I have recently installed 32 fixed vibration sensors across a selection of critical machines and known bad actors on an FPSO operating in the North Atlantic. Several of these assets have historically shown less than seven days between the first indication of a potential defect and actual failure. This has created a distrust by the maintenance crew as to the effectiveness of the CBM program.
The current approach is to evaluate sensor performance on these trial machines, with the intention of fully integrating the monitoring system across the entire facility once the trial is complete
In today’s fast-paced industrial landscape, downtime isn’t just inconvenient—it’s expensive. Smart condition monitoring offers a proactive solution by continuously tracking the health of machinery and infrastructure using wireless sensors and a cloud based condition monitoring platform.
One of the key advancements driving smart condition monitoring is the adoption of wireless sensors. Unlike traditional route-based data collection—which relies on manual inspections and periodic measurements—wireless sensors enable continuous, real-time monitoring without the need for physical presence. This not only reduces labor costs and human error but also allows for data collection in hard-to-reach or hazardous environments. Wireless systems are especially valuable in large or remote facilities, where installing wired infrastructure would be costly or impractical. Their flexibility makes it easy to scale monitoring programs, integrate mobile assets, and respond quickly to emerging issues, ultimately enhancing reliability and operational efficiency.
Traditional maintenance approaches relied upon scheduled checks or reactive repairs, whereas smart condition monitoring empowers businesses to detect anomalies early, predict failures, and optimize performance in real time.
Whether it’s a manufacturing plant, a power grid, or an offshore oil platform, this technology transforms maintenance from a cost center into a strategic advantage. By integrating Internet of Things (IoT) devices and machine learning algorithms, smart condition monitoring not only reduces operational risks but also extends asset lifespan, improves safety, and supports sustainability goals.
In this blog, we’ll explore methods of introducing smart condition monitoring works at your plant, its key benefits and how organizations can harness its potential to stay ahead of the curve. It will also look at practical solutions to vibration problems without being a specialist vibration analyst
Continuous Equipment Tracking
- Condition-based monitoring continuously tracks equipment parameters to identify early failure signs efficiently
- Data analytics processes sensor data to schedule maintenance only when necessary, reducing downtime
- This method avoids unnecessary interventions, minimizing operational disruptions and increasing efficiency
Smart Sensor Integration
IIoT uses smart sensors to continuously monitor the condition of industrial assets and equipment in real time
Communication Networks
Connected networks enable seamless data transfer between sensors and analytics platforms for effective monitoring
Data Analytics Platforms
Analytics platforms process sensor data to provide actionable insights that improve decision-making and maintenance
Automated Maintenance
IIoT facilitates automation in maintenance, reducing downtime and increasing operational efficiency
Advantages of wireless sensors and IIoT over traditional methods of CBM
- Online monitoring provides real-time insight into equipment health, enabling faster detection of potential issues and more accurate trend analysis
- Remote monitoring reduces the need for technicians to access hazardous or hard-to-reach locations for data collection, enhancing worker safety
- Continuous monitoring reduces the need for manual data collection, allowing technicians to focus on more value-added tasks and enabling more efficient use of labour resources
- Automated, continuous data collection minimizes the potential for human error or inconsistency associated with route-based monitoring
- Online monitoring systems often include advanced analytics and visualization tools, facilitating more accurate fault diagnosis and predictive maintenance
- Online monitoring systems can be easily scaled to accommodate additional sensors and equipment as needed
My next post will present data from fixed vibration sensors that detected a bearing defect which progressed to failure within five days—an issue that would not have been captured using traditional monthly route-based CBM practices.
I will also demonstrate how post-maintenance operating conditions revealed that the alignment was still outside an acceptable tolerance an issue that subsequently led to another bearing failure. In addition, the data highlights an underlying coupling problem, which will be reviewed in detail within the post.