Condition-Based Maintenance

Discover the ultimate guide to maximizing the benefits of condition-based maintenance (CBM). Learn about its types, uses, and how to leverage it for optimal results. Let's optimize your maintenance strategy together!

Did you know that equipment failure is not just a one-time occurrence but a gradual process? This idea has become widely recognized in the maintenance industry, and that's where condition-based maintenance (CBM) comes in as a helpful guide. We've compiled some valuable tips, tricks, and tools to help you understand CBM better and use it to your advantage. With these resources, you can optimize your maintenance?operation and ensure it runs like a well-oiled machine.?Let's work together to prevent equipment failure and keep your systems running smoothly.

What is condition-based maintenance (CBM)?

Condition-based Maintenance (CBM) is an advanced maintenance strategy that prioritizes monitoring the actual operational condition of assets to determine the most opportune moments for performing maintenance. This approach ensures that maintenance activities are only initiated in response to specific indicators that suggest?a decline in performance or an impending failure.?Essentially, it offers a predictive method of foreseeing when maintenance will be necessary, moving away from the traditional adherence to a rigid maintenance schedule.

The primary objective of CBM is to detect?potential equipment failures before they occur, allowing for?maintenance to be precisely timed according to need. This strategy heavily relies on the continuous collection and analysis of data, which reveals patterns in the performance of assets and enables an accurate assessment of their current lifecycle stage. By leveraging this information, it becomes feasible to make well-informed decisions regarding various aspects of maintenance management, including the scheduling of activities, allocation of labour, and budgeting considerations.

Implementing a CBM strategy can lead to significant benefits, including enhanced efficiency in maintenance processes, reduction of unnecessary downtime, and substantial cost savings. By focusing on the actual condition of assets rather than on a predetermined maintenance schedule, organizations can optimize their maintenance operations, ensuring that resources are utilized more effectively and that equipment remains operational for longer periods, extending its lifespan.

At the end of the day, CBM is all about being proactive and staying ahead of any potential issues.?By implementing this strategy, you can ensure that your?assets are always performing at their best and that you can make the most informed decisions for your business.

It's important to consider how critical your assets are when deciding on maintenance strategies. Condition-based maintenance is a highly effective method for your most crucial assets. Conducting a criticality analysis can help you identify which equipment is most likely to fail and the impact that failure would have on your operation. If you're just getting started with CBM, it's best to begin with your most critical assets and gradually expand from there.

For condition-based maintenance to be effective, the maintenance team must capture and analyze performance data to make timely decisions.

What are the benefits of condition-based maintenance?

Condition-based maintenance (CBM) offers numerous benefits in environments heavy on equipment and production-intensive. Key advantages include:

- Predictive Maintenance: CBM facilitates predicting and preemptively fixing failures before they occur, significantly reducing unplanned downtime and labour hours while increasing throughput.

- Increased Maintenance Intervals: Repairs are conducted strictly on an as-needed basis, so the time between maintenance activities is extended. This results in decreased downtime, a reduced maintenance backlog, and lower costs.

- Minimal Production Disruption: Since CBM can be performed while assets are operational, it greatly reduces the likelihood of disrupting production processes. Equipment typically does not need to be shut down for inspection.

- Rapid Failure Diagnosis: In the event of an unexpected failure, CBM enables quicker problem identification, reducing breakdown costs.

- Inventory Management: The early warning system provided by CBM allows for more effective control over inventory, reducing the need for emergency spare parts.

- Enhanced Worker Safety: CBM minimizes the risk of equipment failure, making it one of the safest approaches for maintenance technicians, especially when addressing unplanned breakdowns.

- Optimal Maintenance: By determining the optimal amount of maintenance required for an asset, CBM reduces the risk of over-maintenance, which can lead to faster equipment deterioration.

- Flexibility and Seasonality: CBM offers the flexibility to adjust maintenance schedules based on seasonal demands, ensuring that preventive maintenance work orders are completed promptly and efficiently.

Different types of condition-based monitoring

Condition-based maintenance relies on condition-based monitoring, which involves monitoring the state of an asset using specific performance indicators. Various tools and techniques can be used for this purpose, including low-tech methods like observation by a technician or more advanced approaches such as sensor data gathering.

A key feature of condition-based monitoring is that it is non-invasive. This means that measurements are taken without the need to shut down the machine or adjust its operation. Data can be collected at regular intervals or continuously using sensors, visual inspections, performance data, and scheduled tests.

Vibration analysis

Vibration analysis is a form of condition monitoring that can identify potential failures by detecting changes in the regular vibration pattern. The amplitude, intensity, and frequency of vibration can all be affected, and sensors can identify any abnormalities in these elements. This can indicate that there may be a problem with a particular asset. For instance, rotating equipment like compressors and motors typically exhibit a certain vibration level. If the equipment starts to deteriorate or falls out of alignment, the intensity of the vibration may increase.?Sensors can detect when the vibration becomes excessive, and the component can?then be repaired or replaced as necessary.

