Six tips FOR AN EFFECTIVE CBM PROGRAM

Condition-based monitoring (CbM) is a maintenance process where the condition or health of plant equipment is monitored for the earliest signs of impending failure. An effective CbM program does not have to be extremely complicated nor does it have to require a large investment of capital in order to effectively analyze the health of your equipment. There are six tips to consider when implementing a CbM program in a plant. When followed, monetary value and production can increase as energy waste reduces.

Tip 1. Familiarize yourself with the basic technology: Instrumentation used as part of the CbM process should provide the critical and accurate data needed to optimize the scheduling of downtime, labour and materials, so productivity is increased while overall costs are reduced.

The most commonly used technology for CbM is vibration analysis. The use of Fourier algorithms, frequency and harmonics helps locate the causes of the vibration and points the way to eliminating it.

Another CbM technique is infrared thermography, involving the detection and measurement of infrared emissions related to heat. Excessive heat is indicative of component failure, especially the degradation of electrical contacts and terminations, and in the latter stages of bearing failure.

Tip 2. Familiarize yourself with ultrasound technologies: Vibration and infrared analysis are complemented by still another inspection technique — that of airborne/structure-borne ultrasound. Ultrasound is produced by friction, ionization and turbulence, which is why ultrasonic instruments are so effective in testing mechanical, electrical and fluid systems.

These instruments identify early warnings of mechanical failure; locate arcing, tracking and corona in electrical gear; and detect all types of leaks (typically in pressurized or vacuum systems).

With increasing energy consumption costing plants hundreds of thousands of dollars annually, ultrasound instruments can also locate faulty steam traps and compressed air leaks. Locating these leaks early — then accurately correcting the problem — can save countless dollars in downtime and energy waste.

Tip 3. Incorporate the ability to view sound: The ability to view sound as intensity levels while simultaneously listening to sound quality, and to record anomalies for spectral analysis, enhances monitoring effectiveness. This allows inspectors to quickly identify changes in equipment operation and to determine a course of action.

Tip 4. Solve your lubrication problems: Many maintenance departments are switching to ultrasonic condition-based monitoring programs in combination with predictive maintenance (PdM) procedures. Because friction is one of the major contributors to bearing failure, ultrasound monitoring identifies a lack of lubrication in bearings and prevents over-lubrication.

Tip 5. Go green and save: In addition reducing expenses by locating sources of energy waste through compressed air and steam leaks, the conservation of energy is a global necessity. Whenever there is a reduction in the use of energy, there is a direct impact on the user’s carbon footprint. The reduction of carbon emissions can be directly linked to the reduction of steam and compressed air leaks. So it is both possible to reduce your energy bill and to help improve the greening of the planet.

Tip 6. Stay informed: Although there are several ways you can improve plant efficiencies today, the need for expert analysis and technology may be a necessary next step in eliminating the potential for machine failure and a loss of profit.

Alan Bandes is with UE Systems Inc. For more information, visit www.uesoundadvice.com.