This presentation is designed with vibration analysis, Oil Analysis, Thermal Analysis and Ultrasound analysis.

2. www.sajetc.com
Presentation
on
Condition Monitoring Technology
Presented
By
Engr. Md. Shahin Manjurul Alam
Saj Engineering & Trading Company

3. Company Profile
www.sajetc.com
Saj Engineering & Trading Company is established in 1998 to provide the
Non-Destructive Testing (NDT) and Condition Monitoring (CM) solution in
Bangladesh industrial Market. Since then we are providing the NDT and CM
solution in different types of industries like power generation, fertilizer, chemical,
aviation shipbuilding, gas production and distribution, cement, welding, paper,
sugar, pharmaceuticals, research and educational institutions. For the
automobile and industrial market we are supplying lubricants, filter, radiator and
spark plug. For our products we represent the most renowned manufacturers in
the world.
As we have all sorts of latest NDT and CM products we have developed an
industrial inspection service provider under the name of Saj Industrial &
Inspection Company. And till now we have completed 40 Projects
successfully and some projects is in our hand.

4. www.sajetc.com
Automobile & Heavy
Duty Filter
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

5. SAJ
SERVICES
Video-
Borescopic
Inspection
Phased Array
Ultrasonic
Testing
(PAUT)
Magnetic
Particle
Testing
Dye
Penetrant
Testing
Transformer
Oil Leakage
Repair
Hardness
Testing
Thermography
Inspection
Dynamic
Mass
Balancing
Vibration
Analysis
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6. www.sajetc.comObjective
• Condition Monitoring (CM)
• Condition Monitoring Techniques
• Vibration Analysis
• Oil Analysis
• Thermal Analysis
• Ultrasound Analysis

7. Types of machines
Motors
Pumps
Fans
Gearboxes
Engines
Compressors
Steam Turbines
Generators
Gas Turbines
Hydro Turbines
Rotating
Or
Reciprocating Machines
www.sajetc.com

8. www.sajetc.comWhat type of Maintenance
Do we Have

9. 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
Predictive Reactive
We are in here
Machine Condition Chart

10. 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

11. www.sajetc.com
Condition Monitoring
Techniques
1) Vibration Analysis
2) Oil Analysis
3) Thermal Analysis
4) Ultrasound Analysis
A wide range of Condition monitoring techniques is
available in the industries over the world and some have
become standards in many industries. The "standard"
technologies are:

12. 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

13. Vibration Analysis

14. 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

15. 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.
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16. 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

17. 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

18. 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)

19. www.sajetc.com
How we Measure:
Probe Orientation
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

20. www.sajetc.com
Radial Horizontal
Radial
Vertical
Vertical
Axial
Horizontal
Mounting Direction

21. 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

22. Machinery Health Monitoring
Strategy
~125 Machines
~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
www.sajetc.com

23. www.sajetc.comDate Representation
Wave Form Plot or Domain Plot FFT Spectrum Plot
Orbit PlotWaterfall Plot

24. Mass
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

25. Oil Analysis

26. Oil Analysis www.sajetc.com
OIL . . . your engine’s lifeblood . . .
can reveal its internal condition……

27. What is 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
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28. 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, Glycol, Soot etc.)
8. Water-in-oil,
9. Viscosity
10.Wear Debris Analysis (WDA)

29. www.sajetc.com
Elemental Analysis
No. Element Symbol Readout
Range in PPM
1 Aluminum Al 0-1,000
2 Barium Ba 5-6,000
3 Boron B 0-1,000
4 Cadmium Cd 0-1,000
5 Calcium Ca 0-6,000
Carbon C Reference
6 Chromium Cr 0-1,000
7 Copper Cu 0-1,000
Hydrogen H Reference
8 Iron Fe 0-1,000
9 Lead Pb 0-1,000
10 Magnesium Mg 0-6,000
11 Manganese Mn 0-1,000
12 Molybdenum Mo 0-1,000
13 Nickel Ni 0-1,000
14 Phosphorus P 10-6,000
15 Potassium K 0-1,000
16 Silicon Si 0-1,000
17 Silver Ag 0-1,000
18 Sodium Na 0-6,000
19 Tin Sn 0-1,000
20 Titanium Ti 0-1,000
21 Vanadium V 0-1,000
22 Zinc Zn 0-6,000
23 Lithium Li 0-1,000

