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There is no doubt that condition monitoring systems add value to production processes. Nevertheless, companies do not always utilize their full potential. Setting some general goals like reduction of downtime while reducing the production costs may be a challenge when it comes to their implementation. Asking the right questions will lay the proper foundations when defining a solution that will maximize the productivity of your facility.
- What is the purpose of the monitoring system?
The first step should always be to set realistic goals. In this phase, a technical team should closely examine the critical areas that should stay intact and define key functions that a monitoring system should perform:
- Fault detection and analysis
- Measurement of machine parameters
- Warning and protection function
- Condition based maintenance
- Optimum generator management (overloading, life extension, delayed replacements etc.)
- Estimation of the generator condition and its equipment
- Insight into operating conditions and actual generator state
- Exchange of data with other systems (e.g. SCADA, DCS, PMS…) and data storage
- Information access via HMI and online
- What factors influence the scope of monitoring?
Not all machines need a fully equipped monitoring system. To determine the scope consider these key questions:
- How important is the generator in the grid?
- What is the current condition of the targeted equipment, including its age and size?
- What kind of working conditions is the equipment exposed to?
- How frequently do faults occur?
- How much money is saved if an investment is made in a monitoring system?
- What type of monitoring system to install?
Once the decision has been made to invest in the predictive maintenance program, some additional questions need to be considered in order to ensure its easy implementation and uninterrupted production process.
- Will the system be installed on a new or an old rotating machine?
- What type of sensors can be fitted – built-in (magnetic flux, air gap …) or add-on (vibration, speed…)?
- Can the system later be upgraded if additional measurements come into focus?
- Can the system have a protection and diagnostic function?
- How will it communicate with other systems in the factory?
- Will the personnel be able to access key information remotely?
Considering these questions will prepare you for the process of searching for the right supplier and save a lot of time in the later phases. A good condition monitoring program can’t completely eliminate machine failures or production downtime, but it can significantly reduce the number of faults that threat companies’ assets and consequently reduce profitability.
To learn more about condition monitoring basics, check out our interactive tutorial.