Condition monitoring is a multifaceted approach that should not rely solely on one technology or method. It’s essential to employ a strategic mix of tools and tasks tailored to the equipment’s specific needs. While technology plays a significant role, direct observation and inspection are equally important.
Common components like motors, bearings, and seals mean that many machines have similar monitoring and inspection requirements. However, unique operating conditions necessitate specialized inspection to address distinct failure modes and determine machine criticality.
Inspections are as crucial as other monitoring techniques and, in my view, a top-tier inspection program can prevent more issues than all other monitoring methods combined. It complements technology-based monitoring, serving as a strategic tool rather than a replacement.
Technologies like infrared thermography and vibration analysis are typically used to identify active faults and abnormal wear. In contrast, a thoughtfully designed inspection program prioritizes the identification of root causes and early-stage failure conditions, with the detection of advanced wear and imminent failure being a secondary concern.