Infrared and thermal analysis

When certain parts or systems exceed?specified temperatures, it can cause them to deteriorate, warp, break, burn out, or?even cause a fire. To avoid such incidents, infrared cameras and thermal sensors detect when equipment has become too hot. The maintenance team is then alerted to take the necessary steps to fix the problem. Infrared and thermal analysis is particularly useful for?energized?equipment such as electrical conductors and motorized parts that operate at high RPM.

Ultrasonic Analysis

Ultrasonic instruments help detect deep, subsurface defects. They measure sounds that are inaudible to the human ear and convert them to an audible pitch. This makes it easier to identify anomalies in an asset and fix them. For instance, ball bearings become deformed and develop irregular surfaces when they wear out. This results in increased emission of ultrasonic sound waves, which can indicate to a technician that the bearing will likely fail soon.

Acoustic?

Acoustic analysis is a type of analysis that is similar to vibration and ultrasonic analysis. It involves using sensors and microphones to detect sounds that indicate an asset is malfunctioning. While vibration and ultrasonic analysis are mainly used to identify issues in rotating equipment, acoustic analysis has the added benefit of pinpointing gas, liquid, or vacuum leaks. This is particularly useful for oil, energy, and mining production facilities.

Pressure

In many industries, it is crucial to maintain the correct pressure within equipment so that the fluid, gas, or air can flow through a pipeline or hydraulic hose properly. Pressure analysis helps achieve this. If the pressure drops on a piece of equipment, it could indicate an internal problem that requires maintenance. Conversely, a sudden increase in pressure could be a sign of breakage or even an explosion. By conducting pressure analysis, maintenance teams can detect these changes in real time and take appropriate measures to prevent the issue from escalating.

Various condition monitoring methods can be combined to assess the fitness of an asset. For example, multiple sensors can be installed on an asset to monitor different factors such as temperature and pressure, enabling the equipment to operate at its best.

How Enture helps in Condition Based Maintenance?

Enture IIoT Edge Platform significantly enhances the implementation of condition-based maintenance (CBM) strategies within industrial settings; Enture's ability to connect seamlessly with OEM OT devices and utilize standard field bus protocols?enables the collection of real-time data from various sensors and?machinery components. This data, which may include vibration, temperature, pressure, and other relevant operational parameters, is continuously monitored and analyzed at the edge, close to where data is generated. By processing data locally, Enture minimizes latency and reduces the bandwidth needed for data transmission, allowing for immediate detection of anomalies and potential failures. The platform's edge and analytics can effectively predict equipment failure before it occurs by identifying patterns and anomalies that deviate from normal operating conditions. This immediate insight allows maintenance teams to act swiftly, scheduling maintenance only when necessary based on the actual equipment condition, thus optimizing maintenance resources and reducing operational costs.

Enture enhances the CBM process through its customizable alerting and notification systems. Maintenance teams can set specific trigger rules for abnormal conditions that warrant attention, enabling proactive maintenance interventions. For example, suppose a critical bearing exhibits temperature beyond its threshold level. In that case, Enture can automatically alert the maintenance team, who can inspect and replace the bearing before it fails and causes more significant machine downtime. The integration capabilities with SCADA and BMS systems ensure that all data and insights are readily available across the plant's operation.?This?facilitates a unified view of maintenance needs and allows for better planning and execution of CBM strategies.

Using condition-based maintenance effectively

Using condition-based maintenance is one thing. Using it effectively is a whole other story. If you don't have the?right?systems, processes and procedures in place, condition-based maintenance can cost you more time, money and goodwill than it's worth. Here are a few ways maintenance teams can harness the power of CBM and build a sustainable operation around condition monitoring.

Step 1: Map your asset's failure modes and baseline performance

To implement condition-based maintenance, having a basic knowledge of your assets is?not enough.?You must have a comprehensive understanding of how each piece of equipment functions. This knowledge is necessary to calibrate sensors properly, identify issues as soon as they arise, and determine the appropriate solutions.

To begin, you?need to?create a detailed map of each asset and its potential failure modes. This map will help you determine whether each piece of equipment?is suitable for?condition-based maintenance. The first key factor is whether the equipment has a condition that?can be monitored. It's important to note that not all assets are compatible with sensors or other monitoring tools and techniques. Identifying these assets early on can save you?a lot of?time and money later on.

Once you have identified your group of qualified assets, it is?important?to establish baselines for?normal?operation. Baselines are established thresholds that indicate a healthy and fully functional system. For instance, the baseline vibration frequency for a bearing may be between 1000 Hz to 2000 Hz. Any number between those two frequencies means the bearing operates optimally. However, if it goes above 2000 Hz or below 1000 Hz, it could signify a problem.

Baselines, such as manufacturer recommendations or historical trends, can be established in many ways. Creating baselines for each system can eliminate the guesswork in condition-based maintenance and make your decisions more effective and efficient.

Step 2: Understand the potential failure (P-F) curve and its use

The P-F curve, also known as the Prevention-Failure curve, is a graph that helps determine the reliability and performance of an asset over time. It indicates the time interval between the potential failure of an asset (P) and its functional failure (F), which helps identify when preventive maintenance measures need to?be taken.

