25.1 Introduction

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Approximately half of all operating costs in most processing and manufacturing operations can be

attributed to maintenance. This is ample motivation for studying any activity that can potentially lower

these costs. Machine condition monitoring and fault diagnostics is one of these activities. Machine

condition monitoring and fault diagnostics can be defined as the field of technical activity in which

selected physical parameters, associated with machinery operation, are observed for the purpose of

determining machinery integrity. Once the integrity of a machine has been estimated, this information

can be used for many different purposes. Loading and maintenance activities are the two main tasks that

link directly to the information provided. The ultimate goal in regard to maintenance activities is to

schedule only what is needed at a time, which results in optimum use of resources. Having said this, it

should also be noted that condition monitoring and fault diagnostic practices are also applied to improve

end product quality control and as such can also be considered as process monitoring tools.

This definition implies that, while machine condition monitoring and fault diagnostics is being

treated as the focus of this chapter, it must also be considered in the broader context of plant

operations. With this in mind, this chapter will begin with a description of what is meant by

machinery failure and a brief overview of different maintenance strategies and the various tasks

associated with each. A short description of different vibration sensors, their modes of operation,

selection criteria, and placement for the purposes of measuring accurate vibration signals will then

follow. Data collection and display formats will be discussed with the specific focus being on standards

common in condition monitoring and fault diagnostics. Machine fault detection and diagnostic

practices will make up the remainder of the chapter. The progression of information provided will be

from general to specific. The hope is that this will allow a broad range of individuals to make effective

use of the information provided.

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