Presentation on condition monitoring iut
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The document provides an overview of condition monitoring techniques, with a focus on vibration analysis and oil analysis. It discusses how condition monitoring allows maintenance to be scheduled before failures occur. It then describes different machine condition monitoring technologies including vibration analysis, ultrasound analysis, thermal analysis, and oil analysis. The rest of the document goes into technical details about performing vibration analysis and oil analysis to monitor machine health.
Presentation on condition monitoring iut
- 2. www.sajetc.com Presentation & Demonstration on Condition Monitoring By Engr. Md. Shahin Manjurul Alam Saj Engineering & Trading Company
- 3. www.sajetc.comObjective • Condition Monitoring (CM) • Condition Monitoring Techniques • Vibration Analysis • Oil Analysis
- 4. Types of machines Motors Pumps Fans Gearboxes Engines Compressors Steam Turbines Generators Gas Turbines Hydro Turbines Rotating Or Reciprocating Machines www.sajetc.com
- 5. Heat Noise Smell Smoke Feel EquipmentPerformance Time FF PP Mechanical Ultrasound Vibration Analysis Oil Analysis Thermography NDT Lubrication Excellence Proactive Precision Maintenance Alignment, Balance, etc. Select Suppliers Supplier Specifications Metrics Equipment Ranking RCM TPM RCA/FMEA RCD Training Programs Written Procedures Job Planning/Scheduling CMMS System Predictive Reactive We are in here Machine Condition Chart
- 6. www.sajetc.com Condition monitoring is the process of monitoring a parameter of condition in machinery, such that a significant change is indicative of a developing failure. It is a major component of Predictive Maintenance (PdM). The use of conditional monitoring allows maintenance to be scheduled, or other actions to be taken to avoid the consequences of failure, before the failure occurs. Condition Monitoring
- 7. Machine condition monitoring technologies Industrial requirements for machine condition monitoring •Non-intrusive measurements •Early detection to reduce cost •Multiple technologies for complete assessment www.sajetc.com
- 8. Condition Monitoring For your Plant Vibration Analysis Oil Analysis Ultrasound Analysis Thermal Analysis www.sajetc.com If you think this is your plant, then your plant is stand on this 4 technologies
- 9. What Is Vibration ? www.sajetc.com Vibration is a "back and forth" movement of a structure. It can also be referred to as a "cyclical" movement
- 10. Machine failures …and the VIbration is a common cause of failure are very costly… sometimes spectacular, www.sajetc.com
- 11. Vibration Analysis More than 20 years ago someone made the statement, “The vibrations produced in a machine are the best indication of the machine’s health.” This statement still holds true today. Of all the predictive maintenance (PdM) technologies, vibration analysis remains the best measure of machine health. This is true because vibration monitoring can alert us to so many different conditions that may indicate potential machine failures. Unbalance, misalignment, bearing faults, resonance, looseness, cavitations and electrical problems are just a few of the many problems that can be detected with vibration monitoring. www.sajetc.com
- 12. www.sajetc.com Common Problems that Generate Vibration 1. Misalignment 2. Unbalance 3. Worn belts & pulleys 4. Bearing Defects 5. Hydraulic Forces 6. Aerodynamic Forces 7. Reaction Forces 8. Reciprocating Forces 9. Bent Shafts 10.Rubbing 11.Gear Problems 12.Housing Distortion 13.Certain Electrical Problems 14.Frictional Forces
- 13. www.sajetc.com What we Measure for Vibration Analysis Amplitude: How Much Movement Occurs or severity of the vibration. Amplitude measures as 1. Displacement: mm, mils (0.001”) 2. Velocity: mm/sec, in/sec 3. Acceleration: G’s (1g= Force of gravity) or rms (root mean square) Frequency: How Often The Movement Occurs. How many "cycles" in a period of time: a second or a minute Unit: Cycle per second (Hz) Cycle per Minute (CPM) Phase: In What Direction Is The Movement. It also called phase angle. Unit: Degree
