CBM

(condition-based maintenance is the way to reduce the risk of unwanted machine stops)

Introduction to Condition-based maintenance
The condition-based maintenance (CBM) is a maintenance strategy based on information about machine condition.
The main benefits of implementing CBM are:

Availability to ACT ON TIME to mitigate the risk of machine failure and production losses
Better planning of maintenance interventions.
Avoiding unexpected machine failures.

IMPORTANT: CBM strategy can’t exist without properly implemented Condition monitoring (CM) program.
The CBM and CM are very well described in ISO 13372 and 13373 and in Marine Classification societies rules.
The Marine industry is one of few industries that has officially accepted the CBM and created rules to guide and audit fleet CBM and CM Program.

Definitions

Document	Definition of the Condition-based maintenance (CBM)
ISO 13372	Maintenance performed as governed by condition monitoring programms
DNV-CG-0052	CBM is a predictive maintenance form, based on and utilizing the information of an established condition monitoring programme
ABS Rules for survey After construction	A maintenance plan, conducted on a frequent or real-time basis, which is based on the use of Condition Monitoring to determine when part replacement or other corrective action is required.
Lloyd's Register Machinery Planned maintenance and Condition Monitoring	A systems approach to asset management which will include assessment of an asset's criticality and probability of failure, assessment of the consequences of asset failure and development of a strategy to minimise the risks associated with asset failure. This may include, for example, the condition monitoring tools deployed, company policy for spares procurement.

Document	Definition of the Condition Monitoring (CM) programme
ISO 13373-1	After selection of the equipment to be monitored, and determining the type of measurement system that is appropriate, it is recommended that a condition monitoring programme flowchart be developed. However, since each plant and each system is unique, the data flow should be customized to provide the maximum benefits.
DNV-CG-0052	A CM programme is the result of an evaluation of what and how machinery shall be monitored. It contains comprehensive information about all relevant parameters, components and personnel, related to condition monitoring.
ABS Rules for survey After construction	Preventative Maintenance Program (PMP) - A program that consists of Planned Maintenance and/or Condition Monitoring plans. CM - The use of various technologies to determine the condition of equipment, at a specific moment in time, using minimal or non-invasive means.

CBM Cycle

The focus is the machine (functional location).
The first important steps is to collect necessary DATA.
The data as itself do not give us any guidance and therefore must be analyzed. It needs to be done by certified accordion ISO 18436 VA (vibration analyst) that are category II, III or IV.
The machine data analysis process must complete with actionable oriented recommendations based on findings. The recommendations become an input to the CBM strategy and are used in the planning process.
The maintenance team is responsible for the execution and returning the feedback.
The optimum interval for manual data collection is one month and the maximum should be three months.
For the Marine industry two months data collection schedule is sufficient for most of the machines.

CM Data

Most of the people link Condition monitoring to vibrations. The reason is quite simple. The vibration is a movement of a point from a machine. The vibration is a function between force and mobility.

Therefore when the mobility is constant (stiffness of the machine) the increase of vibration will be a result of increased forces. And when the force (load) is constant and there is increase of mobility (loose bolts or cracks) it will cause an increase of vibrations, too.

The vibrations are more dynamic and complex data, compared to other monitoring data sources such as human senses, performance, corrosion, motor current, thermal etc.

We can say that the machine language is called VIBRATIONS.
When we talk about vibrations we consider a wide range of frequencies from 1Hz to 10 000 Hz, where are the running speed and component fault patterns of most of the machines.

Ultrasonic and Acoustic emission are looking in very high frequencies, where we can see very specific fault patterns in the early stage.

This is why Relianeering has decided to focus on vibration data from rotating machines in our ReSES.net cloud based CBM platform.

The vibration monitoring is one of the most sophisticated techniques that require special attention due to:

Data collection must provide reliable data (from the right source, from the same location and secured sensor attachment to the CM Point)
Data analysis requires certified CM specialists (with valid certification according to ISO 18436-2 and understanding the machines and the maintenance)
The vibration data are around 3% of the data sources (CM Points), but they generate 36% of data to be analyzed

Implementation

The implementation of CM program phase is where most of the CM program fail.

The implementation process is very important because of these:

This the fundament of your “CBM house”
Turn the cost of the CM technology to investment in Reliability
Build the CM Database.
Structures the data in a good way.
Prepare CM points for data collection.
Define roles and responsibilities in the CBM process

The implementation process is crucial for the effectiveness of the CM program. With the ReSES.net platform, this process can be done in a few simple steps:

Select machines and define the scope of the CM program.
Map each Functional Location to a ReSES.net CM model.
Provide required data about the equipment: speed, power, etc.
Relianeering’s team of experts build the CM hierarchy and delivers machine CM Points package (RQ-CS-x** with CM Point location label).
Install CM points on the machine.

ReSES.net platform implementation and running of CBM strategy is based on Nine simple steps to mitigate the risk of unwanted machine stops.

The vibrations are more dynamic and complex data, compared to other monitoring data sources such as human senses, performance, corrosion, motor current, thermal etc.

Ultrasonic and Acoustic emission are looking in very high frequencies, where we can see very specific fault patterns in the early stage.

This is why Relianeering has decided to focus on vibration data from rotating machines in our ReSES.net cloud based CBM platform.

The vibration monitoring is one of the most sophisticated techniques that require special attention due to:

Data collection must provide reliable data (from the right source, from the same location and secured sensor attachment to the CM Point)
Data analysis requires certified CM specialists (with valid certification according to ISO 18436-2 and understanding the machines and the maintenance)
The vibration data are around 3% of the data sources (CM Points), but they generate 36% of data to be analyzed