Analysis of the Condition Based Monitoring System for Heavy Industrial

Machineries
Krishna Kant Agrawal1, Prof. G.N.Pandey 2, Dr.Kannan Chandrasekaran3
1
Ph.D. Research Scholar, Indian Institute of Information Technology, Allahabad, India
2
Adjunct Professor, Indian Institute of Information Technology, Allahabad, India and Vice-Chancellor Arunachal
University of Studies, Arunachal Pradesh, India
3
CRM (Applied Met. & Pipeline research), Indian Oil Corporation Ltd., Research & Development center, Faridabad, India
1
rs92@iiita.ac.in 2pandey63@gmail.com 3 kannanc@indianoil.in

Abstract - Condition monitoring of Industrial machines
typically relies on being able to detect the disparity between
a healthy machine and a faulty one. An accurate
interpretation of a machine’s condition requires knowledge
of the effects of different operating conditions. Phrase
Condition monitoring is sometimes used in combination with
predictive maintenance which is maintenance of machines
based on a signature that a problem is about to occur. In
current scenario many industries is replacing predictive
maintenance with run-to-breakdown maintenance and in
some cases with preventive maintenance, where mechanical
parts are replaced periodically regardless of the machinery
mechanical condition. There are a lot of practices available
and discussed in this paper for condition monitoring but
measuring vibration is one of the most essential in detecting
and diagnoses any deviation from usual machine conditions.
Vibration monitoring of Machinery is the most effectual
technique, used to track operating conditions of machines
which will further reduce maintenance costs and subsequent
downtime caused by catastrophic failure of machineries of
the Industry simultaneously. This Research ponders upon
different condition based monitoring techniques available
and state of the art development for identifying the most
effective technique in diverse scenarios.
Keywords -CBM, Vibration analysis, Predictive
maintenance.
maintenance technique could be said as time-based
preventive maintenance or planned maintenance, in which
preventive maintenance is performed periodically
regardless of the status of a machine. With ongoing
development of technology, different products have
become complex where good quality and reliability is
required. By scheduled maintenance irrespective of
current condition of machines makes this technique a lot
expensive and in due course used to become a major
expense of many industries. Due to which more efficient
and advanced maintenance approaches which is
condition-based maintenance (CBM) are being
implemented.
Fig 1 illustrates the correlation among cost of
maintenance, residual useful life (RUL), and system
reliability [2]. As time of failure turn out to be zero,
system went into breakdown status, time to failure of the
system come closer to zero, consistency of the system
decreases [2].Condition Based Monitoring have the
capability of accurately predicting remaining useful life
and system reliability is desirable as practical information
could be provided for choice of a better maintenance
program.

I. INTRODUCTION

Condition based maintenance techniques are gaining

increasing interest and has shown substantial growth for
current health monitoring of industrial machines that
advice maintenance decisions based on different
parameters including vibration, temperature, acoustic,
loose part and stator current monitoring, by analyzing
these optimal parameters it makes us achieve the exact
condition of the machine under monitoring. The major
purpose of implementing a condition based monitoring is
not only for planned maintenance rather to increase
productivity, degrade overall maintenance cost and
enhance safety. These techniques can also be used for
allowing the choice of most efficient technique to
minimize the operation cost. As the technology is
Fig 1. Correlation among RUL, maintenance cost, and reliability [2]
developing at a fast rate, different products are becoming
more complex, which eventually makes cost of preventive
A large amount of industrial machineries requires
based maintenance technique much higher.
condition based monitoring to increase availability and
The initial technique used for maintenance is safety of the equipments like temperature, acoustic and
breakdown maintenance, unplanned maintenance, which loose part monitoring. One such monitoring technique is
used to takes place on breakdown of machines. Further based on vibration analysis, vibration signature received

