Condition Monitoring: A Catalyst for Predictive Maintenance Success

Equipment failures can cost millions, jeopardize safety, and trigger regulatory penalties. Unplanned downtime, missed deadlines, and costly replacements are just the beginning.

Integrating a comprehensive predictive maintenance (PdM) program with condition monitoring (CM) transforms asset management from reactive to proactive. By recording live performance data—vibration, temperature, oil quality, and flow—plant managers gain a scientific basis for decision‑making.

When plants apply the same rigor to equipment as they do to production processes, they discover that monitored assets almost never cause unexpected outages. Maintenance teams can then focus on long‑term improvements and boost technician morale.

Initial CM deployments often reveal hidden, low‑level issues that require investment. However, once those problems are resolved, the PdM program quickly recoups its costs through reduced emergency work orders and extended equipment life.

Over time, as teams master asset conditions, the frequency of new problems drops further, turning the program into a reliable source of cost savings. The upfront expense for sensors, software, and training typically pays off after one or two high‑value “saves.”

OEMs Filling the Gap

Routine data collection lets technicians spot trends and anticipate failures well before they occur. Yet many facilities lack the internal bandwidth to run CM efficiently.

In many plants, the same crew that performs daily operations also handles CM data, leaving little time for long‑term trending. Additionally, a single vibration expert is a critical risk if that person leaves the company.

To address these challenges, leading OEMs partner with CM hardware and software vendors to offer end‑to‑end monitoring solutions. They provide continuous vibration and temperature analysis, oil sampling, thermography, and ultrasonic flow measurement, all tailored to each asset’s criticality and accessibility.

End‑to‑End Monitoring with Flowserve

Flowserve’s Condition Data Point Monitoring (CDPM) is part of its LifeCycle Advantage suite, delivering full‑scale PdM support for pumps, compressors, fans, valves, and gearboxes.

• Technicians collect and analyze data, delivering comprehensive reports within three business days.
• Reports pinpoint critical issues, recommend corrective actions, and track implementation status.
• Flowstar.net, the companion asset‑management platform, allows real‑time data updates, failure‑cause analysis, and reliability metrics.

Stepwise Implementation

Flowserve’s CM program is tailored to each plant’s needs:

• Vibration Analysis: Detects bearing wear, cavitation, misalignment, and rotor bar failures.
• Temperature Trending: Identifies abnormal operating conditions across bearings, seals, and process equipment.
• Trigger Point Monitoring: Uses proven failure triggers—pressure, flow, speed—to schedule preventive inspections.
• Lube Oil Analysis: Applies spectroscopy, particle counts, and water tests to uncover hidden wear.

Case studies illustrate the value: In a U.S. chemical plant, early vibration detection of a 56x running‑speed spike identified a cracked rotor bar, preventing catastrophic motor failure. At a Midwest refinery, temperature differentials in an API 11 seal flush plan revealed a plugged orifice, allowing a low‑cost repair that avoided a costly pump teardown.

Measuring ROI

Track the average cost per work order on rotating equipment. Predictive maintenance reduces emergency jobs and enables planned maintenance, lowering overall ownership costs.

Record each CM‑derived “save,” assigning a monetary value by estimating the cost of catastrophic failure minus the repair expense. Include downtime losses, reduced output, and safety or environmental mitigations for a complete picture.

Industry averages show payback periods as short as one month, providing compelling evidence when presenting to senior leadership.

By combining CM, PdM, and advanced asset‑management tools, plants achieve sustained ROI and operational excellence.

For more information, call 972‑443‑6500 or visit www.flowserve.com.