitoring offers many advantages for maintenance scheduling, some
operators prefer to simply schedule maintenance on a regular basis. For example, it may be
preferable to service a machine every six months, rather than waiting for it to show signs of
wear at an unexpected time. However, most modern condition monitoring techniques offer
advanced warning of a potential failure, offering plenty of time to schedule maintenance.

Applications
Condition monitoring has a wide range of applications right across industry wherever there is
machinery or equipment in use.

It can be used in all forms of manufacture to check the efficient and safe running of
machinery, preventing failure and the associated unplanned downtimes for repair or
replacement.

Condition monitoring is also used to detect leaks, cavitation or flow, such as when managing
piping, pipelines, pressure vessels and storage containers in the oil and gas industry.

CM techniques have also been applied to aircraft and aging vehicles, and has been used in the
rail industry for vibration analysis of train door control systems and railway condition
monitoring. These same techniques are also used to maintain other industrial assets, including
in the marine environment and the power generation industries, such as the operational
condition of a wind turbine's machinery and rotating components.

What is Online Condition Monitoring?

Online Condition Monitoring is used for the continuous monitoring of a machine or
production process. Although this provides an uninterrupted process, many online systems
will generate their most data during critical start-up and shutdown periods for a machine.

Because online condition monitoring systems can work remotely, they allow retrieval of data
and analysis to be performed at a distance, managed by an external specialist.

Online monitoring systems send out warnings when pre-set limits are exceeded. These
troubleshooting measures usually occur at lower limits than alarm values for fixed monitoring
systems. This way they will indicate excessive wear and potential maintenance requirements
rather than immediate risk.

By allocating the alarms to a specialist, any change in machine behaviour can be analysed
immediately and, if necessary, action can be taken.

Conclusion
Condition monitoring is becoming increasingly common across industry as a method to
ensure the safe working of assets and to improve efficiencies. Allowing for scheduled and
directed maintenance and eliminating unnecessary procedures can save both time and money,
while also ensuring production schedules are met.

While there are still some instances where preventive maintenance is preferred to CM-
assisted predictive maintenance, many asset owners are realising the benefits of condition
monitoring system.

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