Condition Monitoring Route Template
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.
Fill in
Condition Monitoring Route Template
Condition Monitoring Route Sheet
Company: Acme Precision Plant 2 Route: Route 04 - Utilities and Pumps Area: Utilities building Technician: J. Rivera Date: 2026-10-20 Frequency: Monthly Instrument: Handheld analyzer SN 20481
Safety and access notes
Wear hearing protection near compressors. Do not remove guards. Lock out before any contact with rotating parts.
Measurement points
| Asset | Point | Technique | Alert | Danger | Reading | OK? |
|---|---|---|---|---|---|---|
| Cooling pump P-101 | Motor DE horizontal | Vibration velocity mm/s RMS | 2.8 | 4.5 | ||
| Cooling pump P-101 | Pump DE horizontal | Vibration velocity mm/s RMS | 2.8 | 4.5 | ||
| Cooling pump P-101 | Motor DE bearing | Temperature deg C | 75 | 90 | ||
| Compressor K-3 | Gearbox casing | Ultrasound dB | ||||
| Compressor K-3 | Main motor | Infrared thermography | ||||
| Fan F-5 | Fan NDE vertical | Vibration velocity mm/s RMS | 4.5 | 7.1 |
Observations
Record leaks, noise, odour, loose guards, oil level, oil colour and anything unusual:
Follow up actions
| Asset | Finding | Action | Notification no. | Priority |
|---|---|---|---|---|
Sign off
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.
Load route results into your ERP
Optional review of how to turn route readings into measurement documents and notifications.
Optional. The tool and every export work without this. No spam.
How to use the template
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.
- 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
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
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
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.
Frequently Asked Questions
What is a condition monitoring route?
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?
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?
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?
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.
If you want route results loaded into your ERP maintenance module and exceptions raised as notifications automatically, Netray can help design that integration.
Related Tools
Vibration Severity ISO 10816 Zone Reference
Look up the A/B, B/C and C/D zone boundaries in mm/s RMS for ISO 10816 machine classes and groups, with a plain-language note on what each zone means.
Maintenance & ReliabilityBearing Defect Frequency Calculator (BPFO, BPFI, BSF, FTF)
Enter shaft speed, ball count, ball and pitch diameter and contact angle to get the four bearing fault frequencies in Hz for spectrum analysis.
Maintenance & ReliabilityP-F Interval Calculator
Use the P-F interval to set condition-based inspection frequency, check the chance of catching a failure and see if you have time to react.
Maintenance & ReliabilityLubrication Schedule Worksheet
Build a lubrication schedule with points, lubricant, method, quantity and interval, and see annual lubricant consumption per line and in total.
Maintenance & ReliabilityCondition Monitoring Program Readiness Assessment
Answer 10 questions about assets, data, skills and follow through to see how ready your plant is for a predictive maintenance program.
More Maintenance & Reliability tools
See all- Motor Efficiency and Energy Cost Calculator
- Compressed Air Leak Cost Calculator
- MTBF and MTTR Worksheet
- TPM Autonomous Maintenance CIL Standard Template
- TPM Autonomous Maintenance Standard Template
- TPM Pillars and Autonomous Maintenance 7 Steps Reference
- Preventive Maintenance Schedule Template
- Maintenance Work Order Template
- Inherent vs Operational Availability Calculator (MTBF, MTTR)