30. www.sajetc.com
Wear Metal Trends on F-15 F100-100 Engine
Hours Reason
Fe Ag Al Cr Ni Ti Action
424 R 4 0 0 0 1 1 A
426 R 4 0 2 1 1 1 A
427 R 4 0 2 1 1 1 A
428 R 4 0 2 1 1 1 A
430 R 11 0 2 1 1 1 B
430 R 12 0 2 1 1 1 G
430 L 12 0 2 1 1 1 T
R = Routine; L = Lab Requested; B = Submit Special Sample ASAP
A = No Recommendation, Continue Routine Sampling
G = Sample After Each Flight - DO NOT FLY UNTIL RESULTS ARE KNOWN;
T = GROUND UNIT, Examine for Discrepancy,Advise Lab
No. 4 Bearing
Missing Parts
Failure detected based on
increase in
iron wear metal concentration
Elemental Analysis – Case Study

31. www.sajetc.com
Particle Count and Shape
Analysis
Sliding
WearCutting
Wear
NonmetallicFatigue
Wear
Particle Counting
Particle Shape
Analysis

32. www.sajetc.comFerrography

33. Oil Chemistry www.sajetc.com
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 (%)

34. Wear Debris Analysis www.sajetc.com

35. 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

36. Infra-Red Thermography

37. 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

38. www.sajetc.com
Why Thermography?
• Non Contact
• Rapid Scanning
• Data can be recorded in differing formats
• Images produced are comprehensive & reliable

39. Advantages
• Non Contact
• Non Intrusive
• Can work at a distance
• Fast and Reliable
• Portable
• Convincing Results
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40. SEE THE IMAGE,
SEE THE TEMPERATURE
SEE THE TEMPERATURE,
SEE THE PROBLEM
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The Motto of Thermal Imaging

41. Thermal Images

42. www.sajetc.com
Thermal image showing water ingress (dark areas) on illustrated
section of aircraft

43. Boeing 737 Turbine. Shows the heat pattern in the turbine of
this jet.
www.sajetc.com

44. Boeing 737 front wheel. Thermal imaging provided by the
Camera shows no uneven wear or heating on this plane wheel.
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45. Jet Engine analysis
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46. Electrical
• Switch Gear
• Fuse boxes
• Cable runs
• Electrical connectors
• Insulation
• Transformers
www.sajetc.com

47. Fan
1
3
2
2
3
3
R 0 1
www.sajetc.com

48. Fuse Box
2
3
2
3
3
L I 0
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49. Electrical Connections
Used for the detection of;
• Corroded connections
• Slack / loose connectors
• Connectors at too high an
operating temperature
• Hot spots
www.sajetc.com

50. Electronics www.sajetc.com

51. Electric Motor Bearing www.sajetc.com

52. Electrical Motor www.sajetc.com

53. High Voltage Substation www.sajetc.com

54. Process Plant
• Hot spots
• Cold spots (Cryogenics)
• Damaged or missing
insulation
• Tank levels
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55. www.sajetc.com
Ultrasound Analysis

56. www.sajetc.comWhat 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)

57. www.sajetc.com
Advantages of Ultrasound
•Directional
•Locatable
•Multiple applications
•Utilizable in all environments
•Early warning failure indication
•Supports other technologies

58. www.sajetc.com
Application Groups
• Leak detection
– Compressed air
– Specialty gasses
– Vacuum
– Steam traps / valves
• Electrical Inspection
• Mechanical Inspection
– Slow speed bearings
– Lubrication

59. www.sajetc.com
59
Ultrasonic Leak Detector
• Locate the leak
• Measure the Leak
• Calculate costs
• Calculate Greenhouse Gas
emission reduction

60. How Leaks Develop
• Fluid: Liquid or gas
• Turbulent Flow Produces
Ultrasound
PRESSURE
VACUUM
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61. www.sajetc.com
Good Valve – Bad Valve

62. 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

63. 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

64. www.sajetc.com
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

65. 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

66. 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
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67. www.sajetc.com