- 14. www.sajetc.comHow we measure Vibration Axial: Axial direction is always on the parallel to the shaft axis. Vertical: A Transducer Mounted Vertically "Sees“ Only Vertical Movement Horizontal: A Transducer Mounted Horizontally "Sees" Only Horizontal Movement
- 15. www.sajetc.comVibration Transducer Sensors…Transducers…Probes…What is it? ….It basically converts mechanical vibration to an electrical signal Accelerometer Charge Type & Line Drive Constant Voltage & Constant Current Velocity Transducer Displacement Shaft Riders Proximity Probes (Eddy Current Probes)
- 16. www.sajetc.com Radial Horizontal Radial Vertical Axial Vertical Axial Horizontal Mounting Direction
- 17. www.sajetc.comMounting Direction Vert. Axial Hori. Vert. Axial Hori. For detail study of vibration dynamics of machine – vertical, horizontal and axial at each bearing location For monitoring – one point per bearing and add axial when There is a thrust bearing or axial potential faults eg. misalignment
- 18. Machinery Health MonitoringMachinery Health Monitoring StrategyStrategy ~125 Machines ~1375 Machines ~500 Machines ~500 Machines Total # Machines 2,500 Typical Industrial Process Plant 5%5% CriticalCritical 25%25% EssentialEssential 30%30% ImportantImportant 20%20% SecondarySecondary 20%20% Non-EssentialNon-Essential Turbines Generators Compressors Motors Pumps Fans Gears Application at Typical PlantApplication at Typical Plant Online Solutions forOnline Solutions for critical machinerycritical machinery WirelessWireless TransmittersTransmitters Multi TechnologiesMulti Technologies Portable SolutionsPortable Solutions www.sajetc.com
- 19. By the Medical ECG we know the condition of our Heart By the CSI 2140 we check your Machinery Health Condition www.sajetc.com
- 20. www.sajetc.comData Representation Wave Form Plot or Domain Plot FFT Spectrum Plot Orbit PlotWaterfall Plot
- 21. Unbalance Misalignment Structural Looseness Bearing Looseness Structural Resonance Sleeve Bearing Looseness/Rubs Gear Problem Misalignment Pump Cavitation FFT Spectrum Plot for some Problems www.sajetc.com X=RPM=CPM CPM=Cycle per minute=60Hz 1X=1xRPM=1xCPM 2X=2xRPM=2xCPM 3X=3xRPM=3xCPM
- 22. Demonstration on Vibration Analysis Technology www.sajetc.com
- 23. CSI 2140 Machinery Health Analyzer Five Inputs = Four Channels + Tacho Five Inputs: Channel 1 Channel 2 Channel 3 Channel 4 + Tachometer www.sajetc.com
- 24. 4 Channel Volts + Tach Dual Orbits! www.sajetc.com
- 25. 4 Channel Volts + Tach 4 Channel Accel+ Tach4 Channel Accel+ Tach www.sajetc.com
- 26. Multiple Live Plots – Up to 8! www.sajetc.com
- 27. Oil Analysis www.sajetc.com OIL . . . your engine’s lifeblood . . . can reveal its internal condition……
- 28. What Oil Analysis Oil analysis is a quick, nondestructive way to gauge the health of an engine by looking at what's in the oil. It is as like as medical blood test, where we can know about our diseases from our blood. Oil Analysis Blood Test www.sajetc.com
- 29. www.sajetc.com • Friction control --- Separates moving surfaces • Wear control --- Reduces abrasive wear • Corrosion control --- Protects surfaces from corrosive substance • Temp control --- Absorbs and transfer heat • Contamination control --- Transport particles and other contaminants to filters/separators • Power transmission --- In hydraulics, transmits force and motion Functions of Lubricants
- 30. Oil Analysis seeks to provide answers for… Change Filter? Change Oil? Tear Down? www.sajetc.com
- 31. Cost justification for industrial oil analysis Documented case histories and cost savings on-site oil analysis to monitor a wide range of industrial machinery. Realistic Return on Investment: 500%+ Defer maintenance Proactive CONTAMINATION CONTROL Keeping oil clean, dry, and fit for use Reduce oil consumption LESS OIL USED “Test it, don’t change it” Eliminate reactive maintenance Trend FAILURE PROGRESS Predictive vibration & oil analysis www.sajetc.com
- 32. All Test of Your Oil www.sajetc.com 1. Elemental Analysis (Spectral Analysis) 2. Particle count, 3. Particle Shape Analysis 4. Parts per million (PPM) distribution , 5. ISO codes and ASTM standard 6. Ferrography 7. Oil Chemistry ( Dielectric, TBN, TAN, Oxydation, Nitration, Sulfations, Soot etc.) 8. Water-in-oil, 9. Viscosity 10.Wear Debris Analysis (WDA)
