Condition Monitoring

Condition monitoring is the practice of measuring a machine's health while it runs, so maintenance is done when the data shows a fault developing. The two most common signals are vibration, which reveals mechanical problems such as bearing wear and imbalance, and temperature, which reveals electrical and friction related problems.

It measures vibration and temperature at the point where a sensor is mounted, usually a bearing housing. The readings are collected at set intervals, trended against a healthy baseline and used to flag bearing defects, imbalance, misalignment and looseness. Exact measurement parameters are listed in the product brochure.

A route survey takes a snapshot each time a technician visits, often monthly or quarterly. A wireless system measures the same points automatically and continuously, so faults that appear and progress between visits are still captured. It also removes the need to reach hot, high or moving equipment by hand.

Use it on electrical panels, switchgear, busbars, cable terminations and transformers, where loose or corroded connections run hot before they fail. It is also useful on motors, couplings, bearings, steam traps and insulated piping, and for confirming a fault that vibration data has already flagged.

No. Wireless vibration sensors mount on the outside of the machine and report to a gateway, so no cabling or process stoppage is needed. A thermal imager measures without contact, so energised and rotating equipment can be inspected at normal load from a safe distance.

The usual practice is one sensor at each bearing location. A typical motor and pump set therefore needs two to four points, while a machine train with a gearbox needs more. Sertel engineers can define the measurement plan from the asset's criticality and failure history.

Preventive maintenance services parts at fixed intervals whatever their condition, which can replace healthy parts and still miss early failures. Predictive maintenance acts only when measured data shows a fault developing, which cuts unnecessary work and reduces unplanned downtime.

Integration depends on the product and the plant, so confirm the supported interfaces in the product brochure or with the Sertel team. The aim is to bring alarms and asset health status to the people and systems already used for operations and maintenance.