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Objective Condition Monitoring Condition Monitoring Vibration Analysis Oil Analysis Thermal Analysis Ultrasound Analysis(CM)TechniquesTypesofmachinesMotorsPumps Fans Gearboxes Engines CompressorsSteam TurbinesGenerators Gas Turbines Hydro TurbinesRotatingOrReciprocating MachinesWhat type of MaintenanceDo we HaveProactivePredictiveReactivePPPrecision MaintenanceSupplierSpecificationsJob Planning/SchedulingFFTimeMachine Condition ChartEquipment PerformanceLubrication Excellence Precision Maintenanc Alignment, Balance,Select SuppliersSupplier SpecificatMetricsEquipment RankingRCMTPMRCA/FMEA RCDTraining ProgramsWritten ProceduresJob Planning/SchedulinCMMSetc.We are in hereCondition MonitoringConditionparameter significantmonitoringistheinprocessofmonitoringaaItofconditionmachinery,suchthatchange is indicative of a developing failure.isamajorcomponent ofPredictiveMaintenance(PdM).Theuseofconditionalmonitoringallowsto bemaintenancetobethescheduled,orotheractionstaken toavoidconsequencesoffailure,beforethefailure occurs.Condition MonitoringTechniquesAwiderange ofCondition monitoringtechniquesisavailablebecomein the industries over the worldandThesome have"standard"standardsinmanyindustries.technologies are:1)2)3)4)Vibration AnalysisOil Analysis Thermal Analysis Ultrasound AnalysisCondition MonitoringForyourPlantVibrationAnalysisOilAnalysisThermalAnalysisUltrasoundAnalysisIf you think thisis your plant, then yourplant is standonthis 4 technologiesVibration AnalysisWhatIsVibration?Vibration is a "back and forth" movement of a structure.referred to as a "cyclical" movementIt can also beVibrationAnalysisMorethan20yearsagosomeonemadethestatement,Thethevibrationsmachinespredictiveproduced in a machine are the best indication ofhealth. This statement still holds true today. Of all themaintenance(PdM)technologies, vibrationanalysisremains the best measure of machine health. This is true becausevibration monitoring can alert us to so many different conditionsthatmayindicatepotentialmachinefailures.Unbalance,misalignment, bearing faults, resonance, looseness, cavitations andelectrical problems are just a few of the many problems that can be detected with vibration monitoring.Common Problems thatVibrationGenerate1.2.3.4.5.6.7.8.9.MisalignmentUnbalanceWorn belts & pulleys Bearing Defects Hydraulic Forces Aerodynamic Forces Reaction Forces Reciprocating Forces Bent Shafts10.Rubbing11.Gear Problems12.Housing Distortion13.Certain Electrical Problems14.Frictional ForcesWhat we Measure forVibrationAnalysisPhase: In What Direction IsThe Movement. It also calledphase angle.Frequency: HowOften TheAmplitude: How Much MovementOccurs or severity of the vibration.Movement Occurs. How many"cycles" in a period of time: asecond or a minuteAmplitude measures as1. Displacement: mm, mils (0.001)2. Velocity: mm/sec, in/sec3. Acceleration: Gs (1g= Force ofgravity) or rms (root mean square)Unit: DegreeUnit: Cycle per second (Hz)Cycle per Minute (CPM)Vibration TransducerSensorsTransducersProbesWhat is it?AccelerometerCharge Type &VelocityTransducerDisplacementShaft RidersLine DriveConstant Voltage &Constant CurrentProximity Probes(Eddy Current Probes).It basically converts mechanical vibration toan electrical signalHow we Measure:ProbeOrientationHorizontal: A TransducerMounted Horizontally "Sees"Only Horizontal MovementVertical: A TransducerMounted Vertically "SeesOnly Vertical MovementAxial: Axial direction is always onthe parallel to the shaft axis.MountingDirectionRadialVerticalVerticalAxialRadial HorizontalHorizontalMountingDirectionVert.Vert.Hori.Hori.AxialAxialFor detail study ofvibration dynamics of machine vertical, horizontal and axial at each bearing locationFor monitoring one point per bearing and add axial whenThere is a thrust bearing or axial potential faults eg. misalignmentsMachinery Health MonitoringStrategyApplication at Typical PlantTotal # Machines 2,500Typical Industrial Process PlantTurbinesGeneratorsCompressors~125 Machines5%CriticalOnline Solutions forcritical machinery25%EssentialMotorsPumps Fans GearsWirelessTransmitters~1375 Machines30%Important20%Secondary~500 MachinesMulti TechnologiePortable Solutions20%Non-Essential~500 MachinesDateRepresentationFFT Spectrum PlotWave Form Plot or Domain PlotWaterfall PlotOrbit PlotFFTSpectrum Plot forProblemssomeMassUnbalanceMisalignmentStructural LoosenessBearing LoosenessStructural ResonanceSleeve BearingLooseness/RubsGear ProblemMisalignmentPump CavitationX=RPM=CPM1X=1xRPM=1xCPM2X=2xRPM=2xCPM3X=3xRPM=3xCPMCPM=Cycle