Pump condition based maintenance

Condition Monitoring(CBM) is an advanced and very useful tool of predictive maintenance techniques. CBM is a maintenance strategy that uses the actual condition of the asset to decide what maintenance needs to be done. CBM states 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-determined measurements, visual inspection, performance data and scheduled tests. Condition data can be gathered at certain intervals, or continuously. There is a wide variety of condition monitoring techniques currently in use for the diagnosis and prediction of machinery faults.

The application of computers and electronic measuring and detecting system has provided a new improvement for condition monitoring. The goal of CBM is to spot upcoming equipment failure so maintenance can be proactively scheduled when it is needed - and not before. Machine conditions need to trigger maintenance within a long enough periods before failure, so work can be finished before the machine fails or performance falls below the optimal level.

Condition monitoring essentially involves regular inspection of equipment using human sensory facilities and a mixture of simple aids and sophisticated instruments.
CBM is highly effective where safety and reliability is the paramount concern such as the chemical industries, aircraft industries, semiconductor manufacturing, auto industries, cement industries, nuclear industries, Oil and Gas industries etc.

Types of Condition Based Maintenance

Ultrasonic 

Detection of deep subsurface defects.

Vibration analysis  

Vibration monitoring measures the frequency and amplitude of vibrations. Rotating equipment such as compressors, pumps, and motors all exhibits 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

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

Advantages of Condition Based Maintenance

• CBM is performed while the machine is working; this lowers interruptions to normal operations
• Reduces the cost of machine 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
• Improves worker safety