- 33. Wear Metals and Possible Sources Engine Bearing Gear Transmission Hydraulic System Heat Exchanger Compressor Turbine Iron Cylinder Liners, Piston Rings, Valve train, Crankshaft, rocker arms, spring gears, lock washers, nuts, pins, connecting rods, Engine Blocks, Oil pump Rolling element Bearings: rollers (tungsten alloyed steel), raceways and cages, Journal Bearings: Journal shaft, bearing Shoe backing Locking keys Bull gears, pinions, case hardened teeth, locking pins Gears, bearings, Brake bands, clutch, shift spools, pumps, power take off (PTO) Pump, motor, vanes, pump housing, cylinder bores and rods, servo valves, pistons Rotary Screw, lobes, vanes, connecting rods, rocker arm, bearings, cylinders, housing, shafts, roller bearings (see above) oil pump, piston rings Reduction gear, shaft, bearings, piping, case Copper Valve train bushing, Wrist pin bushing, Cam bushings, Oil Cooler core, Thrust washers, governor, connecting rods bearings, valve gear train thrust buttons Rolling element Bearings: alloyed element in cages, Journal Bearings: journal bearing pads, slinger rings, Locking keys Bushings, thrust washers Clutches, steering discs, bearings Pump thrust plates, bushings, cylinder gland guides, pump pistons, oil coolers Cooler tubes, baffles, plates bearings, cylinder guides, wear plates, thrust washers, bearings (see above) oil pump, oil coolers, thermostats, separator filters Bearings (see bearing section) piping, coolers Tin Valve train bushing, Wrist pin bushing, Cam bushings, Oil Cooler core, Thrust washers, governor, connecting rods bearings, valve gear train thrust buttons Rolling element Bearings: alloyed element in cages, Journal Bearings: journal bearing pads (babbited) Bushings Clutches, steering discs, bearings Pump thrust plates, bushings, Can be a residue from catalyst in some oils (Quinto lubric series) bearings, separator filters Bearings (see bearing section) piping, coolers Aluminum Engine blocks, pistons, blowers, Oil pump bushings, bearings (some) Cam bushings(some) , Oil coolers (some) Rolling element Bearings: alloyed element in cages, Locking keys Bushings, thrust washers, grease contamination Bushings, clutches Cylinder gland (some) pump, motor pistons, oil coolers. Aluminum complex grease contaminant Cooler tubes, baffles, plates Housing, bearings, cylinder guides, wear plates, thrust washers, bearings (see above), oil pump, oil coolers Bearings(see above) piping, coolers EHC Systems: Residue from synthetic media (alumina) filters 33 www.sajetc.com
- 34. Wear Metals and Possible Sources (Cont.) Engine Bearing Gear Trans-mission Hydraulic System Heat Exchanger Compressor Turbine Chrome Rings, Liners, exhaust valves, zinc chromate from cooling system inhibitor Rolling element Bearings: alloyed /coated element in rollers, tapers Bearings(some) , shaft coatings, some special gears are chrome plated Bearings, water treatment Cylinder liners, rods, spools Housing, bearings, cylinder guides, wear plates, thrust washers, bearings (see above), oil pump, oil coolers Shaft coating (some) bearings Lead Main Bearings, connecting rod bearings. Lead can be present as a contaminant from Gasoline (Leaded gas) (Octane improver, anti-knock compound) Rolling element Bearings: alloyed element in cages, Journal Bearings: Major alloying element in Babbitt bearings, alloying elements Bearings, can also be red lead paint flakes from gear case walls Bearings Bearings Bearings Silicon Engine blocks (alloying element with aluminum parts), ingested dirt from breathers, external sources. Can also be from defoamant additive in lubricant Rolling element Bearings: alloyed element with aluminum in cages Bushings, thrust washer, silicone sealant, defoamant additive Brake shoes, clutch plates, ingested dirt Elastome ric seals (some) pump, motor pistons, oil coolers Ingested dirt, silicone sealant, bearings, cooler (alloyed with aluminum) Ingested dirt, silicone sealant, defoamant additive Silver Bearings (alloying element) wrist pins, turbochargers (EMD railroad engines) Bearings, oil coolers Baffle & tube solder Nickel Valves, Valve guides, Cylinder liners, Bearings. Can also be from heavy fuel contamination Rolling element Bearings: alloyed element in rollers, races Alloying element for tool steel gears Bearings, servo valve plating pumps, pistons Bearings Bearings, shaft, reduction gears 34 www.sajetc.com
