7 Condition Monitoring Techniques: Use Cases, Pros & Cons

Unplanned equipment failures drain your budget and halt production. When a compressor seizes or a motor burns out without warning, you face emergency repairs at premium rates plus lost revenue from downtime. For BioMethane projects where uptime directly affects cash flow and carbon credit generation, reactive maintenance is too expensive. You need early warning systems that catch problems before they escalate.

This guide walks you through seven condition monitoring techniques used in BioGas and BioMethane operations. You'll learn what each method detects, which assets benefit most, and the tradeoffs between cost and insight. We start with integrated plantwide monitoring for complete systems, then cover targeted techniques like vibration analysis, thermography, oil testing, ultrasonic inspection, electrical monitoring, and process trending. By the end, you'll know how to match the right monitoring approach to your equipment and operational priorities.

1. Plantwide integrated monitoring (99pt5)

Most condition monitoring techniques focus on individual components like a single bearing or motor. Plantwide integrated monitoring tracks the entire system as one interconnected unit, monitoring critical parameters at key process points to catch problems anywhere in your operation before they cascade through downstream equipment.

What plantwide monitoring means

This approach connects data streams from multiple equipment types into a single view of system health. Your BioGas upgrading train includes desulphurization, compression, membrane separation, and drying stages working in sequence. Traditional monitoring would instrument each component individually, creating data silos that require multiple specialists to interpret. A plantwide approach instead tracks flow rates, pressures, temperatures, and gas quality at strategic locations to reveal how the entire system performs together.

How 99pt5 enables condition monitoring

The BioTreater™ system includes built-in sensors throughout the processing chain integrated through BioView™ software. You monitor everything from digester outlet to point of sale via a smartphone app. The system tracks inlet gas composition, compressor discharge pressures, membrane differential pressures, oxygen levels post-catalytic reactor, and final BioMethane purity. Immediate alerts arrive before equipment degrades or output quality drops below specification limits.

Integrated monitoring catches systemic issues that component-level checks miss, like gradual H2S catalyst saturation affecting downstream oxygen removal efficiency.

When this approach makes sense

This monitoring strategy works best when you need guaranteed performance across the complete upgrading process. BioMethane producers facing strict grid injection specifications or carbon credit verification benefit most from this comprehensive view. You want plantwide monitoring when your revenue depends on consistent output quality and uptime, not just keeping individual machines running. Small to mid-size operations gain the most value because you avoid hiring specialists for multiple monitoring disciplines.

Key pros for BioMethane projects

Plantwide monitoring delivers lower total cost of ownership by eliminating redundant sensors and consolidating data platforms. You spot efficiency losses system-wide like pressure drops indicating membrane fouling before flow rates drop noticeably. The approach reduces training requirements because operators learn one interface instead of multiple diagnostic tools. For projects with performance guarantees, integrated monitoring provides documented proof of 99.5% BioMethane recovery and emission reduction targets that component-level checks cannot verify.

Limitations and watchouts

The main limitation is reduced diagnostic depth for specific components. When a compressor shows abnormal behavior, plantwide monitoring flags the symptom but you still need specialized vibration analysis to pinpoint bearing wear or misalignment. You also face vendor lock-in if the integrated system uses proprietary sensors or data formats. Initial setup requires accurate baseline establishment across all monitored parameters, which takes time during commissioning to establish normal operating ranges.

2. Vibration monitoring

Rotating equipment generates characteristic vibration patterns during normal operation. When bearings wear, shafts misalign, or components loosen, vibration frequencies and amplitudes change in measurable ways. Vibration monitoring captures these changes through sensors that detect mechanical oscillations and convert them into diagnostic data showing equipment health.

What vibration monitoring detects

This technique catches problems like bearing defects, shaft imbalance, and gear wear months before they cause catastrophic failure. You'll spot misalignment between coupled components, loose mounting bolts, and cavitation in pumps or compressors. The method also reveals resonance issues where operating speeds match natural frequencies, causing excessive stress on mechanical structures.