As an asset continues to operate, its expected failure rate increases. The P-F curve maintenance technique provides a way to monitor the health of equipment over time. It is?an essential tool in developing effective maintenance strategies as?it can?be used?to?predict the optimal balance between planned and corrective maintenance procedures.

How to read the P-F curve

The P-F curve is a significant tool for analyzing?the?safe range of operation?of any equipment.?It helps engineers determine the device's performance under variable conditions and provides insights into the asset's condition-based maintenance needs. Additionally, it helps to identify potential upgrades needed to achieve optimal performance. It is crucial to read and understand these curves accurately to make informed decisions about necessary repairs or modifications for a piece of equipment. This proficiency in technical decision-making is essential for efficient maintenance and smooth operation.

Point P: Potential failure

Point P on the P-F curve is a significant aspect of managing equipment maintenance. It indicates the point at which potential failure occurs, and if not addressed on time, it can lead to severe consequences. For instance, a piece of manufacturing equipment may?experience power supply issues at point P, resulting in?an abrupt halt in its operation without any warning.

However, regular maintenance can help prevent such situations. By detecting small changes in performance, it becomes possible to identify and fix potential failures before they occur. This way, equipment can continue to function optimally, which, in turn, ensures smooth operations and saves time and money.

Point F: Functional failure

Point "F" on the P-F curve is an?important?tool and indicator of functional failure, which can?be a result of?inadequate or improper maintenance activities.?This?implies that if maintenance?is not carried out?regularly, a particular piece of equipment may eventually experience an unexpected malfunction, leading to complete failure.

For instance, if a car's oil is?not changed?every 3,000 miles as directed by the manufacturer, the engine can get damaged due to overheating and lack of lubrication,?resulting in the vehicle becoming?useless.

It is crucial to understand?the meaning of point "F"?on the P-F curve for anyone who desires to prevent equipment from experiencing unscheduled outages and significant malfunctions.

The P-F interval

The P-F interval is a crucial aspect of the P-F curve, and it is essential to understand it clearly. It directly relates to the time a maintenance team has between identifying a potential failure and when it?actually?occurs.

If the P-F interval is longer,?it means that?the maintenance team will have more time to carry out preventive maintenance procedures, which can help prevent equipment interruptions?or breakdowns. Regular condition monitoring and analysis in a time-based system can also help ensure that the P-F intervals remain long,?allowing appropriate actions to?be taken?before?a real?failure occurs.

Step 3: Leverage new-age maintenance technology

Condition-based?maintenance is a maintenance strategy that?combines recommended guidelines with repair and performance data to determine?which tasks need to?be completed?and how often.?This strategy involves using maintenance software to log sensor data, trigger work orders, and schedule maintenance. By integrating sensor data with maintenance software like Enture, reliability engineers, maintenance managers, and technicians can capture, organize, and analyze information more efficiently and accurately.?

Maintenance software also helps to automate the maintenance process by enabling automatic work order triggers when?certain?measurements fall outside the established baseline. For example, Enture can?be set up?to schedule maintenance on a filter when the differential pressure exceeds?10psi.?This way,?maintenance can be scheduled?at the most appropriate time,?which reduces the likelihood of failure while maximizing resources.

Using maintenance software to manage condition-based maintenance leads to optimized inventory purchasing.?The software can track the history of work orders and generate reports on parts usage,?which allows for easy adjustment of inventory levels.?This?means?that?you will only order the parts you need when?you need them.?By keeping?the necessary parts on hand, downtime?is eliminated, and inventory prices can be cut.

Step 4: Create a training program for your Maintenance Team

Condition-based maintenance (CBM) heavily relies on technology and automated systems such as sensors and software. However, a crucial human element remains involved in the process. To ensure the effectiveness and efficiency of your CBM strategy, it is essential to provide proper training to all maintenance team members?on the concept of CBM, its benefits, and how to use the systems.?This?will?lead to increased buy-in, eliminate user errors, and improve the reliability of the process.

The training program should include a thorough breakdown of the various types of condition monitoring and how they affect the assets in your facility. It should also be clear how each team member can ensure that sensor data?is accurately logged?and how?resulting?maintenance tasks should be handled. To ensure that everyone in your facility, not just the maintenance team, understands how CBM is impacting the organization?as a whole?and its role in ensuring the strategy's success, it is advisable to create an asset management policy at this stage of CBM implementation.

Condition-based maintenance (CBM) is a modern?maintenance?strategy emphasizing a proactive approach to equipment health. By understanding and implementing CBM, organizations can move from reacting to equipment failures to predicting and preventing them. This approach involves integrating technology, sound analysis, and staff training to identify potential issues before they occur.?This?leads to a significant reduction in unplanned downtimes, maximizes equipment lifespan, and streamlines operational costs. Adopting and optimizing CBM practices are essential for businesses that want to achieve maintenance excellence, especially as industries continue to evolve and emphasize efficiency and sustainability.