This document introduces condition-based maintenance (CBM), which uses condition monitoring technologies to predict asset failures and schedule maintenance based on equipment condition rather than time. CBM aims to improve operating performance, ensure safety and environmental protection, reduce maintenance costs, and provide a comprehensive maintenance database. The CBM methodology takes a two-level approach using technologies to identify short-term failures and reduce medium to long-term maintenance tasks. CBM technologies discussed include oil and grease analysis, portable vibration analysis, portable ultrasonic analysis, and portable thermography analysis to monitor various mechanical and electrical equipment conditions.

1. An Introduction to
Condition Based Maintenance (CBM)
An approach to CBM Application and Management by: GAA Optima
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2. The CBM Philosophy
It is about utilising the Condition Monitoring technologies to
predict the failure pattern(s) of an asset.
This will allow maintenance to be scheduled based on
equipment condition and not time.
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3. The Vision is to attain:
Meaningful set of maintenance schedules (Technical
Basis of Maintenance - TBoM)
Improved operating performance
Ensure safety & environmental protection
Reduced maintenance costs
Comprehensive maintenance database (Centralised)
Clearer view of resource requirements
CBM attains lasting benefits & can be applied across all or
just selected equipment
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4. The Methodology
The strategy uses a two level approach by overlaying Techniques &
technologies on monitored components
Level one (Short term): Identify and reduce equipment failures across site
 Use technologies to troubleshoot and examine poor performing assets
 Energy usage examinations
Level Two (Medium to long term): reduce maintenance exam tasks, extend
maintenance exam and Overhaul periodicities (TBoM integration)
 Use technologies to reduce maintenance costs
 Effective utilisation of work force
 Increased knowledge of asset performance and condition
 Feedback into TBoM
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5. CBM Financial Impact
Easy to Labour Low on
services
measure Overheads profit
Reliability
Safety Legislation Design Scrap
out
Availability
Catastrophic Poor
failures maintenance
Breakdowns
& Repairs
Use of
skills Warranty
Low
Flexibility
Hard to
High on
measure
profit

6. Some of the CBM Technologies employed
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7. Oil and Grease Analysis
Three dimensions:
 Wear
 Ferrous
 Nonferrous
 Contamination
 Dust
 Water
 Fuel
 Chemistry
 Oil
 Additive
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8. Portable Vibration Analysis
What does it monitor?
Imbalance Problems
Mis-alignment Problems
Bearing Problems
Electrical Defects
Where?
Cranes
Air Compressor motors
Brake resistor / Traction cooling fans
HVAC equipment
Alternators
Turbo charger
Gearboxes (wheel lathe)
Electrical motors
Cooling system pumps
Lubrication oil system pumps
Fuel Pumps
Diesel Engine
Axle boxes
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9. Portable Ultrasonic Analysis
What does it monitor?
Air Leak Problems
Electrical Problems
Mechanical Problems
Location?
Leak Detection
Valves
Air supply lines
Flexible hoses
Pneumatic systems
Pressurised systems Electrical
Vacuum system problems  Arcing Detection
Compressor
Mechanical
Steam Traps
 Bearing defects
 Lack of Lubrication
 Over Lubrication
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10. Portable Thermography Analysis
What does it monitor?
Electrical Problems
Mechanical Problems
Pipework Problems
Problems detected?
Electrical Problems
High resistance connection
Corroded / hot connections
Earth returns – Higher loading
Relay problems
Internal fuse damage
Internal circuit breaker fault
Cracking insulation
Overload or unbalanced load
Busbar faults
Couplings
Cooling jackets
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11. Questions
abas@gaaoptima.com
Will be happy to answer
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