- 35. Other Wear Metals and Metallic Additives Element Possible Sources in Additives Sodium Corrosion inhibitor additive, also indicates coolant leak into oil, can also be road Salt, Sea water, Ingested Dirt Boron Corrosion Inhibitor additive, Antiwear/Antioxidant additive, can indicate coolant leak, grease contamination Magnesium Detergent/dispersive additive, can also be alloying element in steels Calcium Detergent/dispersant additive, Alkaline reserve additive for high sulfur fueled engines, can be grease contamination, Molybdenum Solid/liquid antiwear additive, alloy in bearing and piston rings Barium Corrosion inhibitors, Detergents, Rust inhibitors Zinc Anti-wear, Corrosion inhibitors, Anti-oxidants, alloying element for bearings, thrust washers, galvanized cases Phosphorus Anti-wear, Corrosion inhibitors, Anti-oxidants additives, EP additives Element Possible Wear Sources Titanium Wear metal for aircraft engines, bearings, Can also be contaminant from paint (titanium dioxide) Vanadium Fuel Contaminant, can also be alloying element for steel 35 www.sajetc.com
- 37. Optical Particle Counting Techniques Readout & Control Readout & Control Laser View Volume Photo Diode Laser Beam Light BlockingLight Blocking Oil Flow Readout & Control Readout & Control Light ScatteringLight Scattering Laser Scattered Light Lens Photo Diode Laser Beam Trap Oil Flow Laser Oil Flow Direct ImagingDirect Imaging CCD Lens Display 37 www.sajetc.com
- 38. 38 Particle Counting Classifications • The count is compared to known standards • ISO 4406 • NAS 1638(out of service, but still widely quoted) • AS 4059 • MIL-STD-1264 • and many other internal industry methods • Two types of counting method • Cumulative • Differential MOST POPULAR 38 www.sajetc.com
- 39. Particle Counting Reporting Codes • A particle counting code is simply an arbitrary number given for a sample that represents a particle count range for a given size range • In ISO 4406, code increases when the particle population is ~ doubled from the previous range 39 www.sajetc.com
- 40. • 60+ Brands, 400+ oils, 30+ fine tuned calibration algorithms and growing • Synthetic, Mineral Fluid, Biodiesels, etc • Comprehensive oil match algorithm to expand new oil library in the field Engine Hydraulic Synthetic Gas Turbine Compressor/ transmission Gear/Turbine Water (ppm) Oxidation (abs/mm2) TAN (mg KOH/g) TBN (mg KOH/g) Alien fluid (%) Anti-Oxidant Additive (%) Anti-wear Additive (%) Nitration (abs/mm2) Sulfation (abs/mm2) Soot (%) Glycol (%) FT-IR Oil Analyzer www.sajetc.com
- 41. Wear Debris Analysis www.sajetc.com
- 42. PLATELETS: Two dimensional particles produced by metal to metal sliding. SPHERICAL: Produced by bearing fatigue or by lubrication failure resulting in local overheating. SPIRALS: Similar in appearance to machining swarf, and are produced by a harder surface abrading into a softer CHUNCKY: Produced by a fatigue mechanism WDA Images www.sajetc.com
- 43. Sliding Wear • Severe sliding wear commences when the wear surface stresses become excessive due to load and/or speed. • Many sliding wear particles have surface striations as a result of sliding. • Severe sliding wear starts with particles greater than 15 µm. Catastrophic Sliding Wear Severe Sliding with Lubrication Starvation Severe Sliding Wear 43 www.sajetc.com
- 44. Three Body Abrasive Wear “Soft” Surface “Hard” Surface Hard abrasive contamination Cutting wear particle 44 www.sajetc.com
- 45. 45 Surface Damage due to Hard Particles 45 www.sajetc.com
- 46. Spheres Spheres generated from an extraneous source such as a welding or grinding process. These spheres are much larger than those generated by bearing fatigue. Spheres generated by a fatiguing bearing < 5 microns 46 www.sajetc.com
- 47. Demonstration on Oil Analysis Technology www.sajetc.com
- 49. FluidScan
