Daye Poly Technic College

Mechanics
Level IV
Learning guide No. 3

Unit of Competence: Analyze Plant and Equipment Condition

Monitoring Results
Module Title: Analyzing Plant and Equipment Condition
Monitoring Results
TTLM Code: IND MCS4 03 0217
By: Labena Manza
Amanuel Taddesse
Ermias Tesfaye

October 2023

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Lo1 Analyze condition monitoring results
Introduction
Condition Monitoring is taken to mean the use of advanced technologies in order to determine
equipment condition, and potentially predict failure. Condition Monitoring includes
 Vibration Measurement and Analysis
 Infrared Thermograph ( instrument that produces a record of the varying temperature or
infrared radiation over an area)
 Oil Analysis
 Ultrasonics (the science and application of ultrasonic waves)
 Motor Current Analysis
It is probably safe to say that most organizations with a significant capital investment in plant
equipment are, these days, employing some form of Condition Monitoring technology in order to
predict at least some failures. However it is highly likely that the frequency at which monitoring
is taking place is far from optimal. Reliability Centered Maintenance (RCM) principles have
taught us that the primary determinant of frequency of a Condition monitoring task is the lead
time to failure.
Condition Monitoring is the time from which an incipient (early) failure can first be
detects (identify), until functional failure occurs. For example, the time interval from
when overall bearing vibration levels reach an "alarm" limit, until the bearing seizes (take hold)
completely.
In order to be completely sure that the failure is detected prior to the functional failure occurring,
the bearing must be monitored at a frequency less than the (Predicative Frailer) PF Interval. So
far so good - in theory, unfortunately, the practice is that the PF Intervals for sophisticated
Condition Monitoring techniques are highly variable. For example, for Vibration Analysis on a
bearing, the PF Interval will vary depending on the type of:-
 Failure detected,
 Bearing installed,
 The severity of its operating cycle,

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  Lubrication applied,
 Ambient (immediate environs) temperature conditions and many other factors.
The need to optimize equipment performance
There have been several articles written about the use of performance monitoring on steam
turbines, using measurements of temperature, pressure, power output and other techniques to
determine turbine condition, and the specific faults that may require attention. It is likely that this
type of monitoring will become more widespread on large equipment. Large Diesel engines,
pumps and other sophisticated equipment may also be able to be monitored using similar
principles. Expect to find work being done to increase the sophistication of techniques such as
ultrasonic flow measurement to assist with the cost-effective application of performance
monitoring techniques to a wider range of equipment
Equipment’s condition monitoring
Equipment’s condition monitoring is the process of monitoring the condition of a machine
with the intent to predict mechanical wear and failure. Vibration, noise, and temperature
measurements are often used as key indicators of the state of the machine. Trends in the data
provide health information about the machine and help detect machine faults early, which
prevent unexpected failure and costly repair.
Machine condition monitoring is important because it provides information about the health of a
machine. You can use this information to detect warning signs early and help your organization
stop unscheduled outages, optimize machine performance, and reduce repair time and
maintenance costs.
Vibrations are the first warning sign that a machine is prone to failure. This warning sign can
provide three months of lead time before the actual failure date. Monitoring this data with
vibration analysis hardware and software helps you predict this failure early and schedule proper
maintenance.
Types of Equipment’s Condition Monitoring
Each of the five main varieties of machine condition monitoring serves a different role.
Route-Based Monitoring

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Route-based monitoring involves a technician recording data intermittently with a handheld
instrument. This data is then used for trending to determine if more advanced analysis is needed.
Portable Equipment’s Diagnostics
Portable Equipment’s diagnostics is the process of using portable equipment to monitor the
health of machinery. Sensors are typically permanently attached to a machine and portable data
acquisition equipment is used to read the data.
Factory Assurance Test
Factory assurance test is used to verify that a finished product meets its design specifications and
to determine possible failure modes of the device.
Online Equipment’s Monitoring
Online Equipment’s monitoring is the process of monitoring equipment as it runs. Data is
acquired by an embedded device and transmitted to a main server for data analysis and
maintenance scheduling.
Online Equipment’s Protection
Online Equipment’s protection is the process of actively monitoring equipment as it runs. Data is
acquired and analyzed by an embedded device. Limit settings can then be used to control turning
on and off machinery.
Equipment’s Resource Manager
Plant Resource Manager is initiative which aims to improve operations and maintenance and
maximize the reliability and availability of plant assets by achieving greater predictability. PRM
is a tool that gives you online access to all your field devices via a field digital network so that
you can carry out essential management tasks such as changing device parameters. PRM helps
both operators and maintenance personnel prevent downtime, and reduce maintenance costs.
Management can project its planning to forecast peak load periods and staff for an overall,
annual average which will plan for production departments to help out at peak load times. When
maintenance is performed on a break down basis, it must, necessarily, use excessively large
crews since break downs must be repaired at once.
Ratios such as,

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 1. Maintenance manpower to total plant manpower,
2. Maintenance expense to value of equipment and
3. Relation of design to maintenance work load.
Are useful guides should be used accordingly, The strict application of ratios should be
performed with great caution for maintenance varies greatly from Industry to Industry and from
plant to plant, depending on equipment used, type of manufacturing process, variation in
accounting, design, and purchasing procedures, and size of plant. Once a ratio is developed from
historical data for a particular plant, it can be extremely helpful in maintaining a proper size
relationship between maintenance and plant manpower.
MAINTENANCE CONTROL
Maintenance Control can be of three types as follows:-
1. Work Control
2. Equipment Control
3. Cost Control

