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8/22/2019 Condition Monitoring Through Non Destructive Technique Ppt
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SEMINAR BY
VISHNU P
1BD11MDE13
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CONDITION MONITORING
SIGNATURE ANALYSIS
NON-DESTRUCTIVE EVALUATIONS(NDE)
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Change in Machine components parameters like
vibration, noise, temperature, oil contamination, wear
debris etc... , called signatures,would dictate a change
in the condition poor health of the machine.
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2.PREVENTIVE
3.PREDICTIVE1.BREAKDOWN
MAINTENANCE
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1.VIBRATION MONITORING
2.ACOUSTIC EMISSION (AE)
3.INFRARED THERMOGRAPHY (IRT)
4.FERROGRAPHY
5.FIELD SIGNATURE MAPPING (FSM)
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VIBRATION MEASURING AND ANALYSIS SYSTEM
VIBROMETER CHANNELSELECTOR
FREQUENCY
ANALYSER RECORDER
fig,(1.a) SIGNAL FLOW DIAGRAM
MACHINE
MINI COMPUTERS
PROBABILITY DENSITY FUNCTION ANALYSIS (PDF)
BY INSPECTION
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Sl
NoFAULT FREQUENCY
DIRECTION OF
VIBRATION
1ROTATING
UNBALANCESAME AS RUNNING SPEED RADIAL
2MISALIGNMENT
OF BEARINGS
2*SPEEDRADIAL AND
AXIAL
3ROLLER BEARING
DEFECT
AT BALL OR ROLLER SPEEED
ULTRA SONIC
FREQUENCIES(20-60KHz)
RADIAL AND
AXIAL
4.
OIL FILM WHIRL
IN HIGHSPEEDTURBO MACHINES
0.5*SPEED RADIAL
5DAMAGED OR
WORN GEARSNo: OF TEETH* RPM RADIAL
1. VIBRATION CAUSE IDENTIFICATION
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MONITORING AT ROURKELA STEEL PLANT maintenance cost 10-15% of prod: cost
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No:
ofmachines
0
20
40
60
80
100
120
94-95 95-96 96-97 97-98 98-99 99-00
break
downsprevented
savings
insitu balancing
trend line
year
BREAK DOWNS PREVENTED-10-102
EQUIPMENTS INCLUDED - 40-140
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AE sensors respond with amazing sensitivity to motion in the low ultrasonic
frequency range (10 kHz - 2000 kHz). Motions as small as 10-12 inches and less
can be detected
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This method is based on the registration of the elastic compression waves that
are emitted by the defects developing in the stressed constructions.
http://www.eltest.ru/video/pip.mpg8/22/2019 Condition Monitoring Through Non Destructive Technique Ppt
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AE data collection systems
Laptop based AE system
DiSP Systems (any number of channels can be used)
Portable AE test system (lunch box)
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Pressurization (Stage 1)
Random AE activity due to
1. Mechanical rubbing between supportstructure and vessel
2. Paint layer peel-off .
Re pressurization (Stage 2)
No significant AE activity
CASE STUDY
AE DURING HYDROTESTING OF A HORTON
SPHERE
MAX: PRESSURE 22 Kg/cm2
Fig.2(f) AE monitoring during hydro
testing of Horton sphere
AE SIGANLS FROM NEWER AREA (local plastic deformation )
NO SIGNAL DURING SUBSEQUENT
PRESSURIZATION
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Infrared thermography is based on the principle of detection andmeasurement of infrared radiations QR) arising from the natural orstimulated thermal radiation of an object21
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TypeVARIOSCAN
3021 ST
Spectral range
[m] 8 ... 12
Detector
materialHg, Cd, Te
Detector cooling Stirling-cooler
I R MEASURING SYSTEMS
ThermaCAM S60 : Real-Time Thermal
highly sensitive thermal imaging,precision temperature measurement,
enhanced connectivity options including
high speed data transfer
extensive thermal analysis capabilities
http://news.thomasnet.com/images/large/2002/12/17793.jpg8/22/2019 Condition Monitoring Through Non Destructive Technique Ppt
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raw thermo g raphic data.
data after remo ving the noise and v ert ical
gradient .
data processed for the loc al gradient in
surface temperature.