978-1-4799-1597-2/13/$31.00 ©2013 IEEE

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 2013 IEEE International Conference on Computational Intelligence and Computing Research
from different sensors deployed on those machines, that
will enable to take decisions about the repair or
replacement of a different machine parts, overhauls, and
standard maintenance practices are made on the basis of
the precise condition of the machine. Suitable machine
condition based monitoring measures will result in lower
maintenance costs and extended life of different
machineries. Continuous monitoring of machineries like
pump systems is the most effective practice to insure
competent operation, able to prevent unexpected
machinery failures, lessen repair costs and downtime, and
also able to provide early warning to avoid loss of
machinery. Specially, in process monitoring and control,
process data like pressure, humidity, temperature and
vibration strength measurements could be gathered
through a sensing unit and can be transferred through
wireless to a Centralized server for operations and
administration.
New developments in diagnostic and prognostic
techniques, promising condition based maintenance
architectures and standards, low-power wireless
communications standards and mechanism e.g. Bluetooth
and IEEE 802.15.4, which enables the deployment of low-
cost distributed sensors nodes.
II. DIFFERENT CATEGORIES OF CONDITION
BASED MONITORING
Condition monitoring systems are of following two types:
a) Periodic Condition Monitoring Systems
b) Permanent Condition Monitoring Systems
In a Periodic Condition Based Monitoring, which is
also identified as an off-line Condition Based Monitoring
where vibration of machines is analyzed at chosen time
intervals on specific points over the machines; and then
further analysis is done either in the field or could be
performed at a laboratory. Different analysis techniques
are usually required to diagnose the fault and for long
term analysis of trend. Scheduled monitoring on a precise
time interval used to give information at a very initial
stage, when failure is about to occur and used where very
early warning of faults is desired, machines are quite
complex locations and measurements have to be taken at
multiple locations on a machine.
In Permanent Condition Monitoring System which is
also called an on-line Condition Monitoring system,
machine’s parameter is measured continuously and is
constantly evaluated with different acceptable levels. The
purpose of permanent monitoring system is to provide a
concern that machine is working in an unacceptable
condition and to shutdown when machine goes beyond a
fixed safety limit, thereby avoiding different catastrophic
failure.
In this technique, sensors are mounted permanently at
selected point, due to which such system used to become
costly, usually implemented only on critical machines
where no personnel are approachable, or to stop machines
breakdown in order to avoid a catastrophic failure,
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otherwise to prevent an instantaneous fault that requires
immediate machine shutdown, and into some hazardous
environment where human involvement could be life risk.
Before selecting permanent monitoring system different
initial measurements must have to be made periodically
over a certain period of time as to become familiar with
the characteristics of the machine. This process eventually
will make it possible to recognize the most appropriate
measurement parameter, frequency range, and interrupt
levels.
III. ASSESSMENT OF DIFFERENT PARAMETERS
Although there are some Condition maintenance
techniques available in the present literature, there are still
some common extremes in current industrial scenario.
Initially to adopt a run-to-failure policy while the other is
to apply a scheduled maintenance and replacement policy
regardless of state of the machine. In many cases, the
above traditional maintenance policies, can be applied
with satisfactory results. Though in many other situations
when both techniques appears to be costly, condition
based maintenance is completely a superior choice than
the traditional ones.
Advanced condition monitoring techniques have not
been implemented properly into an industrial scenario,
this might be due lack of past data, due to improper data
collecting approach, lack of communication between
theoretical developers and practitioners at industries, area
of reliability and maintenance. For some industries its
quite difficult to implement it due to frequent change of
technologies, business policies etc.
IV. MAJOR IDENTIFIED TECHNIQUE OF
CONDITION BASED MONITORING FOR
MACHINES
Different indentified techniques of condition
monitoring with applications into specific fault
identification scenarios are discussed in this section.
Following are major condition based monitoring
techniques:
a) Motor Current Signature Monitoring (MCSA)
b) Oil Analysis
c) Temperature Monitoring.
d) Neural Network Based Monitoring.
e) Acoustic Monitoring.
f) Vibration monitoring
g) Loose parts monitoring
a) Motor Current Signature Monitoring (MCSA)
In this technique, machine condition can be monitored
by analyzing the different spectrum from machine’s
current signature. Different varying in electric background
mark are directly associated with the alteration in the
specific mechanical components of the machine by which,
 2013 IEEE International Conference on Computational Intelligence and Computing Research
fault signature can be identified by motor current
signature analysis technique [3]. There is a limitation that
in most of the cases bearing damage is not much
significant to produce a noticeable current fluctuations,
due to which it becomes quite difficult to discriminate the
signatures from current fluctuations due to voltage
imbalances or stator faults.
b) Oil Analysis
One of the most important to ensure that the machine
is in good condition is ensuring the oil examination for
maintaining the condition that machine. Many factors
such as machine, operating environment are important
factors in the selection of a specific lubricant. The
application of Tribology is frequently referred to as an Oil
Analysis in industries.
A regular program of Oil Analysis of different parts
of a machine is a common Condition-Based Maintenance
practice within industry, particularly in oil and gas
industries where machines are a critical element. By quick
oil analysis by an expert or maintenance engineers on the
Condition of their machinery and can make useful
outcome for corrective/maintenance actions, such as
adding oil/grease or to completely replace the component.
c) Temperature Monitoring
Temperature monitoring techniques are mostly used in
different high temperature and speed environment, usually
heavy industries and industrial purpose tools.
Temperature sensor consists of two metals which are
joined together, and when exposed to some temperature
difference generates a thermoelectric voltage which is
dependent on the specific material properties and
temperature difference [2]-[3].
Bearing related defects generate some excessive heat
in the rotating apparatus of machines. Continuous
monitoring of temperature difference of a housing, casing
or lubricant is one of the effortless methods for fault
identification into machines by temperature analysis.
Machinery defects generate excessive heat which results
in deviation from the allowable temperature range into
rotating components [2]-[3]. Monitoring temperature of
bearing housing is not very efficient for huge industrial
machinery scenario as small deviation into a temperature
becomes quite hard to detect.
d) Neural Network Based Monitoring
Artificial neural networks are different mathematical
models inspired by the brain. This technique has been
used in fault diagnoses, pattern matching and
classification of defects. Neural Network is capable to
model complex processes with multiple inputs and output
as required [5], [6]. The neural network model can learn
by observing the input and outputs, and adjusting internal
weights in between the stages. Neural Network can
identify different patterns that can be later used for fault
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classification. Physical modeling and current knowledge
base for fault analysis is not sufficient enough to identify
a specific defect into a machine rather using a proactive
modeling using a neural network could predict the state of
machine into different stages.
e) Acoustic Monitoring
One of the useful techniques in condition based
monitoring is acoustic-based monitoring. It was the first
to be developed as a Non-Destructive Testing technique
to detect different faults into a real industrial scenario.
Specific acoustic sensors are deployed which are able to
detect acoustic signals generated by the vibration waves
in wear or crack growth which is a transient impulse
generated in any solid matter which is under mechanical
or thermal stress [1].
Detection of fracture in parts of machines is a major
application of acoustic monitoring technique and
consequently, the technique is be used as a means for a
condition based monitoring of damages into a bearing and
shaft cracks. The technique of acoustic monitoring can be
a measurement of machine sound also is engaged for
detecting the defects in bearings. In general, the accuracy
varies with sound pressure and intensity [1]-[3].
f) Loose parts monitoring
This technique is performed in many industries on a
regular basis. This work engage different sensors installed
at several locations over machines. Both audio signals and
noise are used for loose parts monitoring. The audio
signals enables alarms if any part of the system is found
significantly loose. The different alarm set points are
selected on the basis of specific plant and the sensitivity
of the loose parts monitoring machine. If an alarm is
activated, sensor output data are analyzed to identify its
size and location. Localization of a loose part is can be
achieved by comparing signals from different sensor in
various locations by identifying signal transmission times.
g) Vibration monitoring
In recent years, predictive maintenance through
vibration analysis has turn out to be the most significant
practices in industrial processes. By means of
accelerometers/vibration sensors and many other similar
sensors with varied axis, the vibration of machinery is
measured and further to identify any deviations from the
expected or normal performance. By this technique it is
simple to successfully identify the current status of
machines and many upcoming troubles by predicting the
condition of machines with industrial equipment and
especially with rotating machinery.
Fig 2 shows different tools and techniques with
functions as condition based monitoring technique.
 2013 IEEE International Conference on Computational Intelligence and Computing Research

