A calm plant floor and steady, reliable production line is the ideal state in manufacturing. Now that it's achievable through condition monitoring, more and more facilities are looking to implement an early warning system that provides information on the condition of their assets in real time. With the help of AI and expert support, facility teams can then take proper corrective action to address faults early on.
Many plants start their transition to condition-based maintenance with vibration monitoring. This capability is essential for achieving peak asset health and performance. But for optimal results, it's important to cover all the bases.
By that, we mean adding holistic oil analysis to the mix. Not the usual pass-fail, but a comprehensive analysis that will allow you to identify faults and root causes—even calculate asset lifespan.
Below, we'll explain the unique benefits of vibration and oil analysis. Then we'll share a real-world success story showing the power of combining these condition monitoring approaches to prevent equipment failures.
Real-Time Vibration Analysis: A Powerful Diagnostic Tool
Vibration analysis is used to continuously monitor and diagnose the health of rotating machinery such as motors, pumps, and gearboxes. By using a wireless remote sensor to capture the vibration signals emitted by the equipment in real time, engineers can identify patterns and abnormalities that may indicate deteriorating conditions or potential failures. This approach can be used to identify a wide range of issues including misalignments, imbalances, bearing wear, and loose components.
By detecting these issues early—with increasing precision, thanks to AI, along with prescriptive recommendations from dedicated vibration analysts—facilities can schedule equipment maintenance during planned downtime. This ensures operations continue running smoothly and guards against the financial and human impacts of equipment failure.
>> Learn more about vibration analysis from our CMMS partner, Limble.
Oil Condition Monitoring: A Vital Gauge of Asset Health
Analysis of lubricating oil is another critical component of predictive maintenance, as it provides valuable insights into the condition of a machine's lubricant and internal components. By analyzing oil samples holistically across a range of criteria, engineers can evaluate the cleanliness of the lubricant and identify signs of contamination, machinery wear, and lubricant degradation, which may indicate potential problems with the equipment.
Issues commonly detected through a comprehensive oil analysis include:
- Increased levels of wear particles and debris, indicating friction between components
- The presence of water or other contaminants, which can cause corrosion and damage to parts
- Changes in the oil's viscosity or acidity, which may affect its lubricating properties
With help from a dedicated lubrication expert, your team can identify these issues early and address them before they escalate into more significant problems. An oil condition monitoring service that offers teams a distinct read on equipment health makes prediction and prevention of failures even easier.
>> How oil samples are taken can affect the quality of the analysis. Check out our free oil sampling guide here.
Vibration + Lubrication: A Greater Degree of Insight
Integrating vibration and oil analysis data within a single system provides a more complete and accurate view of machine health. This can enable engineers to identify issues that may not be apparent when using only one technique.
For example, vibration analysis may detect an abnormal pattern that indicates bearing wear, while oil analysis can confirm this diagnosis by revealing increased levels of metal particles in the lubricant. Conversely, oil analysis may identify contamination issues that are not evident in vibration data, allowing for earlier detection and a more targeted maintenance approach.
Vibration sensor captures anomaly in steel manufacturer's gearbox
Analyzing a vibration alert generated by AI, the plant's dedicated AssetWatch condition monitoring engineer (CME) noted elevated vibration related to the gear mesh. He then recommended inspecting the rotating components of the mill main drive and gearbox, verifying the oil level in the gearbox, and analyzing the condition of the oil.
Oil analysis points to simple preventive fix, saving the plant $50,000
The plant's dedicated AssetWatch lubrication CME reviewed the oil analysis report and noted wear metals, particle count, and water content were all high. Both CMEs collaborated with the customer on a plan to inspect the gearbox, check the oil level, and change the oil.
As a result of this process, the customer found that the input shaft seal was leaking, and there was very little oil left in the gearbox. After the seals were replaced and the oil was changed, the issue was resolved—preventing the need for a gearbox replacement and saving the customer $50,000.
With Vibration and Oil Analysis Combined, Faults Have Nowhere to Hide
Incorporating both vibration and oil analysis as part of a comprehensive predictive maintenance strategy can significantly reduce unplanned downtime and extend equipment life. By combining the strengths of these two techniques, you can create a force multiplier effect, enabling you to identify and address potential issues earlier and more effectively.
You'll also be able to streamline and optimize your maintenance schedules. Engineers who use both vibration and oil analysis data can prioritize maintenance tasks based on the severity of the issues detected, ensuring that the most critical problems are addressed first.
If your vision for your plant is operational excellence, increased productivity, and breakdown prevention through timely corrective action, having a complete picture of your assets' health will empower you to achieve it.
.webp)