Sensor types and data collection

Accelerometers mounted on bearing housings measure vibration velocity and acceleration across different frequency ranges. You collect data through handheld instruments during periodic routes or via permanently installed sensors that transmit continuous readings. Advanced systems perform frequency analysis to identify specific fault signatures, while simpler approaches track overall vibration levels against baseline thresholds.

Best assets and use cases

BioGas boosters, recirculation blowers, and membrane skid motors are prime candidates for vibration monitoring. Any equipment with rotating elements benefits, especially high-speed compressors in upgrading systems where bearing failure causes expensive downtime. You get maximum value on critical path equipment where unplanned failures halt production.

Vibration analysis identifies 70% of mechanical faults three to six months before failure, giving you time to schedule repairs during planned maintenance windows.

Pros of vibration monitoring

This approach delivers early fault detection with minimal training required for basic trending. You avoid opening equipment for inspection because non-invasive sensors detect internal problems externally. The technology works on most rotating machinery regardless of manufacturer, and proven diagnostic rules eliminate guesswork when interpreting data patterns.

Cons and common pitfalls

False alarms occur when external vibrations from adjacent equipment contaminate readings or when you mount sensors incorrectly. Low-speed machinery below 300 RPM produces weak vibration signals that require expensive ultra-sensitive accelerometers. You need baseline data from healthy equipment to establish alarm thresholds, which delays full implementation on new installations.

3. Infrared thermography

Thermal imaging captures heat patterns across equipment surfaces without physical contact. Temperature variations reveal problems like loose electrical connections, worn bearings, and insulation breakdown. You point an infrared camera at your equipment and receive instant visual feedback showing hot spots that indicate friction, electrical resistance, or thermal stress.

What thermography reveals

This technique exposes electrical faults before they spark fires and mechanical issues causing abnormal heat buildup. You'll detect bearing failures through temperature rises at journal housings, find leaking seals by spotting cold zones from escaping gas, and identify failing insulation on steam lines. The method also catches phase imbalances in three-phase motors and overloaded electrical panels.

How thermal inspections work

You conduct surveys using handheld thermal cameras that convert infrared radiation into visible heat maps. Most inspections happen during operation when equipment carries normal thermal loads. You establish baseline thermal profiles during commissioning, then compare subsequent scans against these references to spot deviations. Advanced software quantifies temperature differences and generates reports with thermal images overlaid on visual photos.

Best assets and use cases

BioGas compressors, electrical distribution panels, and motor control centers benefit most from thermal monitoring. You gain value on equipment inaccessible for contact measurements and gear reducers with hidden bearing assemblies. Critical heating elements in H2S removal systems warrant regular thermal checks because catalyst bed temperature affects desulphurization efficiency.

Thermal imaging detects electrical connection problems six months before they fail, preventing fires and unplanned shutdowns in BioMethane facilities.

Pros of thermographic monitoring

This approach provides non-contact measurement that works while equipment operates at full load. You survey large areas quickly, inspecting dozens of components per hour. The visual output requires minimal interpretation training compared to vibration frequency analysis, and you need no baseline data for obvious problems like glowing hot connections.

Cons and practical limits

Environmental factors like wind, rain, and reflected sunlight distort readings and create false positives. You miss internal faults if equipment housings insulate heat from external surfaces. The method requires clear line of sight to components, making it useless for buried pipes or enclosed assemblies. Surface emissivity variations between materials cause measurement errors without proper calibration corrections.

4. Oil and lubricant analysis

Lubricants carry microscopic evidence of machinery health as they circulate through equipment. Metal particles from worn bearings, oxidized compounds from heat stress, and contaminants like water or fuel dilution accumulate in oil samples. Laboratory testing reveals this hidden story of component degradation before you see symptoms in equipment performance.

What oil analysis tells you

Lab reports quantify wear metal concentrations that indicate bearing erosion, gear tooth damage, or cylinder liner scuffing. You learn about oil condition through viscosity tests, acid numbers, and oxidation levels that predict remaining service life. Contamination analysis exposes coolant leaks, dust ingress, or fuel seepage degrading lubrication quality.

