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Condition-Based Monitoring.

Imagine a Powerplant or an Oil and gas plant that spreads across acres of land with a lot of physical assets running. The production goes well and every operation delivers output seamlessly. Now if any one motor or pump in a production line goes down, what will happen? The streamlined production is stopped abruptly. This causes a Downtime. Even a small downtime can cause a big loss. Now Just imagine, what if a major breakdown happens? Yes, It will end the organization with a huge loss. Now, What if I say, the machine breakdown/ failure can be predicted?


What if I say, the cost spent on operating assets, and downtimes due to poor maintenance can be completely eradicated? Let’s see how it can be done.


Condition Based Monitoring (CBM)


 Predictive Maintenance is a part of Industry 4.0, where the real-time data of the performing physical assets are measured, observed over time, and analyzing it with the help of Artificial Intelligence (AI) to identify and prevent possible failures at the earliest. This information will be very helpful for the decision-makers to plan for a timely shutdown of their units without affecting the entire production. Also, the life of the physical assets is improved by timely maintenance and the cost of purchasing a new asset is avoided, hence assuring the ROI.


When and where it is needed?


There are certain factors to be taken into consideration, though condition monitoring can play a beneficial role in any organization’s maintenance, it is implemented in a manner without an in-depth understanding of some factors that will always impact its effectiveness in the system.  


• Condition monitoring can be used on most assets, equipment must meet certain requirements for CBM to be used effectively.  


• The changes in the asset’s condition can be observed and notified in time, addressing the failure.


• The monitored asset should be critical to the production line or the success of the business


• The maintenance team must be able to capture performance data, analyze it, and make timely decisions based on the results. When all the above conditions are satisfied, Condition-Based Maintenance is effective in use. Apply all the above-seen factors to the scenario of the Power plant / Oil & Gas. Here is where it is needed. 

Benefits of Condition-Based Monitoring (CBM):


CBM can assist in reducing unexpected downtime and labor hours while improving throughput since it is much simpler to predict failure and rectify it in advance. Repairs are only made, when necessary, and there is an increase in the amount of time between maintenance. Therefore, it results in Less downtime, a smaller backlog, and lower expenses. Responding to an unplanned breakdown is one of the riskiest tasks for a maintenance technician. Condition-based maintenance creates a safer workplace by reducing the likelihood of equipment failure.  Physical parameters such as Vibration, Machine Heat, Surface defects, Coolant level, Input current, Pressure, Noise level, etc., with all these data, the asset’s life and status are analyzed and notified the possible failures in advance.



[1] "Condition-based monitoring (CBM)," Fiix by Rockwell Automation, [Online]. Available:


[2]  Caroline Eisner, "What Is Condition-Based Maintenance?," Maintain X, [Online]. Available:


[3]  Jonathan Davis, "A Simple Guide to Condition-Based Maintenance," hippo CMMS, 06 OCT 2021. [Online]. Available: 

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