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Correct analysis and accurate design are the key principles of a well-functioning system however, the longevity and effectiveness of any system depend on appropriate maintenance.
There are many strategies for maintenance. Establishing the correct strategy of maintenance is key to ensuring the longevity of the system. In this article, we will discuss condition-based maintenance.
What is Condition-Based Maintenance?
Most maintenance strategies are planned around the sub-elements of the system. For example, a typical ball bearing has a service time of around 2000 working hours while motor oil lifespan under nominal working conditions is around 500 hours. An industrial blower, which utilizes both ball bearings and motor oil, is usually maintained in 500-hour intervals since the motor oil is the component with the shortest lifespan. This approach to maintenance is called preventative maintenance. It is one of the most effective maintenance techniques however, for systems that cannot have planned maintenance schedules or systems that are flexible, a preventative approach may not be enough.
Condition-based maintenance or CBM for short is the maintenance strategy based on monitoring and analyzing the condition of a system to foresee the next maintenance window.
How Is Condition Based Maintenance Performed?
To foresee the next maintenance window of a system, thorough analysis, and data collection is crucial. Various parameters can signal the need for maintenance or malfunctions such as abnormal vibration, noise, and, an increase in working temperatures. To organize an efficient CBM plan, these parameters need to be monitored continuously and accurately.
Experts generally use monitoring devices integrated into the system to collect data regarding critical parameters. Decibel meters, thermometers, and vibration sensors are one of the most commonly used monitoring devices in CBM plans. Constant monitoring and data collection allows experts to get a better idea about the nominal working parameters of a system so any abnormalities can be detected before they cause irreversible damage to the entire system.
Special software or algorithms are another important tools for CBM experts. The software constantly compares the present parameters of the system against the nominal values to provide feedback to the engineers regarding the next maintenance window. The implementation of specialized software provided a huge breakthrough in CBM systems because it takes human error out of the entire maintenance strategy. Some high-end algorithms can even detect possible reasons for the parameter changes and suggest solutions, allowing even shorter stoppage times in maintenance.
Advantages of CBM
The first and most obvious advantage of CBM is its ability to detect abnormalities before they cause critical failures in the system. However compared to other maintenance methods which also proactively fix problems, CBM optimizes preventative measures. Preventative maintenance strategies are based on component life spans. However, in a preventative maintenance approach, the measures are performed regardless of whether them being needed or not. In summary, the regular preventative approach of maintenance is too safe compared to CBM thus, not as time and cost-effective.
Another huge benefit of condition based maintenance is its ability to foresee dangerous malfunctions before they turn into critical system failures. Other strategies of maintenance can fall short in this regard. Coming up with long-lasting solutions for critical errors before they cause catastrophic system failure elongates the expected life span of the components, therefore the system.
Disadvantages of CBM
Establishing a condition based maintenance system can be challenging. Monitoring equipment, specialized software, and algorithms require a certain amount of initial investment. Most monitoring equipment is purpose-built, precise measurement tools which can be quite costly. In addition, monitoring devices need to be constantly checked for calibration since the wrong accumulation of data can lead to faulty and unnecessary interference with the system.
Even if the correct accumulation of data is secured, the expertise which is required to analyze the data can be quite challenging to develop. The organization might need to hire additional experienced experts or outsource consultation to be able to process the data correctly.
Final Words
Despite the mentioned challenges, CBM is one of the most popular and effective approaches to maintenance. The optimization of a proactive maintenance approach that CBM provides organizations with proves to be crucial.
For companies in the oil and gas industries, implementing a condition-based maintenance system can greatly benefit their operations.
The constant monitoring of critical parameters using specialized equipment and software can detect abnormalities and foresee potential malfunctions, preventing critical failures that can result in costly downtime and safety hazards. CBM also optimizes preventative measures, providing a more time and cost-effective approach compared to traditional preventative maintenance strategies.
However, establishing a CBM system requires initial investment in monitoring equipment and specialized software, as well as expertise to analyze the collected data. Despite the challenges, the benefits of CBM prove to be crucial in ensuring the longevity and effectiveness of the systems in the oil and gas industries.