Condition Monitoring of Machine Components

IPE 3203: Materials Handling and Maintenance Engineering

Md. Ariful Alam

Lecturer
Dept. of IPE, BAUST
 Vibration based monitoring
Vibration monitoring and analysis: One of the most widely used PTI
approaches, it is useful in assessing the condition of rotating equipment
and structural stability in a system.
The techniques of vibration monitoring and analysis include spectrum
analysis, torsional vibration, waveform analysis, shock pulse analysis,
and multichannel vibration analysis. The vibration monitoring and
analysis approach is applicable to items such as engines, shafts,
motors, pumps, gearboxes, bearings, turbines, and compressors.
Vibration based monitoring is the main stream of current applications
of condition monitoring in industry. Vibration based monitoring is an
on (off) line technique used to detect system malfunction based on
measured vibration signals. Generally speaking, vibration is the
variation with time of the magnitude of a quantity that is descriptive of
the motion or position of a mechanical system, when the magnitude is
alternatively greater than and smaller than some average value or
reference.
 Vibration based monitoring
Vibration monitoring consists of essentially in identifying two
quantities:
- the magnitude (overall level) of the vibration
- the frequency content (and/or time waveform)
Potentially, all machines can benefit from vibration monitoring
except, perhaps, those running at very low speed (below about 20
rev/min), and those where isolation (or damping) occurs between the
source and the sensor.
 Oil based monitoring
A detailed analysis of a sample of engine, transmission and hydraulic oils is a
valuable preventive maintenance tool for machines. In many cases it enables the
identification of potential problems before a major repair is necessary, has the
potential to reduce the frequency of oil changes, and increase the resale value of
used equipment.
Oil based monitoring involves sampling and analyzing oil for various properties
and materials to monitor wear and contamination in an engine, transmission or
hydraulic system etc. Sampling and analyzing on a regular basis establishes a
baseline of normal wear and can help indicate when abnormal wear or
contamination is occurring.
Oil analysis works as follows. Oil that has been inside any moving mechanical
apparatus for a period of time reflects the possible condition of that assembly. Oil
is in contact with engine or mechanical components as wear metallic trace
particles enter the oil. These particles are so small they remain in suspension.
Many products of the combustion process also will become trapped in the
circulating oil. The oil becomes a working history of the machine. Particles caused
by normal wear and operation will mix with the oil. Any externally caused
contamination also enters the oil. By identifying and measuring these impurities,
one can get an indication of the rate of wear and of any excessive contamination.
An oil analysis also will suggest methods to reduce accelerated wear and
contamination.
 Oil based monitoring
Today there exist a variety of forms of oil based condition monitoring
methods and techniques to check the volume and nature of foreign
particles in oil for equipment health monitoring. There are spectrometric
oil analysis, scan electron microscopy/energy dispersive x-ray analysis,
energy dispersive x-ray fluorescent, low powered optical microscopy,
and ferrous debris quantification. One purpose of the oil analysis is to
provide a means of predicting possible impending failure without
dismantling the equipment.
 Bimetallic and Magnetic Temperature Sensors
A bimetallic temperature sensor is a mechanical element constructed
from two different metals bonded together. As the temperature changes,
the two metals expand at different expansion rates causing movement at
the free end of the bimetallic pair. Magnetic temperature sensors refer to
devices fitted with magnets to allow attachment of the temperature
gauge to any ferrous metallic object for which its local temperature is
desired.
• Typical P-F interval: Provides a continuous output, data recorded
several times per day (permanently installed) Weeks to months
(magnetic – not permanently installed)
• Skill level: No specific training needed
 Temperature-indicating Paint
This contact measurement technique is used to indicate the surface
temperature of objects upon which a special paint has been applied. The paint
will change colors as the surface temperature of the monitored object
increases, and it retains the color of the highest temperature the surface has
encountered. This technique can be used to locate hot spots and insulation
failures.
• Typical P-F interval: Weeks to months
• Skill level: No specific training needed
Advantages. Advantages of this technique include the following:
i) The test is simple and no special training is required to observe the results.
ii) The paint retains the color of the highest temperature reached, providing a
permanent record.
Disadvantages. Disadvantages of this technique include the following:
i) Once the paint color changes, it does not change back to the original color.
ii) The effective life of an application of the paint is usually one (1) or two (2)
years, or until the paint changes color.
