Online Monitoring System
Rich experience
Our products are developed from over 30 years experience and designed to achieve all necessary parameters to conduct a reliable machine analysis.
Technological development
We provides turnkey solutions for machinery Condition Monitoring in the predictive maintenance field. We develops and manufactures vibration measuring instruments, machine condition monitoring equipment and software with user functionality in mind.
Wide range of products
Vibration Analyzer; Portable Rotor Balancer; vibration meter; Wireless intelligent vibration sensor; Accelerometer; Dynamic Balancing.
Professional team
There is/are Above 50 People R&D Engineer(s) in the compan. With a professional R & D team and leading scientific research ability.
What is online monitoring system
Online monitoring system is the process of utilizing permanently mounted sensors to regularly check the condition of a machine. Online monitoring system should consist of more than just vibration sensors. Given there are many different failure modes it is best to utilize a variety of sensor types to monitor the necessary variable to ensure early warning of failure.
Online monitoring system systems can be wired, or wireless. With recent advances in battery and wireless transmission technology wireless online monitoring system of machine, condition has become easier, less costly, and technologically advanced as compared to traditional wired solutions.
How Does Online Monitoring System Work
Online monitoring system relies on the collection and analysis of data from various sensors and monitoring devices. These devices are strategically placed on equipment to measure parameters such as vibration, temperature, pressure, electrical signals, and more. The collected data is then analyzed to identify anomalies, patterns, and trends that indicate potential faults or deviations from normal operating conditions.
The process of online monitoring system typically involves the following steps:
Sensor placement: Sensors are installed on the equipment in critical areas or positions where they can capture relevant data. The selection of sensor types and their optimal placement depends on the specific equipment and the parameters to be monitored.
Data collection: Sensors continuously gather data on the select parameters. This data can be collected in real-time or at regular intervals, depending on the monitoring system.
Data analysis: The collected data is analyzed using specialized software or algorithms to compare data with historical trends to help identify anomalies, patterns or indictors of potential issues.
Alert generation: When the analysis detects abnormal behavior or potential faults, alerts or notifications are generated to inform maintenance personnel. These alerts can be transmitted via email, sms, or dedicated monitoring software.
Maintenance actions: Proactive maintenance can be implemented to prevent failures and optimize the overall maintenance strategy.
Classic Vs Online Monitoring Systems
Traditional and online monitoring system are both methods of detecting and diagnosing potential problems and failures in industrial equipment and systems. However, there are some critical differences between the two:
Frequency of data collection: Online monitoring system involves continuously collecting data from the equipment or system in real-time, while traditionally, it must be done manually.
Data analysis: Online monitoring system often involves using software and predictive analytics techniques to analyze data automatically and identify patterns and trends that may indicate potential problems, while traditionally, it involves manually analyzing data and identifying potential issues based on knowledge and experience.
Response time: Traditional condition monitoring relies on scheduled inspections or maintenance tasks to address potential problems, which may not be timely enough to prevent unexpected downtime or other disruptions. Online monitoring system can provide almost immediate notification of potential problems, allowing maintenance teams to take timely action to address them.
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If you are interested in learning more about condition monitoring and building a proactive predictive maintenance plan for your plant, here is a quick "get started" outline and next steps to guide your path forward.
Step one: Install the hardware
The first step is the installation of monitoring sensors on serviceable assets including rotating machinery (turbines, compressors, pumps, motors, fans) and stationary assets (boilers, heat exchangers). Plant managers work with the vendor installation team to retrofit or modify machines as needed to ensure the appropriate installation of monitoring instrumentation. Different assets require different approaches. Not all assets are created equal, and as such, a variety of condition monitoring products and approaches are required.
Step two: Measure your data
Once installed, sensors can immediately begin to measure the following machine elements:
● Vibration and position – Indications of dynamic and static motion of the rotor or machine case.
● Rotor speed – An important part of analyzing vibration data and determining machine malfunctions. Machine vibration frequencies can show up as direct multiples or sub-multiples of the rotative speed of the machine.
● Temperature – RTD's and Thermocouples measure the temperature of the machine's radial and thrust bearings, lube oil, stator windings, and steam temperatures.
● Operating process sensors – These are typically already installed at the machine OEM level or as part of the process control system. Valuable data from these sensors combines with the dedicated condition monitoring sensors to provide machine operating context enabling a complete picture of how the machine is performing its intended function.
Step three: Monitor your machines
Data is transmitted from installed condition monitoring and process sensors to a centralized condition monitoring software system for evaluation and diagnostics. Trained maintenance technicians are alerted anytime an abnormality is detected and use data provided to determine if the machine requires immediate attention.
What Monitoring Can Online Monitoring Systems Be Used For
Condition based monitoring consists of a range of methods and strategies, for evaluating the health of assets. Lets explore some of the used approaches to condition based monitoring;
Analyzing vibrations
Vibration analysis entails examining how assets react to vibrations offering insights into flaws in components. By analyzing vibrations through methods like shock pulse analysis and broadband vibration analysis maintenance teams can. Evaluate structural issues such as imbalance and misalignment.
