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Condition Monitoring Technology
This document provides information on condition monitoring technology for machinery. It discusses vibration analysis, oil analysis, ultrasound analysis, and thermal analysis as the key condition monitoring technologies. It describes common machine problems that can be detected by vibration analysis like misalignment, unbalance, bearing defects, and gear problems. It provides details on vibration measurement, oil analysis tests, particle counting classifications, and wear debris analysis. The overall document is about condition monitoring techniques and technologies to monitor machine health and enable predictive maintenance.
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Condition Monitoring Technology
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- 3. Automobile & Heavy DutyFilter Different types of Scientific Equipments Non Destructive Testing (NDT) Products Lubricants/Engine Oil/ Motor oil Condition Monitoring Products Predictive Maintenance Services MRO & Packaging Products Cold Welding Materials & Services
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- 5. Objective • Condition Monitoring(CM) • Condition Monitoring Techniques • Vibration Analysis • Oil Analysis • Thermal Analysis • Ultrasound Analysis
- 6. Types of machines Motors Pumps Fans Gearboxes Engines Compressors SteamTurbines Generators Gas Turbines Hydro Turbines Rotating Or Reciprocating Machines
- 7. EquipmentPerformance Time FF PP 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
- 8. Condition monitoring isthe 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
- 9. Machine condition monitoringtechnologies Industrial requirements for machine condition monitoring • Non-intrusive measurements • Early detection to reduce cost • Multiple technologies for complete assessment Condition Monitoring Technologies Oil Analysis Vibration Analysis Infrared Thermography Ultrasound
- 10. Condition Monitoring For yourPlant Vibration Analysis Oil Analysis Ultrasound Analysis Thermal Analysis If you think this is your plant, then your plant is stand on this 4 technologies
- 11. What Is Vibration? Vibration is a "back and forth" movement of a structure. It can also be referred to as a "cyclical" movement
- 12. Machine failures …and theVIbration is a common cause of failure are very costly… sometimes spectacular,
- 13. Vibration Analysis More than20 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.
- 14. Common Problems thatGenerate 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
- 15. What we Measurefor 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
- 16. How we measureVibration 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
- 17. Vibration Transducer Sensors…Transducers…Probes…What isit? ….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)
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- 19. Mounting Direction Vert. Axial Hori. Vert. Axial Hori. Fordetail 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
- 20. Machinery Health Monitoring Strategy ~125Machines ~1375 Machines ~500 Machines ~500 Machines Total # Machines 2,500 Typical Industrial Process Plant 5% Critical 25% Essential 30% Important 20% Secondary 20% Non-Essential Turbines Generators Compressors Motors Pumps Fans Gears Application at Typical Plant Online Solutions for critical machinery Wireless Transmitters Multi Technologies Portable Solutions
- 21. By the MedicalECG we know the condition of our Heart By the CSI 2130 we check your Machinery Health Condition
- 22. Date Representation Wave FormPlot or Domain Plot FFT Spectrum Plot Orbit PlotWaterfall Plot
- 23. Unbalance Misalignment StructuralLooseness Bearing Looseness Structural Resonance Sleeve Bearing Looseness/Rubs Gear Problem Misalignment Pump Cavitation FFT Spectrum Plot for some Problems X=RPM=CPM CPM=Cycle per minute=60Hz 1X=1xRPM=1xCPM 2X=2xRPM=2xCPM 3X=3xRPM=3xCPM
- 24. Oil Analysis OIL .. . your engine’s lifeblood . . . can reveal its internal condition……
- 25. What Oil Analysis Oilanalysis 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
- 26. • 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
- 27. Oil Analysis seeksto provide answers for… Wear Particles Lubricant Contamination Lubricant Degradation Change Filter? Change Oil? Tear Down?
- 28. Cost justification forindustrial 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
- 29. All Test ofYour Oil 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)
- 30. Wear Metals andPossible 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 30
- 31. Wear Metals andPossible 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 31
- 32. Other Wear Metalsand 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 32
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- 34. Optical Particle Counting Techniques Readout& Control Laser View Volume Photo Diode Laser Beam Light Blocking Oil Flow Readout & Control Light Scattering Laser Scattered Light Lens Photo Diode Laser Beam Trap Oil Flow Laser Oil Flow Direct Imaging CCD Lens Display 34
- 35. 35 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 35
- 36. Particle Counting ReportingCodes • 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 36
- 37. • 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
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- 39. PLATELETS: Two dimensional particlesproduced 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
- 40. Sliding Wear • Severesliding 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 40
- 41. Three Body AbrasiveWear “Soft” Surface “Hard” Surface Hard abrasive contamination Cutting wear particle 41
- 42. 42 Surface Damage dueto Hard Particles 42
- 43. Spheres Spheres generated froman 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 43
- 44. Thermography Infra Red Thermographyis 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.
- 45. Why Thermography? • NonContact • Rapid Scanning • Data can be recorded in differing formats • Images produced are comprehensive & reliable
- 46. Advantages • Non Contact •Non Intrusive • Can work at a distance • Fast and Reliable • Portable • Convincing Results
- 47. SEE THE IMAGE, SEETHE TEMPERATURE SEE THE TEMPERATURE, SEE THE PROBLEM The Motto of Thermal Imaging
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- 49. Electrical • Switch Gear •Fuse boxes • Cable runs • Electrical connectors • Insulation • Transformers
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- 52. Electrical Connections Used forthe detection of; • Corroded connections • Slack / loose connectors • Connectors at too high an operating temperature • Hot spots
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- 57. Process Plant • Hotspots • Cold spots (Cryogenics) • Damaged or missing insulation • Tank levels
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- 59. What is Ultrasound Highfrequency (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)
- 60. Advantages of Ultrasound •Directional •Locatable •Multipleapplications •Utilizable in all environments •Early warning failure indication •Supports other technologies
- 61. Application Groups • Leakdetection – Compressed air – Specially gasses – Vacuum – Steam traps / valves • Electrical Inspection • Mechanical Inspection – Slow speed bearings – Lubrication
- 62. 62 Ultrasonic Leak Detector •Locate the leak • Measure the Leak • Calculate costs • Calculate Greenhouse Gas emission reduction
- 63. How Leaks Develop •Fluid: Liquid or gas • Turbulent Flow Produces Ultrasound PRESSURE VACUUM
- 64. Good Valve –Bad Valve
- 65. 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
- 66. 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
- 67. Bearing Inspection • Veryeffective 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
- 68. Levels of Severity Dblevels 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
- 69. What’s In YourPDM Toolbox? • One Technology CAN NOT do Everything!!!!!! • Successful Integration is the key to getting the most out of your resources: – Awareness – Proper training – Documentation
Editor's Notes
- #42 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.
- #44 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.