Condition based maintenance (CBM) in the process industry helps in determining the residual life of equipment, avoiding sudden breakdown and facilitating the maintenance staff to schedule repairs by optimizing demand–supply relationships. One of the prevalent issues in CBM is to predict the residual life of the equipment. This paper proposes a novel framework to predict the remnant life of the equipment, called residual life prediction, based on optimally parameterized wavelet transform and multi-step support vector regression (RWMS). In optimally parameterized wavelet transform, a generalized criterion is proposed to select the wavelet decomposition level which works for all the applications; decomposition nodes are selected by characterizing their dominancy level based upon relative fault signature–signal energy contents. The prediction model is based on multi-step support vector regression to determine the nonlinear crack propagation in the rotary machine according to Paris’s fatigue model. The results both for the simulated as well as the actual vibration datasets validate the enhanced performance of RWMS in comparison with the existing techniques to predict the residual life of the equipment.
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