Sampling and testing methods

You draw samples from circulation systems through designated sampling ports during normal operation when oil carries representative debris. Send samples to labs for spectrographic analysis that identifies metal types and concentrations, particle counting that measures debris size distribution, and viscosity testing that confirms lubrication properties. Some operations use portable test kits for basic checks between comprehensive lab analyses.

Oil analysis detects gearbox failures up to twelve months early by tracking iron particle accumulation from gear tooth micro-pitting.

Best assets and use cases

BioGas compressor gearboxes, hydraulic systems on digester mixers, and high-speed reciprocating engines benefit most from oil analysis. You target equipment where oil changes cost more than testing and machinery running 24/7 without scheduled shutdowns. This condition monitoring techniques approach suits assets with large oil reservoirs where contamination develops gradually.

Pros of oil based monitoring

This method provides trend data spanning years that reveals gradual degradation patterns. You reduce unnecessary oil changes by confirming actual condition instead of following arbitrary time intervals. The approach catches multiple fault types simultaneously through one sample.

Cons and implementation challenges

Results arrive days after sampling, delaying response to urgent problems. You need consistent sampling procedures because contaminated samples from improper collection techniques produce false wear readings. Interpreting trends requires expertise when multiple contaminants appear together.

5. Ultrasonic and acoustic monitoring

High-frequency sound waves above human hearing range reveal equipment faults through ultrasonic emissions that escape during leaks, friction events, and electrical discharge. You detect these signals with specialized sensors that convert ultrasound into audible frequencies for analysis. This condition monitoring techniques approach catches problems that produce little vibration or heat but generate characteristic acoustic signatures.

What ultrasound monitoring detects

Ultrasonic sensors identify compressed air and gas leaks by picking up turbulent flow noise at leak points. You catch bearing lubrication failures through friction sounds before temperature rises, detect electrical arcing in switchgear through corona discharge, and find steam trap malfunctions. The method also reveals cavitation in pumps and hydraulic system internal leaks that waste energy without visible symptoms.

Airborne vs structure borne techniques

Airborne ultrasound uses directional microphones to locate gas leaks and electrical faults from several meters away. You scan equipment externally without contact, making this approach ideal for pressurized systems and energized electrical components. Structure-borne methods employ contact sensors that detect ultrasound traveling through solid materials, catching internal bearing friction and valve seat leakage that airborne sensors miss.

Best assets and use cases

BioGas pipeline networks, pneumatic control systems, and membrane separation skids benefit most from ultrasonic leak detection. You gain value on electrical distribution equipment where arcing precedes catastrophic failures and slow-speed bearings that generate weak vibration signals. Hydrogen sulfide removal systems warrant regular ultrasonic checks because small leaks pose safety hazards.

Ultrasonic leak detection identifies compressed air losses that cost facilities 20 to 30 percent of compressor energy consumption annually.

Pros of ultrasonic methods

This approach provides real-time fault location during inspections without shutting down equipment. You need minimal training to operate basic leak detectors, and portable instruments cost less than vibration analysis systems. The technology works in noisy environments because ultrasonic frequencies sit above ambient industrial noise.

Cons and false alarm risks

Background ultrasound from adjacent equipment creates false leak indications when you scan densely packed pipe racks. You miss intermittent problems during brief inspections, and interpretation requires experience to distinguish bearing defects from normal operational sounds. Wind noise interferes with outdoor measurements.

6. Motor and electrical monitoring

Electric motors and control systems power critical equipment throughout BioMethane operations. Motor circuit analysis and electrical testing reveal insulation degradation, winding faults, and power quality issues before they cause fires or equipment damage. You measure electrical parameters like current draw, voltage balance, and resistance to assess motor health without opening housings or disconnecting power feeds.

What motor and electrical checks cover

This condition monitoring techniques category tracks motor winding integrity through insulation resistance tests that detect moisture ingress and thermal aging. You monitor current signatures that reveal rotor bar cracks, stator faults, and bearing problems through changes in electrical patterns. Power quality analysis exposes voltage imbalances, harmonic distortion, and phase losses that reduce motor efficiency and shorten lifespan.