Work Control is done through periodic reporting of the progress of various maintenance
activities. Equipment Control is the process of carrying out Failure Analysis and Downtime
Analysis and of taking corrective measures such as Design-out Maintenance and
Design-for Maintenance
Cost control is exercised by the identification of high-cost areas through periodic
reporting of PM Costs & CM Costs department/section/equipment-wise and initiating necessary
action to reduce the same.
Maintenance Management is an orderly and systematic approach to planning, organizing,
monitoring and evaluating maintenance activities and their costs. A good maintenance
management system coupled with knowledgeable and capable maintenance staff can prevent
health and safety problems and environmental damage; yield longer asset life with fewer
breakdowns; and result in lower operating costs and a higher quality of life. This document
provides general information and guidance on establishing Maintenance Management Systems

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for use in First Nations communities. It describes a system framework from the initial step of
inventory gathering to preparing a community maintenance budget for asset maintenance
planning and monitoring. Depending on the application and design, Maintenance Management
Systems may have various formats and procedures, (e.g., various formats of work orders, reports
and computer screens, etc.), but the basic principles of all these systems are similar to the one
presented in this document.
Types of Maintenance
The word “Operation” is usually linked with “Maintenance”. To put these terms in
context, Operation is the performance of work or services and the provision of materials and
energy to ensure the day-to-day proper functioning of an asset, e.g., the work activities,
associated chemicals and electricity to run a water treatment plant. As such, it has a direct but
simple impact on the cost of operating an asset. Maintenance is the work performed on an asset
such as a road, building, utility or piece of equipment to preserve it in as near to its original
condition as is practical and to realize its normal life expectancy.
This Technical Information Document, as its name implies, concentrates on maintenance
management systems only. In general, maintenance can be classified into the following
categories:
A. Routine - ongoing maintenance activities such as cleaning washrooms, grading roads and
mowing lawns, which are required because of continuing use of the facilities;
B. Preventive - periodic adjustment, lubrication and inspection of mechanical or other
equipment to ensure continuing working condition;
C. Major projects such as floor replacement, re-roofing, or complete re-painting which are
performed once every few years; and
D. Emergency - unexpected breakdowns of assets or equipment. These are unpredictable or
reactive type of maintenance and are more difficult to schedule than the above three
categories.

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 Repair is restoring an asset by replacing a part which is broken or damaged, or
reconditioning that part to its original or acceptable working condition. The need for repairs can
result from normal wear, vandalism, misuse or improper maintenance.
Preparing a Maintenance Plan
Depending on the application and design of a maintenance system, the format and steps
of preparing a maintenance plan can vary. The key steps in preparing a typical maintenance plan
are:
1. Prepare an asset inventory - identifying the physical features (e.g., area, material, etc.)
of all assets (e.g., schools, roads, etc.) which require maintenance;
2. Identify maintenance activity and tasks - defining the type of maintenance task
(activity) to be performed on each asset and what work should be done under each
activity, e.g.
For example 1. Activity: cleaning. Work to be performed: clean chalk boards, vacuum
carpets, etc.; or,
2.Activity: Preventive Maintenance
Work to be performed: Inspect attic space for signs of dampness caused by leaks in roof.
Inspect roof for loose, torn, folded or missing shingles. Repair or replace shingles as required.
Inspect flashings eaves troughs and down spouts, and caulk or replace as required. Visually
check soffit and facia for loose or damaged materials;
3. Identify the frequency of the task - determining how often the activities should be
performed (frequency of service); this is important particularly in preventive type of
maintenance. Emergency or reactive type of repairs are unpredictable, but with good
preventive maintenance, the frequency of emergency situations occurring may be
reduced;
4. Estimate the time required to complete the task - indicating how long each task should
take to complete;
5. Develop an annual work schedule - planning what time the maintenance work for the
entire year should take place;

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 6. Prepare and issue a work order - identifying what, when, where and by whom
maintenance work is to be done; and
7. Determine a Budget - determining the costs for all maintenance activities by calculating
labour hours, material, equipment, and contracting costs.
Inventory
The inventory is a list of physical features (area, material, etc.) of capital assets that
require maintenance. The types of data to be kept vary with the maintenance activity and the task
required.
Work Schedule
The work schedule lists all maintenance work to be done for the whole year for each
asset. It can be used to identify work load peaks and valleys, i.e., using load balancing and
overtime and/or part-time help is needed. It also serves as a basis for preparing and issuing
scheduled work orders and for preparing the maintenance budget. When all work orders have
been listed and the hours distributed, the sub-totals of each period for each worker are calculated.
This process is repeated for work orders to be carried out by other workers, and extended to all
capital assets to obtain the annual work load profile for each worker.
Balancing Work Load
Work load balancing may reduce the extreme demands of personnel and provide a more
even work load, leading to better use of human resources, reduced administrative paper work and
improved efficiency. To balance the work load, one may:
a. Shift some of the work in the peak period(s) to other weeks, either sooner or later than
originally planned. If the demand in certain weeks is still greater than the available hours
from a regular shift, the deficit could be made up by overtime;
b. Assign part-time personnel for the peak periods; or,
c. Assign additional duties or emergency work to the worker in the period where the worker is
not busy.
Decisions of this type are required to make the total work load for each worker as even as
possible to facilitate staffing and to identify periods when additional help is required.

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Work Orders
Work orders provide information on what, where, when, how long and by whom
maintenance is to be carried out .

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