An online condition monitoring preventive maintenance schedule lists the checks and jobs done on the equipment at fixed intervals, how long each takes, and in what order of frequency, so problems are found before the online condition monitoring fails. This page gives the schedule used in the PlantOps360 task library for online condition monitoring (: vibration, temperature and oil sensors), which follows common industry practice for general-purpose equipment. It is also searched for as vibration monitoring, condition monitoring, vibration sensor, accelerometer.
The maker’s manual and your site safety procedures always come first where they differ. Intervals set by law differ by state.
Online condition monitoring preventive maintenance schedule and checklist
| How often | Task | Estimated time |
|---|---|---|
| Weekly | Review alarms and trends of critical machines; check sensor status | 15 min |
| Monthly | Check sensor mountings and cables; check the data collector or gateway | 30 min |
| Quarterly | Verify machine baselines with a portable analyser; check alarm limits | 60 min |
| Half-yearly | Check sensor sensitivity and connections; update the software | 120 min |
| Annual | Calibrate instruments and portable analysers; review by a certified analyst | 240 min |
Online condition monitoring maintenance frequency and yearly workload
At the estimated times, one online condition monitoring needs about 31 hours of preventive maintenance a year. The biggest single job is “Calibrate instruments and portable analysers; review by a certified analyst” at 240 minutes, done annual. Multiply by the number of units you have to see the workload for your plant.
| Frequency | Tasks | Time per round | Hours per year |
|---|---|---|---|
| Weekly | 1 | 15 min | 13.0 h |
| Monthly | 1 | 30 min | 6.0 h |
| Quarterly | 1 | 60 min | 4.0 h |
| Half-yearly | 1 | 120 min | 4.0 h |
| Annual | 1 | 240 min | 4.0 h |
What goes wrong on an online condition monitoring without preventive maintenance
- Loose sensor mountings and damaged cables
- Alarm limits left unreviewed
- Baselines out of date
- Data collection gaps
What to watch between services
- Alarms and trends on critical machines
- Sensor mountings and cables
- Baseline checks with a portable analyser
Safety and statutory notes for online condition monitoring maintenance
A monitoring system only pays off if its alarms are acted on. Record what each alarm led to.
Where an online condition monitoring preventive maintenance schedule is used
This equipment is used in the industries below. Each link opens the preventive maintenance schedule guide for that industry, and the maintenance software page where we have one.
- Preventive maintenance schedule for automotive plants · maintenance software for automotive
- Preventive maintenance schedule for engineering and fabrication shops
- Preventive maintenance schedule for electronics manufacturing plants · maintenance software for electronics
- Preventive maintenance schedule for pharmaceutical plants · maintenance software for pharmaceutical · maintenance software for api bulk drugs
- Preventive maintenance schedule for chemical, fertiliser and petrochemical plants · maintenance software for chemical
- Preventive maintenance schedule for food, dairy and beverage plants · maintenance software for food processing · maintenance software for dairy
- Preventive maintenance schedule for agro, grain, edible oil and sugar plants · maintenance software for sugar and distilleries
- Preventive maintenance schedule for fmcg and consumer goods plants · maintenance software for fmcg
- Preventive maintenance schedule for packaging, paper and printing plants · maintenance software for packaging · maintenance software for paper and pulp
- Preventive maintenance schedule for plastics, rubber and polymer plants · maintenance software for plastics · maintenance software for tyre and rubber
- Preventive maintenance schedule for textile and garment mills · maintenance software for textile
- Preventive maintenance schedule for steel, foundry, forging and metal plants · maintenance software for steel and metals
- Preventive maintenance schedule for cement, glass, ceramics and building materials plants · maintenance software for cement
- Preventive maintenance schedule for mines and mineral processing plants · maintenance software for mining
- Preventive maintenance schedule for oil, gas and refinery facilities · maintenance software for oil and gas
- Preventive maintenance schedule for thermal and hydro power plants · maintenance software for power plants
- Preventive maintenance schedule for solar, wind and renewable energy plants · maintenance software for renewable energy
- Preventive maintenance schedule for water and wastewater utilities
- Preventive maintenance schedule for railways, metro, airports and depots
Related equipment maintenance schedules
- Pressure and temperature instrument preventive maintenance schedule
- Flow meter or level instrument preventive maintenance schedule
- Online process analyser preventive maintenance schedule
- Weighbridge, platform scale preventive maintenance schedule
- PLC, DCS, SCADA preventive maintenance schedule
- Laboratory balance preventive maintenance schedule
- Laboratory fume hood preventive maintenance schedule
- Materials testing machine preventive maintenance schedule
Browse the full list of equipment preventive maintenance schedules (317 types).
Run this online condition monitoring schedule in maintenance software
In preventive maintenance software, each row above becomes a recurring task on the asset with its checklist, time estimate and parts. Tasks can be triggered by calendar date, running hours, meter readings or production cycles, each completed task is recorded with the person and date, and a failed check can open a work order. For the method behind it, read the guide to the preventive maintenance schedule, or use the free generator to get a 12-month plan for your whole equipment list.
Build my preventive maintenance schedule (free Excel)
Frequently asked questions
How often should an online condition monitoring be serviced?
In our schedule an online condition monitoring has 5 tasks: 1 weekly, 1 monthly, 1 quarterly, 1 half-yearly, 1 annual. The biggest job is “Calibrate instruments and portable analysers; review by a certified analyst”, which is done annual. Always follow the maker’s manual where it gives a different interval.
What is included in online condition monitoring preventive maintenance?
It covers routine checks and jobs such as “Review alarms and trends of critical machines; check sensor status”, “Check sensor mountings and cables; check the data collector or gateway”, “Verify machine baselines with a portable analyser; check alarm limits”, up to the annual overhaul or inspection. The full list with times is in the table above.
How many hours of maintenance does an online condition monitoring need per year?
About 31 hours per unit per year at the estimated times in our library, including all scheduled rounds. Use it to plan workload, not as a benchmark.
Is there a free online condition monitoring maintenance checklist?
Yes. The table on this page is a ready checklist. The free preventive maintenance schedule generator turns it into a 12-month Excel schedule for your list of equipment, with monthly workload hours.