The document discusses the process of implementing condition-based maintenance (CBM) in companies. It describes the main elements of the implementation process as selecting components to monitor, choosing monitoring techniques/technologies, installing the technologies, and analyzing results. The implementation process is divided into four phases - feasibility study, technique selection, technology selection, and data analysis/evaluation. Key steps involve considering organizational, economic, and technical feasibility, selecting appropriate monitoring techniques, installing sensors, analyzing sensor data, evaluating results, and improving the process. The document provides an example of implementing CBM on gas circulation fans to monitor for motor bearing failures using vibration and shock pulse monitoring.

1. - ABHILASH
MSE
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2. Introduction
Implementation of CBM
Discussion
Conclusion
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3.  In order to reduce operation cost, maintenance cost at
once, increasing performance and reliability of production
equipment, many of companies have implemented CBM
 This paper presents the process of implementation and the
elements included in the process
 The main elements in the implementation process are
selection of components to be monitored, techniques and
technologies as well as installation of technologies and
finally how to analyze the results from condition
monitoring
 The results are recorded, this information is leading to
useful and reliable knowledge for maintenance work to be
cost effective and be able to increase the Overall
Equipment Availability (OEA)
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4. Implementation method is mainly divided into four
phases
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5. Feasibility test,
Selection of appropriate techniques to
detect failures
Selection of technologies
Data analysis
Evaluation
Improvement
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6. In order to implement CBM, the company should
consider different aspects in the early phase of the
implementation to estimate the feasibility of
implementing CBM. These aspects are classified in
organizational, economical and technical aspects.
In organizational aspect
 if CBM is feasible and for instant what type of
technologies are appropriate to use
 A SWOT analysis and maintenance audits of the
company’s maintenance activities can also bring
useful information to investigate whether using
CBM is a proper decision
 It should be assessed if CBM can improve the
work environment
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7. Economical aspect
• In early stage the financial issue cannot be
calculated with a high validity
• A list of requirements can be estimated to
evaluate whether implementation of CBM will
be cost effective
• The cost of maintenance and production loss
per breakdown should also be estimated
• This will make a pre-estimation of
implementation cost as well as the paybacks
that implementation of CBM can have
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8. Technical aspect
• A criticality analysis and maintenance audit can
be very helpful to assess the technical feasibility
of implementing CBM
• By using proper tools or techniques we can
detect the failure of the component
• By predicting the failure it is possible to prevent
the major damage of the component
• Plan for maintenance in a time that does not
affect production, in order to reduce
maintenance cost and production loss
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9.  In order to select the techniques several factors
should be considered including; availability of the
technology to monitor the parameters, the
competence and manpower required to use the
technology and the cost effectiveness of applying
the techniques.
 The condition monitoring techniques can be
performed in different levels of technology
 Condition monitoring can be performed either
humans, monitoring by their senses, or by using
measuring systems
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10.  The measuring systems can be applied either online or off-
line. The online measuring systems can provide continuous
monitoring of the assets
 different technologies require different knowledge
within organization
 Higher effectiveness of the technologies with lower
cost would be the best choice in selecting the
technologies
 Bearing Condition Monitoring can be described by
two techniques
o Shock Pulse Method
o Vibration analysis
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11.  The level of performing the data analysis depends on
the type of technologies that is used
 The data can be analyzed in a simple way by looking at
the graphs which are provided by computer software
and analyze the trends
 Data analysis can be performed in more specifically
frequency analysis in a more advanced level which can
provide more accurate and reliable data from bearing
conditions
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12.  An important phase of implementation process is to
evaluate if the implementation has been performed in
an appropriate way and if it can provide the desired
outputs
 Some factors can be considered in this regard, such as
the type of sensors, positioning of the sensors, cost
and the time between detection of a failure and fault
 The implementation should start with an estimation
of cost, after implementation there is a clearer picture
of cost, especially for the cost of condition monitoring
tools
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13.  it can be observed whether implementation has
been performed in a cost effective way
 An important success factor for the
implementation is to find out the most precise
interval time between detecting a failure and fault
 the best instance for the manufacturing company
is to have sufficient time after detecting a failure to
plan for a maintenance activity in a correct time
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14.  The results from evaluation phase are used for
improvement of the implementation
 Some technical examples of the improvement can be
to change the type of sensors, positioning of the
sensors and number of sensors
 the organization should follow up the activities,
increase the competence to analyze the data and use
CBM effectively, but management support will still be
required
 company should establish a routine monitoring
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15.  It should be clear to what to measure and when to
measure. More accurate warning limits will be set by
measurement after measurement
 The techniques should also be used to detect the most
failure modes and the most critical assets should be
covered by these techniques
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16.  Gas circulation fans electric motor
• A gas circulation fan is mounted on top of 920oC pre-
heating furnace
• It is running 24*7 to keep the gas atmosphere of cracked
Methanol and Nitrogen smooth and steady
• The fan has a heavy impeller which is assembled to a 4 KW
standard electric motor with a long shaft which is rotating
at 945 rpm
• The bearing in the electric motor is exposed to a high load
due to the extra -long motor shaft and a relatively big
impeller
• the unbalances can cause a failure in the electric motor’s
bearing
• Due to the working conditions of 920°C in the furnace the
motor shaft and the impeller are exposed to a high wear
due to material fatigue/metal dusting (erosion of material)
which causes unbalance, and in the long run vibration
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17. • An unbalance in a fan and electric
motor, or a fault in a bearing
produces extra vibrations and
noises
• These parameters can be the
failure indicators for the fans
electric motors which are
measurable by vibration analysis
and SPM techniques
• In this study, online condition
monitoring has been selected to
continuously monitor the
vibrations and shock pulses from
the fans and trigger a warning
alarm whenever something wrong
is detected
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18.  Two shock pulse transducers
and one vibration transducer
have been installed on the
electric motors
 The transducers are
connecting to a system unit
by cables. Depending on the
type of the unit, it can have
several channels for vibration
and shock pulse
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 By installing computer software provided by a
condition monitoring supplier, the data are being
analyzed autonomously
 The computer software is also able to trigger warning.
Hence, the early measurement from the objects can be
used as the baseline data and setting warning limits
according to the standards

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21.  According to the observed breakdowns on the fans,
one of the main inquiries to be discussed is the reason
of the late warnings before breakdowns
 by having the late warnings, the company is not able to
schedule the maintenance work outside of production
time to reduce production losses
 Therefore, some factors have been reconsidered such
as the type of sensors, positioning and placing the
sensors
 The result of failure analysis has shown that the
lubricant in the bearing has been quite dried
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22.  Thus, a possible reason for the failure is the heat from
the furnace which dries the lubricant in the bearing
 it has been suggested to use an appropriate lubricant
than can sustain in high temperatures. Using the
sprays on the bearing that protect the lubricant in
front of the heat can also be worthwhile
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23.  The process of an implementation of CBM is proposed
in order to consider different aspects in the decision
making phase and implementation phase of CBM
 The implementation process can also be a good guide
when implementing CBM in manufacturing
companies without existing experience in CBM
 As long as applying CBM is costly, having an
appropriate approach for implementation can help to
succeed and gain paybacks from CBM
 analyze the data and follow up the activities is
important to have a continuous improvement
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