- 50. Thermography Infra Red Thermography is a technique for producing a visible image of invisible (to our eyes). Infra red radiation emitted by objects due to their thermal conditions. The amount of radiation emitted by an object increases with temperature; therefore, thermography allows one to see variations in temperature. www.sajetc.com
- 51. www.sajetc.com Why Thermography? • Non Contact • Rapid Scanning • Data can be recorded in differing formats • Images produced are comprehensive & reliable
- 52. Advantages • Non Contact • Non Intrusive • Can work at a distance • Fast and Reliable • Portable • Convincing Results www.sajetc.com
- 53. SEE THE IMAGE, SEE THE TEMPERATURE SEE THE TEMPERATURE, SEE THE PROBLEM www.sajetc.com The Motto of Thermal Imaging
- 54. Thermal Images
- 55. Electrical • Switch Gear • Fuse boxes • Cable runs • Electrical connectors • Insulation • Transformers www.sajetc.com
- 58. Electrical Connections Used for the detection of; • Corroded connections • Slack / loose connectors • Connectors at too high an operating temperature • Hot spots www.sajetc.com
- 63. Process Plant • Hot spots • Cold spots (Cryogenics) • Damaged or missing insulation • Tank levels www.sajetc.com
- 64. What’s In Your PDM Toolbox? • One Technology CAN NOT do Everything!!!!!! • Successful Integration is the key to getting the most out of your resources: – Awareness – Proper training – Documentation www.sajetc.com
- 66. What is Ultrasound High frequency (ultrasound) sound Waves range in size from 1/8” (0.34 cm) To 5/8” (1.7 cm) (Assuming ultrasound range from 20 khz-100khz) Low frequency sound waves range in size from 3/4” (1.88 cm) to 56’ (16.9 m) (Assuming the average hearing range from 20Hz to 20KHz) www.sajetc.com
- 67. Advantages of Ultrasound •Directional •Locatable •Multiple applications •Utilizable in all environments •Early warning failure indication •Supports other technologies www.sajetc.com
- 68. Application Groups • Leak detection – Compressed air – Specially gasses – Vacuum – Steam traps / valves • Electrical Inspection • Mechanical Inspection – Slow speed bearings – Lubrication www.sajetc.com
- 69. 69 Ultrasonic Leak Detector • Locate the leak • Measure the Leak • Calculate costs • Calculate Greenhouse Gas emission reduction www.sajetc.com
- 70. How Leaks Develop • Fluid: Liquid or gas • Turbulent Flow Produces Ultrasound PRESSURE VACUUM www.sajetc.com
- 71. Good Valve – Bad Valve www.sajetc.com
- 72. Electric Inspection • Switchgear • Transformers • Insulators • Relays • Breakers 26.8 24.4 *>28.4°F *<23.0°F 23.0 24.0 25.0 26.0 27.0 28.0 www.sajetc.com
- 73. Electric inspection • Corona • Tracking • Arcing • Good for medium and high voltage 26.8 24.4 *>28.4°F *<23.0°F 23.0 24.0 25.0 26.0 27.0 28.0 www.sajetc.com
- 74. Bearing Inspection • Very effective on S L O W S P E E D ! • 3 Types of testing performed – Comparison – Historical Trending – Spectrum Analysis: • Fault frequency identification ©UE SYSTEMS INC. All Rights Reserved www.sajetc.com
- 75. Levels of Severity Db levels over baseline 8 db LUBRICATION 12 db minor damage-microscopic faults 16 db damage-visual faults 35+ db catastrophic failure imminent ©UE SYSTEMS INC. All Rights Reserved www.sajetc.com
- 76. What’s In Your PDM Toolbox? • One Technology CAN NOT do Everything!!!!!! • Successful Integration is the key to getting the most out of your resources: – Awareness – Proper training – Documentation www.sajetc.com
- 77. www.sajetc.com
Editor's Notes
- #45: Cutting wear particles are curved, forming loops and spirals, much like miniature machining swarf. Another Scanning Electron Photomicrograph of Cutting Wear Particles. In this view some large, abrasive contaminant particles may also be seen.
- #47: Metal spheres may be generated by welding and grinding. Fly ash from coal fired power plants contain large numbers of both ferrous (magnetic) spheres and glass (nonmetallic and transparent) spheres. Metal spheres are generated in large numbers at steel mills and foundries. Scanning Electron Photomicrograph of Ferrous Spheres. On rare occasions, ferrous spheres may be generated by the surfaces of rolling element bearings as a precursor to fatigue spalling. Spheres generated by this wear mode are all of the same approximate size and are small, less than 5 µm.