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Presentation on

Condition Monitoring Technology

Presented

By

Engr. Md. Shahin Manjurul Alam

Saj Engineering & Trading Company

Company Profile www.sajetc.com

Saj Engineering & Trading Company is established in 1998 to provide theNon-Destructive Testing (NDT) and Condition Monitoring (CM) solution inBangladesh industrial Market. Since then we are providing the NDT and CMsolution 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 theautomobile and industrial market we are supplying lubricants, filter, radiator andspark plug. For our products we represent the most renowned manufacturers inthe world.

As we have all sorts of latest NDT and CM products we have developed anindustrial inspection service provider under the name of Saj Industrial &Inspection Company. And till now we have completed 40 Projectssuccessfully and some projects is in our hand.

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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 WeldingMaterials & Services

SAJ SERVICES

Video-BorescopicInspection

Phased Array Ultrasonic

Testing (PAUT)

Magnetic Particle Testing

Dye Penetrant

Testing

Transformer Oil Leakage

Repair

Hardness Testing

ThermographyInspection

Dynamic Mass

Balancing

Vibration Analysis

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www.sajetc.comObjective

• Condition Monitoring (CM)

• Condition Monitoring Techniques

• Vibration Analysis

• Oil Analysis

• Thermal Analysis

• Ultrasound Analysis

Types of machines

Motors

Pumps

Fans

Gearboxes

Engines

Compressors

Steam Turbines

Generators

Gas Turbines

Hydro Turbines

Rotating

Or

Reciprocating Machines

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www.sajetc.comWhat type of Maintenance

Do we Have

Equip

ment P

erfo

rmance

Time

FF

PPLubrication 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

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Condition monitoring is the process of monitoring aparameter of condition in machinery, such that asignificant change is indicative of a developing failure. Itis a major component of Predictive Maintenance(PdM). The use of conditional monitoring allowsmaintenance to be scheduled, or other actions to betaken to avoid the consequences of failure, before thefailure occurs.

Condition Monitoring

www.sajetc.comCondition Monitoring

Techniques

1) Vibration Analysis

2) Oil Analysis

3) Thermal Analysis

4) Ultrasound Analysis

A wide range of Condition monitoring techniques isavailable in the industries over the world and some havebecome standards in many industries. The "standard"technologies are:

Condition Monitoring For your Plant

Vibration

Analysis Oil Analysis

Ultrasound

Analysis

Thermal

Analysis

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If you think this is your plant, then your plant is stand on this 4 technologies

Vibration Analysis

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

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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Common Problems that Generate Vibration

1. Misalignment2. Unbalance3. Worn belts & pulleys4. Bearing Defects5. Hydraulic Forces6. Aerodynamic Forces7. Reaction Forces8. Reciprocating Forces9. Bent Shafts10.Rubbing11.Gear Problems12.Housing Distortion13.Certain Electrical Problems14.Frictional Forces

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What we Measure for Vibration Analysis

Amplitude: How Much Movement Occurs or severity of the vibration.

Amplitude measures as1. Displacement: mm, mils (0.001”)2. Velocity: mm/sec, in/sec3. 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

www.sajetc.comVibration Transducer

Sensors…Transducers…Probes…What is it?

….It basically converts mechanical vibration to

an electrical signal

AccelerometerCharge Type &

Line Drive

Constant Voltage &

Constant Current

Velocity

Transducer

DisplacementShaft Riders

Proximity Probes

(Eddy Current Probes)

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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

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Radial Horizontal

Radial

VerticalVertical

Axial

Horizontal

Mounting Direction

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

Machinery Health Monitoring Strategy

~125 Machines

~1375 Machines

~500 Machines

~500 Machines

Total # Machines 2,500Typical 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

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www.sajetc.comDate Representation

Wave Form Plot or Domain Plot FFT Spectrum Plot

Orbit PlotWaterfall Plot

Mass Unbalance

Misalignment Structural Looseness Bearing Looseness

Structural Resonance Sleeve BearingLooseness/Rubs

Gear ProblemMisalignment

Pump Cavitation

FFT Spectrum Plot for some Problems www.sajetc.com

X=RPM=CPM CPM=Cycle per minute=60Hz1X=1xRPM=1xCPM2X=2xRPM=2xCPM3X=3xRPM=3xCPM

Oil Analysis

Oil Analysis www.sajetc.com

OIL . . . your engine’s lifeblood . . .

can reveal its internal condition……

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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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)

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Elemental Analysis

No. Element Symbol ReadoutRange 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

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Wear Metal Trends on F-15 F100-100 EngineHours 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

www.sajetc.comParticle Count and Shape

Analysis

Sliding

WearCutting

Wear

NonmetallicFatigue

Wear

Particle Counting

Particle Shape

Analysis

www.sajetc.comFerrography

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-OxidantAdditive (%)

Anti-wear Additive (%)

Nitration (abs/mm2)

Sulfation (abs/mm2)

Soot (%)

Glycol (%)

Wear Debris Analysis www.sajetc.com

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 Imageswww.sajetc.com

Infra-Red Thermography

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.

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www.sajetc.comWhy Thermography?

• Non Contact

• Rapid Scanning

• Data can be recorded in differing formats

• Images produced are comprehensive & reliable

Advantages

• Non Contact

• Non Intrusive

• Can work at a distance

• Fast and Reliable

• Portable

• Convincing Results

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SEE THE IMAGE,

SEE THE TEMPERATURE

SEE THE TEMPERATURE,

SEE THE PROBLEM

www.sajetc.comThe Motto of Thermal Imaging

Thermal Images

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Thermal image showing water ingress (dark areas) on illustrated

section of aircraft

Boeing 737 Turbine. Shows the heat pattern in the turbine of

this jet.

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Boeing 737 front wheel. Thermal imaging provided by the

Camera shows no uneven wear or heating on this plane wheel.

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Jet Engine analysis

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Electrical

• Switch Gear

• Fuse boxes

• Cable runs

• Electrical connectors

• Insulation

• Transformers

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Fan

18. 7°C

37. 4°C

20

25

30

35

A R01

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Fuse Box

23. 3°C

38. 1°C

25

30

35

LI 01

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Electrical Connections

Used for the detection of;

• Corroded connections

• Slack / loose connectors

• Connectors at too high an operating temperature

• Hot spots

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Electronics www.sajetc.com

Electric Motor Bearing www.sajetc.com

Electrical Motor www.sajetc.com

High Voltage Substation www.sajetc.com

Process Plant

• Hot spots

• Cold spots (Cryogenics)

• Damaged or missing insulation

• Tank levels

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Ultrasound Analysis

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)

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Advantages of Ultrasound

•Directional•Locatable•Multiple applications•Utilizable in all environments•Early warning failure indication•Supports other technologies

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Application Groups

• Leak detection

– Compressed air

– Specialty gasses

– Vacuum

– Steam traps / valves

• Electrical Inspection

• Mechanical Inspection

– Slow speed bearings

– Lubrication

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59

Ultrasonic Leak Detector

• Locate the leak

• Measure the Leak

• Calculate costs

• Calculate Greenhouse Gasemission reduction

How Leaks Develop

• Fluid: Liquid or gas• Turbulent Flow Produces

Ultrasound

PRESSURE

VACUUM

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Good Valve – Bad Valve

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

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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

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www.sajetc.comBearing 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

Levels of SeverityDb 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

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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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