Presentation on Condition Monitoring

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

2. 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. 3. 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 4. 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 www.sajetc.com 5. www.sajetc.comObjective Condition Monitoring (CM) Condition Monitoring Techniques Vibration Analysis Oil Analysis Thermal Analysis Ultrasound Analysis 6. Types of machines Motors Pumps Fans Gearboxes Engines Compressors Steam Turbines Generators Gas Turbines Hydro Turbines Rotating Or Reciprocating Machines www.sajetc.com 7. www.sajetc.comWhat type of Maintenance Do we Have 8. 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 9. 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 10. 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: 11. 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 12. Vibration Analysis 13. 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 14. Vibration Analysis More than 20 years ago someone made the statement, The vibrations produced in a machine are the best indication of the machines 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. www.sajetc.com 15. 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 16. 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: Gs (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 17. www.sajetc.comVibration Transducer SensorsTransducersProbesWhat 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) 18. 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 19. www.sajetc.com Radial Horizontal Radial Vertical Vertical Axial Horizontal Mounting Direction 20. 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 21. 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 22. www.sajetc.comDate Representation Wave Form Plot or Domain Plot FFT Spectrum Plot Orbit PlotWaterfall Plot 23. 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 24. Oil Analysis 25. Oil Analysis www.sajetc.com OIL . . . your engines lifeblood . . . can reveal its internal condition 26. 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 www.sajetc.com 27. 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) 28. 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 29. 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 30. www.sajetc.com Particle Count and Shape Analysis Sliding WearCutting Wear NonmetallicFatigue Wear Particle Counting Particle Shape Analysis 31. www.sajetc.comFerrography 32. 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 (%) 33. Wear Debris Analysis www.sajetc.com 34. 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 35. Infra-Red Thermography 36. 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 37. www.sajetc.com Why Thermography? Non Contact Rapid Scanning Data can be recorded in differing formats Images produced are comprehensive & reliable 38. Advantages Non Contact Non Intrusive Can work at a distance Fast and Reliable Portable Convincing Results www.sajetc.com 39. SEE THE IMAGE, SEE THE TEMPERATURE SEE THE TEMPERATURE, SEE THE PROBLEM www.sajetc.com The Motto of Thermal Imaging 40. Thermal Images 41. www.sajetc.com Thermal image showing water ingress (dark areas) on illustrated section of aircraft 42. Boeing 737 Turbine. Shows the heat pattern in the turbine of this jet. www.sajetc.com 43. Boeing 737 front wheel. Thermal imaging provided by the Camera shows no uneven wear or heating on this plane wheel. www.sajetc.com 44. Jet Engine analysis www.sajetc.com 45. Electrical Switch Gear Fuse boxes Cable runs Electrical connectors Insulation Transformers www.sajetc.com 46. Fan 1 3 2 2 3 3 R 0 1 www.sajetc.com 47. Fuse Box 2 3 2 3 3 L I 0 www.sajetc.com 48. Electrical Connections Used for the detection of; Corroded connections Slack / loose connectors Connectors at too high an operating temperature Hot spots www.sajetc.com 49. Electronics www.sajetc.com 50. Electric Motor Bearing www.sajetc.com 51. Electrical Motor www.sajetc.com 52. High Voltage Substation www.sajetc.com 53. Process Plant Hot spots Cold spots (Cryogenics) Damaged or missing insulation Tank levels www.sajetc.com 54. www.sajetc.com Ultrasound Analysis 55. 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) 56. www.sajetc.com Advantages of Ultrasound Directional Locatable Multiple applications Utilizable in all environments Early warning failure indication Supports other technologies 57. www.sajetc.com Application Groups Leak detection Compressed air Specialty gasses Vacuum Steam traps / valves Electrical Inspection Mechanical Inspection Slow speed bearings Lubrication 58. www.sajetc.com 59 Ultrasonic Leak Detector Locate the leak Measure the Leak Calculate costs Calculate Greenhouse Gas emission reduction 59. How Leaks Develop Fluid: Liquid or gas Turbulent Flow Produces Ultrasound PRESSURE VACUUM www.sajetc.com 60. www.sajetc.com Good Valve Bad Valve 61. Electric Inspection Switchgear Transformers Insulators Relays Breakers 26.8 24.4 *>28.4F *28.4F *