Condition monitoring: Developing a strategy for the future

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To benefit from the real power of CM, it must form part of a company-wide asset management programme. Integration now provides the maintenance scheduler and planner the ability to prioritise work and gives objective feedback on the quality of work carried out. Focusing only on what needs to be maintained, with minimal effect on output, offers the greatest opportunity for productivity.

The British Institute of Non-Destructive Testing (BINDT) is the professional institute for all those engaged in CM and non-destructive testing (NDT). It is concerned with the education and training of its members and the advancement of the science and practice of the subjects. BINDT manages the CM activity through its Condition Monitoring Technical Committee (CMTC).

Working groups

A key aim of the CMTC is to provide a distinct forum within BINDT that concerns itself with all aspects of CM whilst also appealing to everyone interested in the science, technologies, practice and benefits of CM. The Committee promotes best practice and the exchange of knowledge within the CM, diagnostic and prognostic community worldwide.  The CMTC oversees six main working groups, which are active in specialist areas and generally meet four times a year.

The Infrared Thermography Working Group (IRTWG) was formed in 2001 to undertake the development of the new International Standard ISO 18436.

The Vibration Analysis Working Group (VAWG) was then formed in 2002 and now manages and organises the training programme and examinations for vibration analysis practitioners and provides а continuous review of the question bank for the training and examinations available.

In 2004, the Acoustic Emission Working Group (AEWG) was formed to undertake the development of PCN training in acoustic emission (AE) and was originally responsible for writing the examination questions in AE for the BINDT PCN question bank.

The Lubrication Analysis Working Group (LAWG) was also formed in 2004 and was similarly responsible for writing the examination questions in LA.

The General Condition Monitoring Working Group (GCMWG) was formed in 2019 to undertake the development of PCN training in general CM and to provide a basis for the verification of existing competencies in all industries, whilst also providing a platform for the development of the CM role within industry at higher levels.

Danny Shorten, Chair of the GCMWG, said: “The GCMWG is currently in the process of creating a scheme called ‘Overseeing a General Condition Monitoring Programme’. On completion of the programme, operators will be certificated as a ‘Condition Monitoring Category 2 Practitioner’. One of the aims of the GCMWG is to develop a training scheme to provide knowledge to those that oversee a CM programme. The working group has developed the documentation for this, including the training syllabus, and will submit this to the International Organization for Standardization (ISO) to create a new part of the 18436 training series standards. The applications for the training of this group could be applied to everything from factories to ships; as the name implies, it is ‘General Condition Monitoring’.”

2019 also saw the formation of the Ultrasonic Working Group (USWG) to undertake the development of PCN training in ultrasonic condition monitoring and is responsible for writing examination questions for the BINDT question bank.

Tom Murphy, Chair of the USWG, commented: “The USWG is currently in the process of creating an ultrasound training scheme that will be PCN certified to ISO 18436-8. The scheme will be called ‘Condition Monitoring and Diagnostic Personnel for Ultrasound’ and practitioners will be certificated to Ultrasound Category 1, 2 or 3. Over the course of the last two years, the working group has developed the PCN documentation required, created the Category 1 questions and exam papers and is currently in the process of creating the Category 2 questions. The group is also in the process of creating an expanded training programme to provide a more structured syllabus.”

Training schemes

Training schemes in the main CM methods are delivered by BINDT-approved training organisations (ATOs) at various levels and the examinations conducted by BINDT, resulting in the award of a recognised PCN certificate, are available in Categories 1 to 4, depending on the method chosen. Certification in this way provides the individual with an assurance level compliant to the relevant ISO 18436 standard.

Acoustic emission training and PCN examination is currently available at Category 1, with Category 2 and 3 expected to be available in due course.

Infrared thermography and lubrication analysis training and PCN examination are currently provided for Categories 1 and 2, with Category 3 also expected to be available in due course.

The ultrasound and general condition monitoring training schemes will be available in due course at Categories 1 and 2, with the ultrasound CM scheme additionally being available at Category 3.

Vibration analysis training is available at Categories 1, 2 and 3, with Category 4 training and associated examinations expected to be available in due course.

The CM PCN Scheme is operated by BINDT for the certification of proficiency of CM and NDT operators. Technicians and engineers practising CM and NDT play an important role in the quality chain in order to maximise the reliability of inspections. Achieving PCN certification provides assurances to employers of independence, impartiality and conformity to international standards of proficiency in CM and NDT. The PCN Scheme has built an excellent reputation over the many years it has operated and it has been adopted in countries around the world.

Following the successful launch of BINDT PCN online examinations in 2019, discussions are taking place to expand the training scheme to allow for virtual training and e-learning. This will enable the ATOs to provide more adaptable training solutions to meet customer needs. For example, training could take place one day a week or only in the mornings, providing a flexible approach that is entirely appropriate in the current working environment.

A new book from BINDT, titled: An Introduction to Condition Monitoring and Diagnostic Technologies, edited by Professor A Hope and Mr D Whittle, was launched at the start of 2021 and introduces the reader to the wide range of technologies that can be used for the CM and diagnostics of structures, plant and machinery through surveillance, monitoring and analysis and provides a useful background and introduction to the main condition monitoring technologies for those undertaking training and examination, and for researchers, academics, CM practitioners and those overseeing the asset management process.

Long-term strategy

A future long-term strategy for the CM working groups under consideration is the creation of an ‘introducing series’, which will be short media presentations and videos providing an overview of the various CM methods. The aim of this initiative is to provide information for those that have little knowledge of the field but would like to find out more about the world of CM, how it works and the technologies within. These tools can then be used as part of an outreach programme with the hope of increasing inclusivity and diversity and further cementing BINDT’s position as the focal point for CM.

Matthew Calver, CM Administrator at BINDT, summarised: "The Institute and its committees and volunteers are dedicated to providing the best CM scheme possible. To this end, we are adapting to both the existing world circumstances and the current industry feedback with the development of new certification schemes. We are looking forward to these exciting new developments and encourage you to learn more about them as information becomes available."

More information about BINDT’s condition monitoring activities, as well as the latest developments in industry and CM technologies, can be discovered at the CM2021 conference, which is taking place virtually from 14-18 June 2021, with the theme: ‘The Future of Condition Monitoring’. Further information about this prestigious event can be found at: www.cm-mfpt.org

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