Condition-based maintenance (CBM) is a maintenance strategy that monitors and assesses the condition of a physical asset. CBM is based on the premise that asset maintenance should be scheduled when performance indicators show signs of decline or indicate potential failure.

When is CBM performed?

CBM is performed only if a decrease in equipment performance has been observed. An alternative method, preventive maintenance, schedules the machine for maintenance at regular intervals and is not really dependent on the state of the asset. The application of CBM increases the period between maintenance repairs and adopts a fix “as-needed” protocol. It increases machine uptime and decreases lifecycle costs.

CBM derives data from sensors in the field that constantly stream data such as temperature, pressure, flow, etc. Older equipment can also be retrofitted with sensors to enable field monitoring.

When a problem is identified, it’s decision time: should there be an immediate field inspection or should a company take a “wait-and-see” approach? This is a mission-critical decision that can only be optimized if the right data analytics regimen is in place.

The systems that require high capital investment up front and influence output quality are equipped with intelligent self-monitoring, making real-time data collection much easier. In particular, CBM is highly effective in industries which value safety and reliability like aviation, semiconductor manufacturing, nuclear and oil and gas.

Let’s consider an example of a large wind farm comprised of hundreds of wind turbines. O&M costs might easily account for 20-25 percent of the total cost per kWh produced over a turbine’s lifetime. If that wind turbine is equipped with sensors that monitor performance and operational condition, CBM can use that sensor data to reduce turbine downtime and increase key performance metrics.

Advantages of CBM

1. Accurate
2. Performed while the asset is working, reducing machine downtime
3. Early problem identification
4. Reduces equipment failure
5. Improves equipment reliability
6. Spare parts can be ordered in advance, saving costs associated with emergency spare parts
7. Optimizes maintenance intervals, typically stretching the average maintenance guidelines
8. Improves worker safety as it eliminates the need for physical inspection.

Take Away

CBM is a data-driven advancement in asset maintenance, with the goal of increased cost savings and superior equipment performance. Peaxy provides Digital Twin technology anchored on a proven large-scale data architecture that collects and analyzes sensor data to detect anomalies in asset performance. Automated advanced analytics are essential when designing a CBM regime for a piece of industrial equipment or system.