 Infrared Thermography
This non-contact technique uses infrared cameras to measure the temperature
of heat-radiating surfaces within the line of sight of the camera. [Note: Infrared
radiation is emitted from all objects above the temperature of absolute zero (–
273°C)]. The camera measures temperature variations on the surface of the
object being monitored and converts the temperature data into video or audio
signals that can be displayed or recorded in a wide variety of formats for future
analysis. This form of condition monitoring produces color or gray-scale
images that identify temperature differences in the surface being examined.
The thermal image quality can be affected by the following factors:
• The distance between the camera and the object.
• Excess humidity in the measured environment from rain or condensed steam,
for example.
• Extraneous radiation emitted from surrounding objects or bright sunlight.
• The presence of insulation material between the camera and the object.
• The shape (such as angular relation to the camera) and surface condition.
• Typical P-F interval: Minutes* to months (* for permanently mounted
cameras)
• Skill level: Trained and experienced technician
Advantages of this technique include the following:
i) Cameras can be portable and are generally considered easy to operate.
ii) It provides dramatic images of the object’s temperature profile.
iii) It provides non-contact testing (i.e., safe to measure energized electrical
systems, can measure object without disturbing its temperature).
iv) The temperature of large surface areas can be observed quickly and
continuously.
v) A wide variety of equipment options is available, including various lenses
and zoom-view capabilities.
vi) Test data can be recorded, printed, logged, or fed to other digital
equipment.
Disadvantages: Disadvantages of this technique include the following:
i) Equipment costs are considered moderate to expensive. Price ranges from
US$400 to 10,000 depending on instrument sensitivity and various features.
ii) Interpretation of the results requires training and experience.
iii) The cameras do not measure well through metal or glass housings or
barriers.
 The acoustic emission (AE)
The acoustic emission (AE) based method is used widely for monitoring the
condition of rotating machinery. Compared to traditional vibration based
methods, the high frequency approach of AE has the advantage of a
significant improvement in signal to noise ratio.
An item to note is that AE transducers need to have a relatively narrow band
to be able to detect high frequency faults. The Motor current noise signature
analysis methods and apparatus for monitoring the operating characteristics
of an electric motor-operated device, such as a motor-operated valve, have
been frequently used for early detection of rotor related faults in AC
induction Motors. Frequency domain signal analysis techniques are applied
to a conditioned motor current signal to distinctly identify various operating
parameters of the motor driven device from the motor current signature.
All the techniques briefly introduced above can offer some help for
indicating the current state or condition of the plant monitored. Based on the
technical analysis of the observed condition monitoring data, a maintenance
decision has to be made to maintain the plant in a cost effective way. We
discuss in the next section, how modeling can be used to support such a
decision making utilizing available monitoring information.
 Electrical condition monitoring
This includes various technologies and approaches that provide a
comprehensive system evaluation. By monitoring important electrical
parameters it provides useful data to detect and rectify electrical related
faults such as phase imbalance, insulation breakdown, and high
resistance connections. Electrical faults are costly and present safety
concerns because in systems they are seldom visible. Table lists several
electrical condition monitoring methods. These methods can monitor
equipment such as electrical motors, electrical distribution cabling,
generators, electrical distribution transformers, electrical distribution
switchgear and controllers, and distribution systems. The specific
electrical condition monitoring methods for these six types of equipment
are presented in Table.
 Lubricant and wear particle analysis
Three reasons for performing this type of analysis are: to assess wear
condition of equipment, to assess the lubricant condition, and to assess
if the lubricant is contaminated. The test used for the above purposes
will depend on factors such as cost, sensitivity and accuracy of the test
results, and the equipment construction and application. A list of
standard analytical tests is presented in Table.
 Nondestructive testing
This technique can determine material properties and quality of
manufacture for high-value parts/assemblies without damaging the
product or its function. Usually, nondestructive testing (NDT) is
practiced when approaches such as destructive testing are cost-
prohibitive or ineffective. NDT is associated with welding of large high-
stress parts such as pressure vessels and structural supports. In addition,
oil refineries and chemical plants use NDT methods to assure pressure
boundaries’ integrity for systems processing of volatile substances.