Condition Monitoring
Condition monitoring is the systematic collection and review of equipment-condition information to identify deterioration, abnormal operation, or developing failure.
What this term means in maintenance
Condition monitoring is the systematic collection and review of equipment-condition information to identify deterioration, abnormal operation, or developing failure.
Condition-monitoring methods
Common methods include:
- Vibration analysis
- Infrared thermography
- Oil analysis
- Ultrasound
- Motor-current analysis
- Temperature monitoring
- Wear measurement
- Process-performance trending
- Operator inspection
Practical example
Monthly vibration readings on a motor show a steady increase at bearing frequencies. The trend triggers inspection and planned bearing replacement before breakdown.
Program requirements
A useful program needs:
- Defined assets and points
- Consistent measurement method
- Baseline or normal condition
- Alert and alarm limits
- Collection frequency
- Review responsibility
- Follow-up workflow
- Failure confirmation
Condition monitoring and maintenance
The data should support work requests, work orders, planning, and maintenance decisions. It should not remain isolated in specialist reports.
Common mistake
Collecting large amounts of data without thresholds, trend review, or action ownership creates monitoring activity without reliability improvement.
Related concepts
Related maintenance terms
Keep exploring connected CMMS, reliability, and maintenance planning terms.
Condition-Based Maintenance
Condition-based maintenance is work initiated when inspection, measurement, or monitoring shows that an asset’s condition has reached a defined action threshold.
Vibration Analysis
Vibration analysis is the measurement and interpretation of machine vibration to detect conditions such as imbalance, misalignment, looseness, resonance, and bearing damage.
Oil Analysis
Oil analysis is the laboratory or field examination of lubricant condition, contamination, and wear debris to assess both the lubricant and the equipment it protects.
Condition Monitoring FAQs
- What equipment conditions can be monitored?
Vibration, temperature, oil condition, ultrasound, current, pressure, flow, wear, process performance, and visual condition.
- How is condition monitoring different from preventive maintenance?
Condition monitoring measures asset condition, while preventive maintenance is the broader strategy used to reduce failure risk.
- What makes a condition-monitoring program effective?
Consistent measurements, baselines, thresholds, trained review, action ownership, and work-order follow-up.