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Provide students with an opportunity to conduct on the job research of an industry based condition monitoring service and to develop a detailed improvement strategy with justifications.

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Interview the manager/superintendent of your condition monitoring program, and if the program is contractor supplied, interview the contractor as well. From the interview you need to determine the full extent of the service from a management perspective (personnel involved, amount of possible equipment included in the program and your estimate of the cost of the program). From Part 1, you have determined what equipment is being monitored. Interview the condition monitoring technicians and establish what parameters are being collected, for example, vibration, oil, temperature, NDT and proces...

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Question Preview:

Interview the manager/superintendent of your condition monitoring program, and if the program is contractor supplied, interview the contractor as well. From the interview you need to determine the full extent of the service from a management perspective (personnel involved, amount of possible equipment included in the program and your estimate of the cost of the program). From Part 1, you have determined what equipment is being monitored. Interview the condition monitoring technicians and establish what parameters are being collected, for example, vibration, oil, temperature, NDT and process values (e.g. pressure, flow). Detail the exact tests that are carried out on 5 different items of equipment (state what the equipment is), down to the type of vibration reading with frequency ranges, what oil analysis is done and how temperature is monitored, and what process parameters are collected. With the collected information, explain why the data is collected (what fault/problems the technicians are looking for) and then, if you believe there is a short-fall (probably there will be!), recommend additional parameters/readings and actions that are required to cover the short fall. From the monitoring that is occurring, briefly describe how the information is integrated into a CMMS and/or database then used by maintenance to achieve a corrective outcome. Include a flow diagram detailing the information flow. If some or all of the results from the condition monitoring program do not seem to be used, what changes in management, personnel or systems are required to fully utilise the information being produced.

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Solution Preview

It has been experienced over times that even the most comprehensive and thorough program of routine maintenance is unable to prevent faults emerging in any kind of machinery. Therefore, the businesses also face the scenarios of faults leading to unpredicted breakdown.

Condition Monitoring assists in actively preventing unexpected stoppage and optimizes the resources as and when they are required. With Condition Monitoring the machine’s health is assessed through intermittent monitoring and data analysis attained at the time of operation trending the outcomes against acceptability levels. Condition Monitoring is efficient, non-interfering in the process of production and has the potential for saving a lot of money that may be spent on lost production, secondary damage, and needless maintenance. In all, it is the established and defensive approach for maintenance for early detection and prevention of fault in all kinds of machinery of production.

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