Condition Monitoring

Condition monitoring (CM) is the process of monitoring a particular condition in machinery, to identify changes that could indicate a developing fault. It is a major part of predictive maintenance as implementing condition monitoring allows for maintenance to be scheduled and preventive actions taken to prevent further failure and subsequent unplanned downtime.

What is Condition Monitoring

Condition monitoring is a systematic set of processes and technologies that assesses, and monitors the condition of industrial machinery for a given time-period or environment. This is typically done through physical means, such as vibration monitoring, inert gas monitoring, or thermal. The use of these technologies can make a huge impact in maintaining industrial machinery. It improves worker safety and reduces the chances of collateral damage to the system. Traditionally, vibration analysis was the preferred means of condition monitoring, however, nowadays, modern, innovative techniques such as sensors and sophisticated softwares are being used to monitor the condition of the machines in real-time. The unique advantage of condition monitoring is that it addresses the conditions of the equipment that would shorten its lifespan, long before they develop into catastrophic failure.

Condition monitoring

How does Condition Monitoring work?

Condition Monitoring works in the following three steps:


In order to monitor the condition of any machine, it is essential to collect data, which can be accomplished by installing a monitoring system. Machines / instruments are fitted to the machines to monitor their output. By collecting data on the output parameters of the machine and analyzing its performance, the condition monitoring system can detect if a machine has a fault or not.

Establishing a Baseline

The system once installed correctly, can begin to collect the data to measure the performance of the equipment. This data may consist of vibration, speed, and temperature among others, which may be used to create a baseline which is indicative of ideal operating condition, against which future performance of the machine will be measured.

Condition Monitoring

Data is transmitted and evaluated by the condition monitoring system from which the performance and diagnostics are evaluated. The system processes the data and notifies the maintenance and reliability professionals if any abnormality is detected, thereby enabling the professionals to take immediate action, preventing catastrophic failures.

Condition Monitoring Sensors

Remote Condition Monitoring is utilized for the real-time monitoring of a machine or plant. The system generally consists of condition monitoring sensors that are installed on the machines, which capture the data and send it to softwares installed either on-premise or on the cloud, where the data is analysed. The system captures the data, processes and notifies the maintenance teams when the pre-set limits (benchmarks) are exceeded.

Condition monitoring sensors measure how a machine operates and inform the system how the machine is performing. These sensors are used to detect wear, overheating, vibrations or noise; This information is then interpreted and delivered to the main system. These sensors are usually installed at the system level and data processing and visualisation takes place in the main monitoring room. The specific sensor readings are taken and are used to produce real-time displays of the condition of the machine. These displays are important to identify potential problems and prevent downtime, with automated detection and response. These sensors help prevent or reduce failures, through early detection of anomalies or faults.

Condition Monitoring Sensors

Condition Monitoring Services

Condition monitoring services offer the promise of optimizing manufacturing operations. The demand for condition monitoring services have been rising due to the increased focus on overall plant & machine health as well as breakdown monitoring.
Condition monitoring is a tried & tested, effective & powerful maintenance tool that is being used by an increasing number of industries. Condition monitoring frameworks provide significant advantages from a monetary, functional and safety perspective. When used with associated systems, it allows to make the most of planned maintenance schedules, by addressing multiple problems in one schedule which otherwise may cause unplanned downtimes. One major advantage of condition monitoring is that it helps companies to make more accurate decisions and therefore there is a high potential for companies to increase their profitability and minimise the risk of operational losses.
Nanoprecise Sci Corp is an automated end-to-end condition monitoring service provider that offers real-time predictive information about the genuine health and performance of industrial assets. Nanoprecise specializes in the implementation of Artificial Intelligence and IoT technology for predictive asset maintenance and condition monitoring. The AI-based predictive maintenance solution monitors different parameters to provide enhanced visibility of the machine health thereby offering increased transparency to the manufacturing operation as a whole. Nanoprecise provides accurate prognostic and diagnostic solutions that predict the remaining useful life of any asset at any point during its lifetime, thereby empowering users with the right data across several industries.
Nanoprecise works with customers across the world, in diverse sectors, to prevent catastrophic failures, saving time & money. Machine-Doctor™ sensors and RotationLF™ platform from Nanoprecise provides accurate diagnostics to customers across sectors such as steel, oil & gas, metals, mining, chemicals and pharmaceuticals among others, to help the maintenance teams identify the potential issues that could cause catastrophic failures. Nanoprecise continues to build trust with our customers by allowing the maintenance and reliability teams to identify problems and ensure that they are getting to the root cause. Reach out to Nanoprecise for wireless condition monitoring services to ensure zero downtime and maximize the efficiency of your machines

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    Frequently Asked Questions

    An effective condition monitoring and maintenance system will help prevent catastrophic failures that can cause serious downtime and worker safety issues.

    Equipment damage and resultant downtime leading to lost production is one of the most crucial risks that need to be mitigated, to gain a competitive advantage in today’s marketplace. Condition monitoring helps to reduce these risks significantly by identifying changes in the machine that can result in potential failures.

    The advantages of condition monitoring include reduced unplanned downtime, improved availability of machines, improved worker safety and better productivity as well as lesser time spent on maintenance.

    Monitoring different aspects of a machine or equipment set such as lubricant/oil analysis, acoustic emissions, surface temperature, RPM, Vibration, Magnetic Flux, etc. to gain a clear picture of the current condition of the machines, are some examples of condition monitoring.