A maintenance technique known as condition-based maintenance (CBM) uses real-time asset condition monitoring to identify what repair needs to be done. Contrary to preventive maintenance, which makes scheduling and performing maintenance decisions using calendar-based maintenance or other methods, condition-based maintenance stipulates that maintenance should only be carried out when these real-time indicators reveal irregularities or signs of declining performance.
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Condition-based maintenance proactively schedules maintenance by continually monitoring assets for signs of approaching breakdown. This real-time monitoring aims to provide maintenance teams with ample forewarning before a malfunction happens or performance deviates from ideal levels.
Types of Condition-Based Maintenance
a.Vibration Analysis
One of its largest benefits is that condition-based maintenance is non-invasive or that real-time data is collected while the system operates without changing how it functions. You can decide to use methods like sensors, eye examination, planned testing, or systematic data collection. Let’s examine some of the most prevalent categories of condition-based monitoring methods utilised in CBM.
The method of determining the vibration levels and frequencies of machinery and utilising that data to assess the machine’s condition and parts is known as vibration analysis. Problems including imbalance, bearing failure, mechanical looseness, resonance, bent shafts, and more can be found via vibration analysis.
- Infrared Thermography
Infrared thermography is the method of detecting radiation emitted from an item with a thermal imager, converting it to temperature, and instantly showing a picture of the temperature distribution. Infrared thermographic pictures can demonstrate whether an asset is becoming overheated and are frequently used with a baseline image for comparison. Infrared thermography is used when assessing the levels of gas, liquids, and sludge, as well as the electrical and mechanical health of motors, bearings, and refractory insulation.
Spot infrared thermographers are examples of infrared instruments used to monitor thermal radiation on difficult-to-reach assets or assets working in harsh circumstances, infrared scanning systems, and more.
- Ultrasonic Analysis
By detecting high-frequency noises and turning them into audio and digital data, ultrasonic analysis employs sound to find possibly deteriorating assets. The data gathering techniques determine the forms of ultrasonic failure that can be detected. There are two types of methods: contact (structure-borne) and non-contact (airborne). Contact techniques are typically employed for mechanical difficulties, including faulty bearings, lubrication troubles, gear damage, and pump cavitation. These issues all produce loud noise at high frequencies. Because damaged or loose rotor bars can produce a high-frequency, rhythmic pattern, ultrasonic contact techniques are also useful for finding electrical defects in motors. Lastly, faulty steam traps may have steam constantly leaking past the internal seals, producing a rattle that can be detected by ultrasound.
d.Oil Analysis
Oil analysis is a regular process for evaluating oil’s health, pollution, and wear. A lubricated machine’s proper operation may be confirmed with oil analysis software. To determine if the necessary additives are active, oil analysis examines the fluid characteristics of the oil. Have the additives run out? Is the viscosity at the proper level? Oil analysis also examines whether there are harmful pollutants in the oil and, if there are, aids in identifying the likely source. Oil analysis can also determine the presence of particles caused by mechanical wear, corrosion, or other machine surface deterioration.
- Electrical Analysis
The incoming power quality of assets is examined using electrical analysis, which measures the current in a circuit using motor current measurements from clamp-on ammeters. The ability to observe whether an asset is receiving an unusually high power is facilitated for maintenance staff.
- Pressure Analysis
Equipment must be kept at the proper pressure to ensure adequate fluid, gas, or airflow via a pipeline or hydraulic hose. Nanoprecise Maintenance staff can respond to and resolve problems before a more severe event happens because of pressure analysis’s ability to monitor pressure levels in real-time and warn of abrupt decreases or spikes.