What is Condition-Based Maintenance?

Condition-based maintenance (CBM) uses data from the asset to determine when and how much maintenance it needs. Care is required by CBM when there are signs that performance is getting worse or that a breakdown is about to happen.

To look for these signs on a machine, you can use non-harmful methods. Then, depending on what is needed, data about the system's state can be collected all the time. Both high-priority and low-priority assets can enjoy condition-based maintenance.

In the last ten years, the number of industrial solutions that use the Internet of Things (IoT) has grown by leaps and bounds. In the past, monitoring the condition of a machine required both human work and technological progress. But as sensors, connections, analytics, storage, and multi-cloud technologies improve, you no longer have to do manual time-based tests to check your machine's health. Machine condition monitoring is improving as the Internet of Things gets smarter and more automated.

By networking their equipment, businesses can collect data from sensors and connected devices. This lets them reduce unplanned downtime and the costs that come with it, improve operational efficiencies, increase supply chain optimization opportunities, and speed up their digital transformation efforts.

The Different Types of CBM

Vibration Monitoring

When you measure vibration and frequency, you can learn about the health and performance of different assets and their parts. Technicians can use this information to predict problems like worn bearings, resonance, imbalance, loose parts, and shafts that are about to break.

Infrared Thermography

Infrared thermography uses thermal imagers to keep an eye on things based on their condition. Images show where the radiation is hot and cool in real time. So this helps spot the signs of a machine getting too hot. Tools that use infrared light include thermal imaging cameras, scanning systems, and thermographers, but that's not all. They are used to check the amount of gas, liquid, and sludge, the condition of the bearings, the insulation, and the mechanical and electrical health of the motor.

Ultrasonic Analysis

The ultrasonic analysis listens for and figures out what high-frequency noises mean to find things that are getting worse. This CBM system can find several ways that something could go wrong and collects data both ways. Problems with lubrication, bearings, broken rotor bars, or broken or worn gears usually cause high-frequency noise. Contact methods are the best way to find out what's wrong with any of these problems. Non-contact technologies can be used for various electrical tasks and to find pressure and vacuum leaks in compressed gas systems.

Electrical Analysis

An in-depth electrical analysis is another valuable tool in a CBM program. This is because machinery needs different amounts of power at other points in its operation. This device can determine the power supply's reliability by measuring the amount of current going through a motor with ammeters. It lets repair workers know if one piece of equipment uses massive power.

Pressure Monitoring

It is essential to keep the pressure inside a pipeline or hydraulic hose at the right level for fluid, gas, or air to flow freely through the pipe or hose. Pressure analysis can analyze and let maintenance workers know if there are any sudden changes in pressure so they can fix things before they get out of hand.

Advantages of Condition-Based Maintenance

Integrating CBM into your existing maintenance program can yield notable gains for your business. The following are some of the most important advantages −

• Improved Dependability − Greater equipment reliability is possible when your assets can "inform" you when they are ready to break.

• Lower Interruptions − As a result, your operators will have more to do throughout their shifts, and your equipment will run more.

• Increased Efficiency − This will increase output in the long run. Better output from your production processes means satisfied customers and increased earnings.

• Save Money on Repairs − Keeping your assets in top shape is crucial, but unnecessary repairs may add up quickly. By focusing only on the issues that can't wait, you may get the most out of your maintenance budget by using a condition-based maintenance strategy.

• Fast Detection of Problems − Failure indicators such as temperature or pressure sensors will alert you promptly if an issue arises.

• Reduced Unexpected Failures − Instead of shutting down a line for unexpected maintenance, you can produce work orders for planned outages.

• Enhanced Security − With CBM, you may "detect" problems before they escalate, reducing workers' risks.

Condition-Based Maintenance: When to Use It

Temperature-Sensitive Assets

The temperature of a piece of machinery is a simple and useful way to judge how well it works. It can be used in several situations. For example, keeping a freezer within safe temperature ranges in the food business ensures quality and safety and keeps a motor from overheating. In buildings, keeping an eye on temperatures may keep people comfortable and save energy.

Pressure-Sensitive Applications

Businesses that use equipment powered by pressurized air, water, or gas would enjoy installing sensors that can measure pressure. One can find small leaks soon by looking for pressure drops. High-pressure problems can get fixed before they cause significant damage or put workers in danger.

Conclusion

Condition-based maintenance is an important part of any maintenance plan. CBM can be a great way to keep an asset in good shape and stop it from breaking down completely while keeping maintenance costs low. This is because readings of the asset's temperature or pressure can get used to predicting when it might break down.