reducing maintenance cost, enhancing safety of operators,

lengthening equipment’s life, minimizing accident and
direct involvement of human into a hazardous
environment.
This exhaustive research clearly shows and concludes
that the Vibration Based Condition Monitoring is the most
effective form of condition monitoring. Different research
in past years demonstrates that digital signal processing
and neural network based intelligence techniques are
essential in developing a novel Condition monitoring
system. Owing to increasing benefits of advanced
computer practices and wireless communication
Fig 2. Condition monitoring of equipment and systems technique, digital signal processing is becoming the most
powerful tools for next generation of Condition based
V. RESULTS AND ANALYSIS monitoring which will operational with a high level of
sensitivity, intelligence, and most prominently with
Broad selections of different industrial sectors by cheaper alternatives.
means of varied monitoring techniques are represented in
this research, the condition based monitoring techniques ACKNOWLEDGEMENT
are most widely used in critical oil and gas industries. By
analyzing different parameters like of misalignment, This research work is supported and funded by
bearing and gear damage, etc of all the major techniques, research grants from Indian Oil Corporation Limited,
a conclusion has been drawn, which clearly shows that the Research & Development Center, Faridabad, India and
Vibration Based Condition Monitoring is the most Indian Institute of Information Technology, Allahabad,
effective form of condition monitoring which covers most India.
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