# Condition Monitoring Route Template

> Source: https://netray.co/tools/condition-monitoring-route-template
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

Generate a route sheet that lists assets, measurement points, techniques, alarm limits and sign off so a technician can walk it and record readings.

## Category

maintenance

## Industry

Process and Discrete Manufacturing

## Audience

- Reliability engineer
- Condition monitoring technician
- Maintenance supervisor

## Tool

**Kind:** template

**Output:** document

**Fields:**

#### Company or plant

**Key:** company

**Type:** text

**Default:** Acme Precision Plant 2

#### Route name

**Key:** route_name

**Type:** text

**Default:** Route 04 - Utilities and Pumps

#### Area

**Key:** area

**Type:** text

**Default:** Utilities building

#### Technician

**Key:** technician

**Type:** text

**Default:** J. Rivera

#### Route date

**Key:** date

**Type:** date

**Default:** 2026-10-20

#### Route frequency

**Key:** frequency

**Type:** select

**Options:**

- Weekly
- Every 2 weeks
- Monthly
- Quarterly

**Default:** Monthly

#### Instrument and serial

**Key:** instrument

**Type:** text

**Default:** Handheld analyzer SN 20481

#### Route safety notes

**Key:** notes

**Type:** textarea

**Default:** Wear hearing protection near compressors. Do not remove guards. Lock out before any contact with rotating parts.

**Blocks:**

#### Condition Monitoring Route Sheet

**Body:** Company: {{company}}
Route: {{route_name}}
Area: {{area}}
Technician: {{technician}}
Date: {{date}}
Frequency: {{frequency}}
Instrument: {{instrument}}

#### Safety and access notes

**Body:** {{notes}}

#### Measurement points

**Table:**

**Columns:**

- Asset
- Point
- Technique
- Alert
- Danger
- Reading
- OK?

**Rows:**

**0:** Cooling pump P-101

**1:** Motor DE horizontal

**2:** Vibration velocity mm/s RMS

**3:** 2.8

**4:** 4.5

**0:** Cooling pump P-101

**1:** Pump DE horizontal

**2:** Vibration velocity mm/s RMS

**3:** 2.8

**4:** 4.5

**0:** Cooling pump P-101

**1:** Motor DE bearing

**2:** Temperature deg C

**3:** 75

**4:** 90

**0:** Compressor K-3

**1:** Gearbox casing

**2:** Ultrasound dB

**0:** Compressor K-3

**1:** Main motor

**2:** Infrared thermography

**0:** Fan F-5

**1:** Fan NDE vertical

**2:** Vibration velocity mm/s RMS

**3:** 4.5

**4:** 7.1

#### Observations

**Body:** Record leaks, noise, odour, loose guards, oil level, oil colour and anything unusual:

#### Follow up actions

**Table:**

**Columns:**

- Asset
- Finding
- Action
- Notification no.
- Priority

**Rows:**

#### Sign off

**Signatures:**

- Technician
- Reliability engineer
- Maintenance supervisor

**Notes:** Example limits are placeholders. Replace them with limits from the machine builder, ISO 10816 or your own baseline data. Measure at the same points, in the same direction and at similar operating conditions every time.

## Content

**Intro:** A condition monitoring route is the list of machines and measurement points a technician walks on a fixed cycle. This template builds a printable route sheet with limits, space for readings and a follow up section.

**Sections:**

#### How to use the template

**Body:** Fill in the plant, route name, area, technician and instrument, then edit the table rows to match your assets. Each row is one measurement point and one technique. Keep the points in walking order to save time, and group by area. Export the sheet to PDF for the clipboard, or to Word or Excel for a version your team can keep editing. After the route, enter any findings in the follow up table with the notification number from your maintenance system.

**Bullets:**

- One row per point per technique
- Order the rows in the physical walking sequence
- Mark point locations on the machine with paint or a tag
- Keep the route length to what a person can finish in a shift

#### Choosing techniques and frequency

**Body:** Vibration analysis suits rotating equipment, ultrasound finds friction, leaks and electrical discharge, infrared thermography shows hot connections and bearings, and oil analysis covers gearboxes and hydraulics. Frequency should be shorter than the P-F interval of the failure you want to catch. Critical machines in a harsh duty may be monthly or even continuously monitored, while a lightly loaded spare pump may be quarterly.

#### Alert and danger limits

**Body:** Start from published limits, such as ISO 10816 zones for vibration, and then adjust after you have a baseline of at least several readings on a healthy machine. Many teams set alert at about 1.5 to 2 times baseline and danger at the zone C/D boundary. Always compare to the previous reading as well, because a fast rise is a warning even when the value is below the limit.

#### Common mistakes

**Body:** Changing the measurement point or direction between visits makes trends meaningless. Taking readings while the machine is at a different load or speed has the same effect. Another problem is collecting data that nobody reviews: assign a reviewer and a deadline. Finally, make sure that findings become work requests in the CMMS, not just notes on paper.

**Cta:** If you want route results loaded into your ERP maintenance module and exceptions raised as notifications automatically, Netray can help design that integration.

**Faq:**

#### What is a condition monitoring route?

**Answer:** It is a defined sequence of machines and measurement points that a technician visits at a set interval, collecting data such as vibration, temperature or ultrasound. The readings are trended to detect developing faults before they cause failure.

#### How many points should be on one route?

**Answer:** Enough for one technician to finish within a shift with time to review findings. A common range is 50 to 150 points depending on how many machines are close together and which techniques are used. Split larger plants into several routes.

#### How do I set alarm limits for new machines?

**Answer:** Use the standard or manufacturer limits at first, then record baseline readings during healthy operation. After a few visits, set alert and danger levels relative to the baseline and the standard, and review them whenever the machine is rebuilt.

#### Can I use this for oil analysis or thermography?

**Answer:** Yes. Change the technique column and the limits column to suit, for example particle count code, water ppm or temperature rise over ambient. The layout works for any technique that has a point, a reading and a limit.

## Search terms

condition monitoring route template, vibration route sheet, predictive maintenance route template, condition monitoring checklist, data collection route form, vibration data collection route, condition based maintenance form, pdm route sheet word

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