Examining oil
Oil analysis is a technique that involves studying lubricants and other fluids to gather information about both the fluid itself and the equipment it serves. Tests can detect wear particles, water contamination, changes in viscosity among indicators. Contaminants found in lubricants and fluids can hint at failures. Common uses of oil analysis include assessing compressors, gearboxes and various aspects within the transportation sector.
Monitoring temperatures
Temperature measurements encompass temperature tracking well as more advanced methods like passive or active thermography. In thermography cameras capture heat emitted from assets allowing for an analysis of images that can reveal areas of failure such as worn parts. Abnormal heat levels or thermal irregularities may indicate issues, like lubrication, worn out components or misalignment.
Analyzing sound
When it comes to analysis the focus is, on examining the sounds produced by equipment to spot any issues. Sonic analysis uses microphones to pick up noises within the range of hearing for lubrication assessment. On the hand ultrasonic analysis goes beyond hearing by using sensors to detect high frequency sounds that could indicate problems like leaks, cavitation or poorly fitted components.
Monitoring electrical systems
Monitoring revolves around scrutinizing parameters to catch faults and track degradation trends in the electrical setup. This approach can help identify traits such as induction, impulse and frequency response, capacitance and resistance. By spotting degradation patterns maintenance teams can carry out preventive measures before equipment breaks down.
Measuring electromagnetic fields
In contrast to monitoring, electromagnetic measurement zeroes in on measuring distortions in fields and alterations in current within assets. By introducing a field or current and analyzing disruptions electromagnetic measurement can pinpoint defects, within equipment.
Radiation inspection
When it comes to radiation inspection the use of radiation imaging plays a role, in examining assets and components like how x rays are used in hospitals. By analyzing how radiation is absorbed by the material under testing this approach can uncover hidden issues such as corrosion that may not be easily noticeable.
Laser measurement technique
The laser measurement technique known as laser interferometry relies on measurements achieved by tracking the wave displacement of two laser beams. This method is effective at pinpointing defects on both the surface and subsurface of materials making it particularly valuable, for applications requiring precision.
How Do You Implement Online Monitoring System
The implementation of online monitoring system directly follows its four pillars: Detection, diagnosis, prognosis, and programme.
Detection details the "when" of the machine fault
This includes when the issue may have started, how early it was noticed, and how long it has to be tended to until it turns into a failure.
Diagnosis focuses on the "what" of the fault
In this step you will focus on the origin of the issue, what stage it's at currently, how fast it's growing, and any machine parts that may be or have been affected.
Prognosis is the step where you forecast the aftereffects of the fault
This is when you'll estimate the severity of the issue, look at possible results and production loss it can cause, as well as all of its side effects.
Programme is all about the schedule of the repair
You'll decide when machines need to be taken for maintenance or repair, decide on a maintenance policy, and make a timeline for the correction and when it can be finished.
Every operation is different, but the benefits of online monitoring system are consistent across the board. Online monitoring system gives you data-driven insights into your assets' maintenance needs so you can stay ahead of machine failure. That's because the more you understand the health of your equipment, the better you can plan your maintenance schedule, inventory needs, and budget.
Online monitoring system is key to purposeful planning and smart resource allocation. Here are just a few of the top benefits of online monitoring system:
● Drastic reductions in downtime: Online monitoring system identifies machine faults early so maintenance crews can get in and make repairs long before machine failure.
● Lower maintenance costs: Online monitoring system eliminates the need for many calendar-based preventive maintenance tasks, thereby reducing labor costs and driving down the cost of spare parts.
● Increased equipment lifespan: Well-maintained equipment lasts longer and runs more smoothly, which is key to extending the life of nearly any asset.
● Improved safety throughout the operation: When your assets are in good working order, your teams are safer. Properly maintained equipment also helps prevent failures that may damage other nearby assets.
● Greater productivity: Online monitoring system boosts uptime and keeps your equipment in good working order, which means sustained productivity.
Our Factory
KM Instrument is a global leader in condition monitoring technology. we provides turnkey solutions for machinery Condition Monitoring in the predictive maintenance field. we develops and manufactures vibration measuring instruments, machine condition monitoring equipment and software with user functionality in mind. Our products are developed from over 30 years experience and designed to achieve all necessary parameters to conduct a reliable machine analysis. With a professional R & D team and leading scientific research ability, the KM series products from KM have a solid reputation for quality and excellent performance.
Our products are used widely in industry and we believe our success comes from our focus on simplicity with a high performance to cost ratio. We continue to move forward and establish new markets in developing areas. The strength of our product range comes through development which has involved some of the world's leading professionals in vibration analysis.
Our Certificate
ISO9001,CE,IP67