per minute=60HzOil AnalysisOilAnalysisOIL . . . your engines lifeblood. . .can reveal its internal conditionWhatisOilAnalysisBlood TestOil AnalysisOil analysis is a quick, nondestructive way toof an engine by looking at what's in the oil. It medical blood test, where we can know about from our blood.gauge the healthis as like as our diseasesAll Test of Your Oil1.2.3.4.5.6.7.Elemental Analysis (Spectral Analysis)Particle count,Particle Shape AnalysisParts per million (PPM) distribution , ISO codes and ASTM standard FerrographyOil Chemistry ( Dielectric, TBN, TAN, Oxydation, Nitration, Sulfations, Glycol, Soot etc.)Water-in-oil,Viscosity8.9.10.Wear Debris Analysis (WDA)Elemental AnalysisNo.ElementSymbolReadoutRange in PPM1AluminumAl0-1,0002BariumBa5-6,0003BoronB0-1,0004CadmiumCd0-1,0005CalciumCa0-6,000CarbonCReference6ChromiumCr0-1,0007CopperCu0-1,000HydrogenHReference8IronFe0-1,0009LeadPb0-1,00010MagnesiumMg0-6,00011ManganeseMn0-1,00012MolybdenumMo0-1,00013NickelNi0-1,00014PhosphorusP10-6,00015PotassiumK0-1,00016SiliconSi0-1,00017SilverAg0-1,00018SodiumNa0-6,00019TinSn0-1,00020TitaniumTi0-1,00021VanadiumV0-1,00022ZincZn0-6,00023LithiumLi0-1,000Elemental Analysis Case StudyWear MetalTrendsonF-15F100-100 Engineiron wearmetal concentrationNo. 4 BearingMissing PartsFailure detected based onincrease inHoursReasonFeAgAlCrNiTiAction424R400011A426R402111A427R402111A428R402111A430R1102111B430R1202111G430L1202111TParticle Count and ShapeAnalysisNonmetallicFatigueWearCuttingWearSlidingWearParticle CountingParticle ShapeAnalysisFerrographyOil ChemistryEngine Hydraulic Synthetic Gas Compressor/ Gear/TurbineTurbine transmissionWater (ppm)Oxidation(abs/mm2)TAN (mg KOH/g)TBN (mg KOH/g)Alien fluid (%)Anti-OxidantAdditive (%)Anti-wear Additive(%)Nitration (abs/mm2)Sulfation (abs/mm2)Soot (%)Glycol (%)Wear Debris AnalysisWDAImagesSPIRALS:Similar in appearance to machiningswarf, and are produced by a hardersurface abrading into a softerPLATELETS:Two dimensional particles producedmetal to metal sliding.bySPHERICAL:Produced by bearing fatigue or by lubricationfailure resulting in local overheating.CHUNCKY:Produced by a fatigue mechanismInfra-Red ThermographyThermographyInfra Red Thermography is a technique for producinga visibleimage of invisible (to our eyes). Infra red radiation emitted byobjects due to their thermal conditions. The amount of radiationemitted by an object increases with temperature; therefore,thermography allows one to see variations in temperature.Why Thermography? Non Contact Rapid Scanning Data can be recorded in differing formats Images produced are comprehensive & reliableAdvantages Non Contact Non Intrusive Can work at a distance Fast and Reliable Portable Convincing ResultsThe Motto ofThermal ImagingSEETHEIMAGE,SEE THE TEMPERATURESEETHETEMPERATURE,SEE THE PROBLEMThermalImagesThermal image showing water ingress (dark areas) on illustratedsection of aircraftBoeing 737 Turbine. Shows the heat pattern in the turbine ofthis jet.Boeing 737 front wheel. Thermal imaging provided by theCamera shows no uneven wear or heating on this plane wheel.Jet Engine analysisElectricalSwitch GearFuse boxesCable runsElectrical connectors Insulation TransformersFan01FuseBoxLIElectricalConnectionsUsed for the detectionof;Corroded connectionsSlack / loose connectors Connectors at too high an operating temperatureHot spotsElectronicsElectric Motor BearingElectrical MotorHigh Voltage SubstationProcess PlantHot spotsCold spots(Cryogenics)Damaged or missinginsulationTank levelsUltrasound AnalysisWhatis UltrasoundLow frequency sound waves range in size from 3/4 (1.88cm) to 56 (16.9 m)(Assuming the averagehearing range from 20Hz to 20KHz)High frequency (ultrasound) sound Waves range in sizefrom 1/8 (0.34 cm) To 5/8 (1.7 cm)(Assuming ultrasound range from 20 khz-100khz)Advantages of UltrasoundDirectionalLocatableMultiple applicationsUtilizable in all environmentsEarly warning failure indicationSupports other technologiesApplicationGroups Leak detection Compressed air Specialty gasses Vacuum Steam traps / valves Electrical Inspection Mechanical Inspection Slow speed bearings LubricationUltrasonic Leak DetectorLocate the leakMeasure the Leak Calculate costs Calculate GreenhouseGasemissionreduction59HowLeaks Develop Fluid: Liquid or Turbulent FlowUltrasoundgasProducesPRESSUREVACUUMGood Valve Bad ValveElectricInspection Switchgear Transformers Insulators Relays Breakers24.426.823.0*>28.4F28.027.026.025.024.0*28.4F24.426.8Good formedium andhigh voltage28.027.026.025.024.023.0*