Condition Monitoring is an integral part of condition based maintenance strategy or predictive maintenance approach being followed in various industries. In the present scenario to avoid unplanned shut downs and to calculate the life expectancy of the plant, Risk Based Inspection (RBI) and condition monitoring are playing vital role. Condition monitoring is a technical activity in which selected physical parameter associated with the components operations are observed for the purpose of determining the integrity of the component whilst it is in operation. In other words it forecast the drift of increasing deviation of operational condition of the equipment away from its standard limit, which in turn helps to decide on the need of predictive maintenance steps to avoid catastrophic failures.
Thus Condition Monitoring not only describes the present state of the component but also provides the reasonable inputs to predict remaining useful life while in operation and can reduce the maintenance cost by 65% through appropriate implementation. The monitoring process can be applied in periodic or continuous manner.
The following technique or a combination of them is used for monitoring the performance of component/machinery/vessel/Tank whilst in operation or offline.
TWI Resources
TWI is augmented with highly skilled engineers and state of art equipment’s to undertake condition monitoring activities; few of those are as listed below:
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Acoustic Emission Testing Equipment from M/s Physical Acoustics
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Fluke Ti 30 portable thermal imaging camera
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LOT Oriel/Thermal wave imaging Inc system
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Plant Integrity Limited Teletest® and Teletest FocusTM
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Force P-Scan system
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Omniscan MX2
Benefits
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Minimizes maintenance cost
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Improved Risk Management
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Allows to use the full cycle capacity of the component
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Optimises maintenance and service activities
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Allows preventive action to be taken to avoid consequence of failure
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Increased reliability and production
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Assists in root cause analysis
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Enhances Safety
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Eliminates unplanned shut downs up to 75% in a typical plant with proper implementation
Applications
Condition monitoring can be practiced in all Oil & Gas, Power, Chemical, Automotive, Steel, Wind power, Mining, Aerospace industries. Few of the application areas are:
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Detecting and monitoring leaks, cavitation and flow
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Diagnostic of reinforced and pre stressed concrete bridges
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Pressure vessel, storage tanks, pipeline and piping
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Air crafts and ageing vehicle
Related links
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