Presentation on Condition Monitoring Technology

www.sajetc.com

Presentation on

Condition Monitoring Technology

Presented By

Engr. Md. Shahin Manjurul AlamSaj Engineering & Trading Company

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 35 Projects successfully and some projects is in our hand.

Products:1.Non-Destructive Testing Products2.Condition Monitoring Products3.Sakura Automobile and Generator Filter4.Air Conditioner Energy Saver5.Maintenance Repair & Overhauling (MRO) Products6.PertaminaLubricants7.Scientific/Laboratory Equipments

Our Services:1. Remote Visual Inspection/Endoscope 2. Ultrasonic Testing 3. Magnetic Particle Testing4. Radiography Testing5. PenetrantTesting6. Vibration Analysis7. Dynamic Balancing8. Transformer Leakage Repair9. Thermography Service10. Hardness Testing

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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

www.sajetc.comObjective

• Condition Monitoring (CM)• Condition Monitoring Techniques• Vibration Analysis • Oil Analysis• Thermal Analysis• Ultrasound Analysis

Heat

Noise

Smell

Smoke

Feel

Equ

ipm

ent P

erfo

rmance

TimeFF

PP

Mechanica

l

Ultraso

undVibration

Analysis

Oil Analysis

Thermograp

hyNDT

Lubrication Excellence

Proactive

Precision Maintenance Alignment, Balance, etc.

Select Suppliers

Supplier Specifications

Metrics

Equipment Ranking

RCM

TPM

RCA/FMEA

RCD

Training Programs

Written ProceduresJob Planning/Scheduling

CMMS System

Predictive Reactive

We are in here

Machine Condition Chart

Types of machines

MotorsPumpsFansGearboxesEnginesCompressorsSteam TurbinesGeneratorsGas TurbinesHydro Turbines

Rotating Or

Reciprocating Machines

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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

www.sajetc.comCondition Monitoring

Techniques

1) Vibration Analysis 2) Oil Analysis3) Thermal Analysis4) 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:

Condition Monitoring For your Plant

Vibration Analysis Oil Analysis

UltrasoundAnalysis

ThermalAnalysis

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

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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www.sajetc.comCommon 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

www.sajetc.comWhat 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.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

www.sajetc.comVibration Transducer Sensors…Transducers…Probes…What is it?

….It basically converts mechanical vibration to an electrical signal

AccelerometerCharge Type &

Line DriveConstant Voltage &Constant Current

VelocityTransducer

DisplacementShaft Riders

Proximity Probes(Eddy Current Probes)

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Radial Horizontal

Radial Vertical

Axial

Vertical

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 whenThere is a thrust bearing or axial potential faults eg. misalignment

Machinery Health Monitoring Machinery Health Monitoring Strategy Strategy

Machinery Health Monitoring Machinery Health Monitoring Strategy Strategy

~125 Machines

~1375 Machines

~500 Machines

~500 Machines

Total # Machines 2,500Typical Industrial Process Plant

5%5%CriticalCritical

25%25%EssentialEssential

30%30%ImportantImportant

20%20%SecondarySecondary

20%20%Non-EssentialNon-Essential

TurbinesGenerators

Compressors

MotorsPumps

FansGears

Application at Typical PlantApplication at Typical Plant

Online Solutions for Online Solutions for critical machinery critical machinery

WirelessWirelessTransmittersTransmitters

Multi TechnologiesMulti TechnologiesPortable SolutionsPortable Solutions

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By the Medical ECG we know the

condition of our Heart

By the CSI 2130 we check your Machinery

Health Condition

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www.sajetc.comDate Representation

Wave Form Plot or Domain Plot

FFT Spectrum Plot

Orbit PlotWaterfall Plot

Unbalance Misalignment

Structural Looseness

Bearing Looseness

Structural Resonance

Sleeve BearingLooseness/Rubs

Gear ProblemMisalignment

Pump Cavitation

FFT Spectrum Plot for some Problems www.sajetc.com

Oil Analysis www.sajetc.com

OIL . . . your engine’s lifeblood . . . can reveal its internal condition……

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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• 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

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CSI 5200 Minilab “The Oil Analyzer”

The Complete Minilab with1.CSI 5200 Main Unit2.52DV Digital Viscometer3.52ZM Stereo Zoom Microscope 4.51CV Camera5.Video Capture kit 6.AMS Machinery Manager

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CSI 5200- Oil Analyzerwww.sajetc.com

All Test of Your Oil www.sajetc.com

The minilab provides comprehensive oil analysis results including 1.Elemental Analysis 2.Particle count, 3.Particle Shape Analysis 4.Parts per million (PPM) distribution , 5.ISO codes,6.Ferrous density, 7.Oil Chemistry ( Dielectric, TBN, TAN, Oxidation, Nitrasion, Sulfation, Soot etc)8.Water-in-oil, 9.Viscosity 10.Detail wear debris analysis (WDA) with WDA image and video.