Key tests and sensors

Megohmmeter testing measures insulation resistance between windings and ground to predict insulation failure months in advance. Current transformers and voltage sensors capture real-time power consumption patterns that indicate mechanical loads and electrical faults. Motor circuit analysis equipment performs offline tests including surge testing, inductance measurements, and phase angle verification to assess overall motor condition.

Best assets and use cases

BioGas compressor motors, membrane skid drive systems, and recirculation blower motors warrant electrical monitoring because failures halt production immediately. You target three-phase motors above 10 horsepower where replacement costs exceed monitoring expenses and critical path equipment without installed spares.

Electrical monitoring detects motor insulation breakdown six to twelve months early, preventing catastrophic failures that destroy windings and require complete motor replacement.

Pros for safety and uptime

This approach catches fire hazards from loose connections and overheated circuits before they ignite. You avoid opening energized panels for visual inspection because sensors capture data remotely. The method validates motor efficiency, helping you identify units wasting energy through electrical losses.

Cons and data complexity

Interpreting current signatures requires specialized training and software to distinguish electrical faults from mechanical problems. You face interference from variable frequency drives that distort waveforms and complicate analysis. Offline testing requires brief motor shutdowns.

7. Process and gas quality trending

BioGas composition and processing conditions drift gradually over time as feedstocks change and equipment ages. Process trending tracks operational parameters continuously to detect slow degradation that escapes snapshot inspections. You establish baseline performance during commissioning, then monitor deviations that signal developing problems before output quality drops or equipment efficiency declines.

Parameters you should trend

BioMethane purity at the outlet tells you whether membrane separation maintains specification or catalyst beds need regeneration. Track inlet H2S concentrations because rising sulfur levels overload desulphurization systems and poison downstream catalysts. Differential pressure across membrane modules reveals fouling that reduces throughput, while oxygen content post-catalytic reactor confirms removal efficiency.

Tools and sensor setup

Most BioGas upgrading systems include inline gas analyzers that measure methane, CO2, oxygen, and H2S continuously. Pressure and temperature transmitters at strategic process points feed data to SCADA systems or dedicated monitoring platforms like BioView™. You need data historians that store trends spanning months to reveal seasonal patterns and long-term degradation.

Best assets and use cases

This condition monitoring techniques approach suits complete upgrading systems where multiple process stages interact. You gain value on operations facing strict grid injection standards because trending proves compliance over time. Projects with performance guarantees benefit most because historical data documents system efficiency against contractual commitments.

Process trending identifies catalyst degradation three months before BioMethane purity drops below grid specifications, allowing scheduled regeneration during planned maintenance.

Pros of process trending

This method catches systemic efficiency losses that component checks miss, like gradual membrane fouling reducing recovery rates. You optimize operations by correlating process variables with output quality and energy consumption patterns. The approach provides documented proof of guaranteed performance for carbon credit verification.

Cons and data quality issues

Sensor drift creates false trends if you skip regular calibration checks. You face data overload when tracking dozens of parameters without clear alarm thresholds. Seasonal feedstock variations complicate baseline establishment because normal ranges shift throughout the year.

Bringing your strategy together

You don't need to implement all seven condition monitoring techniques immediately. Start by identifying your highest-value assets where failures cause the most disruption and financial loss. BioGas compressors and critical motors typically top this list. Match each asset to the technique catching its most likely failure modes: vibration for rotating equipment, thermography for electrical systems, and process trending for system health.

Integrated plantwide monitoring through systems like the BioTreater™ provides comprehensive coverage with lowest administrative overhead. You track multiple parameters through one interface while maintaining guaranteed performance metrics across your entire operation. Projects requiring verified carbon credits and consistent grid-quality output gain most value from this unified approach.

Ready to implement monitoring that delivers guaranteed 99.5% BioMethane recovery? Explore how 99pt5's BioTreater™ system combines built-in monitoring with proven petroleum industry reliability.