What are the daily tasks involved in equipment condition monitoring and fault diagnosis?

It depends on the conditions in your factory. At present, most large compressors and large pumps come equipped with online monitoring systems. I’ve never seen ordinary pumps equipped with online monitoring; perhaps those with sufficient funds will install it on-site. Usually, monitoring is only carried out at a point in the secondary circuit. I understand that for small pumps, it is necessary to regularly check parameters such as temperature and vibration by hand using specialized equipment, or by combining this with data on flow rate and current. For statistical comparison of the equipment’s long-term operation status, it is not necessary to monitor it continuously. There should also be fault statistics; after a period of time, it becomes possible to set up preventive and regular maintenance schedules. Things like inventory tracking of vulnerable parts, planning for minimum stock levels, and so on. In any case, I think it’s a complicated process that won’t show obvious results in a short time, but once such a system is established, it will make things much more efficient

Condition monitoring is divided into online monitoring and offline monitoring; online monitoring is primarily applied to large-scale and critical units； Offline monitoring is generally periodic monitoring. Many of today’s online monitoring systems are equipped with alarm functions ； Secondly, the data collected by online monitoring and those used for operating the DCS come from the same signal source; usually, when operators detect an abnormality, they notify the online monitoring system, which then analyzes the cause of the fault.

With online monitoring, minor changes in the unit’s operating conditions (as small as 5um) are detected in advance (rather than relying on the high/very high alerts displayed by the DCS), and analysis is carried out to identify the causes of these changes and understand their development trends. This enables the avoidance or reduction of sudden shutdowns during unit operation. Condition monitoring cannot cover everything; it is unable to prevent all sudden stoppages.