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2002 Condition Monitoring Survey Results
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Plant Maintenance Resource Center
Overview
This survey of the use of, and benefits derived from, Condition Monitoring and Non Destructive Testing (NDT) technologies was conducted on the Plant Maintenance Resource Center website between March 2002 and May 2002.
Summary of Key Findings
Voluntary (and confidential) responses were sought to the survey, and 70 valid responses were received.
The key findings are:
- Overall, most respondents use a wide variety of condition monitoring technologies
- The most commonly used techniques were Human Senses (look, feel, smell, listen etc.), Vibration Analysis and Oil Analysis
- Human Senses, Vibration Monitoring and Motor Current analysis techniques are most likely to be applied by In-house employees, with oil analysis most likely to be performed by contractors.
- All techiques are considered to provide some benefits, but the greatest benefits are considered to have been obtained from the use of Human Senses, Vibration Analysis and Infra-red Thermographic techniques.
Respondent Data
Of the 70 valid responses, recipients were most commonly from the Manufacturing and Utilities industries.
| Industry |
Responses |
% of Total |
| Manufacturing-Petroleum refining, chemicals and associated products |
11 |
15.7% |
| Manufacturing-Metal products |
6 |
8.6% |
| Utilities-Electricity Generation |
6 |
8.6% |
| Manufacturing-Food, beverages, tobacco |
5 |
7.1% |
| Manufacturing-Wood and paper products |
4 |
5.7% |
| Manufacturing-Other |
4 |
5.7% |
| Oil and Gas-Oil and gas extraction |
4 |
5.7% |
| Services-Business Services/Consulting |
4 |
5.7% |
| Services-Other |
4 |
5.7% |
| Mining-Metal ore |
3 |
4.3% |
| Mining-Coal |
2 |
2.9% |
| Services-Contract Maintenance/Repairs |
2 |
2.9% |
| Services-Healthcare |
2 |
2.9% |
| Utilities-Water, sewerage, drainage |
2 |
2.9% |
| Manufacturing-Machinery and equipment |
1 |
1.2% |
| Manufacturing-Textiles, clothing, footwear, leather |
1 |
1.4% |
| Services-Education/Academia |
1 |
1.4% |
| Services-Property services/Building Maintenance |
1 |
1.4% |
| Services-Transport |
1 |
1.4% |
| Utilities-Electricity Transmission and Distribution |
1 |
1.4% |
| Other |
5 |
7.1% |
Which Condition Monitoring and NDT techniques are most commonly used?
Overall, most respondents use a wide variety of condition monitoring technologies, with the most common, perhaps not unsurprisingly, being the use of the Human Senses (look, feel, smell, listen etc.). Other most commonly used technologies included Vibration Analysis and Oil Analysis.
| Technique |
No of Responses |
| |
Regularly |
For problem solving only |
Never |
Don't Know |
N/A |
| Vibration Analysis |
47 |
7 |
11 |
0 |
1 |
| Oil Analysis |
41 |
15 |
6 |
1 |
7 |
| Infra-red Thermography |
31 |
20 |
7 |
1 |
11 |
| Motor Current Analysis |
16 |
21 |
18 |
4 |
11 |
| Ultrasonic Thickness Testing |
26 |
16 |
14 |
1 |
13 |
| Ultrasonic Crack Detection |
21 |
19 |
13 |
1 |
16 |
| Magnetic Particle Inspection |
16 |
16 |
14 |
6 |
18 |
| Dye Penetrant Examination |
19 |
18 |
12 |
4 |
17 |
| Human Senses |
56 |
4 |
2 |
0 |
8 |
Who performs the Condition Monitoring tasks
In general, Human Senses, Vibration Monitoring and Motor Current analysis techniques are most likely to be applied by In-house employees, with oil analysis most likely to be performed by contractors.
| Technique |
No of Responses |
| |
Inhouse Employee |
External Contractors |
Both |
Don't Know |
N/A |
| Vibration Analysis |
40 |
10 |
6 |
2 |
12 |
| Oil Analysis |
19 |
32 |
8 |
0 |
11 |
| Infra-red Thermography |
29 |
23 |
4 |
0 |
14 |
| Motor Current Analysis |
27 |
7 |
4 |
5 |
27 |
| Ultrasonic Thickness Testing |
24 |
19 |
1 |
1 |
25 |
| Ultrasonic Crack Detection |
16 |
22 |
3 |
1 |
28 |
| Magnetic Particle Inspection |
14 |
19 |
1 |
2 |
34 |
| Dye Penetrant Examination |
24 |
8 |
5 |
3 |
30 |
| Human Senses |
48 |
1 |
4 |
0 |
17 |
What benefits have been obtained from performing Condition Monitoring tasks
All techiques are considered to provide some benefits, but the greatest benefits are considered to have been obtained from the use of Human Senses, Vibration Analysis and Infra-red Thermographic techniques.
| Technique |
No of Responses |
| |
Very High |
High |
Moderate |
Low |
Very Low |
Don't Know |
N/A |
| Vibration Analysis |
20 |
19 |
11 |
1 |
1 |
4 |
14 |
| Oil Analysis |
8 |
20 |
19 |
4 |
0 |
4 |
15 |
| Infra-red Thermography |
15 |
22 |
12 |
3 |
1 |
1 |
16 |
| Motor Current Analysis |
8 |
11 |
15 |
2 |
1 |
8 |
25 |
| Ultrasonic Thickness Testing |
10 |
9 |
16 |
3 |
1 |
5 |
26 |
| Ultrasonic Crack Detection |
10 |
10 |
15 |
3 |
0 |
5 |
27 |
| Magnetic Particle Inspection |
11 |
5 |
11 |
3 |
0 |
7 |
33 |
| Dye Penetrant Examination |
10 |
6 |
14 |
3 |
1 |
4 |
32 |
| Human Senses |
19 |
17 |
14 |
1 |
1 |
0 |
18 |
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(Permission will generally be granted, so long as appropriate credit is given to its origin).
Copyright 1996-2009, The Plant Maintenance Resource Center . All Rights Reserved.
Revised: Thursday, 08-Oct-2015 11:51:55 AEDT
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