CASE STUDY
high strength welds
F ig setup for inf rared testing of lap joints
correspond to low
strength welds.
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1.WEAR DEBRIS ANALYSIS
MODE: ABRASION, IMPACT, FATIGUE, EROSION, CORROSION
RATE : CONCENTRATION OF WEAR DEBRIS
SEVERITY : SIZE OF DEBRIS INDICATES
LOCATION : COLOUR OF THE PARTICLES
2.SPECTROMETRIC ANALYSIS
OIL ELECTRICALLY EXCITED TO THE POINT WHERE LIGHT IS EMITTED.
ELEMENT EMITS A LIGHT OF ITS OWN PARTICULAR COLOR ANDFREQUENCY.
SPECTROMETERS TRANSLATES THE INTENSITY OF THIS RAINBOW OFCOLORS INTO A COMPUTERIZED READOUT.
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HOW IS THE TEST PERFORMED
Tests Conditions Detected
#Abnormal
Wear
Fuel
DilutionDirt Water Coolant
Incorrect
OilOxidation
Additive
Depletion
Glycol Test *
Viscosity * *
Appearance/Odor * * * * *
Spectrometric
Analysis* * * *
Alkaline Reserve * *
Blotter Spot Test * * *
Water Content *
Distillation *
Flash Point *
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METAL WEAR POSSIBLE ORIGIN.
ALUMINIUM BEARINGS,BLOCKS,BLOWERS,BUSHINGS,CLUTCHES,PISTONS.
CHROMIUM BEARINGS,PUMPS,RINGS,RODS.
COPPER BEARINGS,BUSHINGS,CLUTHES,WASHERS.
IRON BLOCKS,CRANK SHAFTS, CYLINDERS,DISCS.
SILVER SOLDERS.
TIN PISTONS.
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ModelT2FMAnalyticalFerrograph.Bi chromatic microscope.
Video camera.
Video capture card.
Image capture software.
industrial standard personal computer.
This m easure th e effects
of Contaminat ion and
electro-chem ical changes
that occur in syn thet ic
and petro leum based oi ls
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The FSM Inspection Tool (FSM) is a newtechnology for monitoring and inspection ofmetallic pipes and structures, pipelines andstorage vessels
Reduce life cycle inspection costs
Reduce inspection time
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Sensing pins (electrodes) in an
array over the monitored
area to detect changes
in the electrical field pattern.
The voltage = the signature.
Graphical plots indicating theseverity and location of corrosion,
and calculates actual corrosion
and metal loss
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A typical refinery monitors high temperature
areas such as heater bends in the
distillation unit.
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NDTTECHNIQUE
DETECTIONCAPABILITY
NON CONTACTINSPECTION
AUTOMATEDINSPECTION
DEFECTSIZING
VIBRATION VOLUMETRIC POSSIBLE POSSIBLE POSSIBLE
ACOUSTIC
EMISSIONVOLUMETRIC POSSIBLE POSSIBLE
NOT
POSSIBLE
I R THERMO-
GRAPHY
SURFACE ,
NEAR
SURFACE
POSSIBLE POSSIBLE POSSIBLE
FERROGRAPHY VOLUMETRIC POSSIBLE POSSIBLEPOSSIBLE
F S M
SURFACE,
NEAR
SURFACE
POSSIBLE POSSIBLE POSSIBLE
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The implementation of condition monitoringmethodologies to components and plants is very essential
for ensuring safety and reliability and for increasing
productivity of plants.
Nondestructive evaluation techniques which aim at
detection and characterization of defects, fatigue, stresses,
corrosion, dimensional changes and micro structural
degradations in materials,
bear unique potential for applications related to the
condition monitoring of components and plants.
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