Wear Debris Analysis www.sajetc.com

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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 WearSevere Sliding with Lubrication Starvation

Severe Sliding Wear

35

Break-In of a Wear Surface

Ridges on the wear surface are flattened and form cornices which break away and form long flat particles

Typical surface finish

Schematic view of grinding marks from surface finishing. Plastic Deformation

36

Three Body Abrasive Wear

“Soft” Surface

“Hard”Surface

Hard abrasive contamination

Cutting wear particle

37

38

Surface Damage due to Hard Particles

38

Rolling Element Bearing Failures

Surface initiated cracks propagate at acute angles to the surface

Cracks initiated in subsurface by high shear stress

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The Fatigue Process

Fatigue of bearing components occurs due to cyclic stressing between rollers and raceways. High stresses are generated underneath the raceway. Maximum stresses are at some distance below the race way surface.

Cracking can initiate at inclusions and propagate until it finally breaks out at the surface causing spalling. The edges of the spall act as stress risers causing further removal of material at the spall. A repaired spall can also propagate subsurface cracking and eventually flake out adjacent to the initial repaired area.40

Rolling Fatigue• Fatigue spall particles originate as material removed as a pit opens up.• The fatigue spall particles start at approximately 10 µm and are flat

platelets with a major dimension to thickness ratio of 10:1.• Fatigue spall particles have a smooth surface and a random, irregular

shaped circumference.

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Rolling Contact Fatigue Particles

Irregularly shaped fatigue spall particle with a smooth heavily pitted surface

Rolling element fatigue spall particles – smooth surfaces and irregular contours

Thin laminar fatigue particle < 1 micron thick

Laminar fatigue particle with holes

Increased Mag

Increased Mag

42

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 microns43

Combined Rolling and Sliding (Gear Systems)

Pitch line Pitch line

Pitch CirclePitch Circle

Scuffing / Scoring(Increasing Sliding Component)

Fatigue pitting

Gear systems combine both rolling and sliding. At the pitch line, the contact is rolling so the particles will be similar to rolling contact fatigue particles. The contact has an increasing sliding component as the root or tip is approached. The particles will show signs of sliding such as striations and a greater ratio of major dimension to thickness.

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Fatigue Particles from Combined Rolling and Sliding

Irregularly shaped smooth surface fatigueparticle.

Fatigue chunk

Pitch Line Fatigue Wear (Rolling)

Root / Tip Sliding Wear (Scuffing)

Individual Scuffing wear particles showing signs of oxidation.45

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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

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

Thermography for Aircraft www.sajetc.com

Thermography can be an indispensable tool for inspecting the planes. An entire aircraft can be surveyed in 20 minutes with no downtime. Images are recorded digitally for later analysis at an image processing workstation.There are many more instances when thermography can be utilized

Aerospace Applications

1. Water ingress in airplane control surfaces and

radomes2. Tire and brake system diagnosis

3. Windshield and wing surface deicing system diagnosis4. Stress crack and corrosion identification and location5. Jet and rocket engine analysis6. Composite materials delamination and disbanding location7. Target signature analysis

Thermography Applications in Aircraft

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Advantages

• Non Contact

• Non Intrusive

• Can work at a distance

• Fast and Reliable

• Portable

• Convincing Results

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CSI 9830 (HOT SHOT) IR Thermal Image Camera

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SEE THE IMAGE, SEE THE TEMPERATURE

SEE THE TEMPERATURE, SEE THE PROBLEM

www.sajetc.comThe Motto of CSI 9830

Thermal Images of Aircraft

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Water ingress in airplane control surfaces and radomes

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Thermal image showing water ingress (dark areas) on illustrated section of aircraft

Boeing 737. The cockpit of a Boeing 737 when being boarded as shown by the Thermal Image Camera.

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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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Tire and brake system analysis

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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

AR01

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Fuse Box

23.3°C

38.1°C

25

30

35

LI01

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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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