Presentation on Condition Monitoring Technology
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Presentation on Condition Monitoring Technology
- 2. www.sajetc.com Presentation on Condition Monitoring Technology Presented By Engr. Md. Shahin Manjurul Alam Saj Engineering & Trading Company
- 3. 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 Products 2.Condition Monitoring Products 3.Sakura Automobile and Generator Filter 4.Air Conditioner Energy Saver 5.Maintenance Repair & Overhauling (MRO) Products 6.PertaminaLubricants 7.Scientific/Laboratory Equipments Our Services: 1. Remote Visual Inspection/Endoscope 2. Ultrasonic Testing 3. Magnetic Particle Testing 4. Radiography Testing 5. PenetrantTesting 6. Vibration Analysis 7. Dynamic Balancing 8. Transformer Leakage Repair 9. Thermography Service 10. Hardness Testing
- 4. 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
- 5. www.sajetc.comObjective • Condition Monitoring (CM) • Condition Monitoring Techniques • Vibration Analysis • Oil Analysis • Thermal Analysis • Ultrasound Analysis
- 6. Heat Noise Smell Smoke Feel EquipmentPerformance Time FF PP Mechanical Ultrasound Vibration Analysis Oil Analysis Thermography NDT 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 System Predictive Reactive We are in here Machine Condition Chart
- 7. Types of machines Motors Pumps Fans Gearboxes Engines Compressors Steam Turbines Generators Gas Turbines Hydro Turbines Rotating Or Reciprocating Machines www.sajetc.com
- 8. 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
- 9. 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:
- 10. 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
- 11. 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
- 12. 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. www.sajetc.com
- 13. 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
- 14. 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: 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
- 15. 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
- 16. www.sajetc.comVibration Transducer Sensors…Transducers…Probes…What 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)
- 17. www.sajetc.com Radial Horizontal Radial Vertical Axial Vertical Axial Horizontal Mounting Direction
- 18. 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
- 19. Machinery Health MonitoringMachinery Health Monitoring StrategyStrategy ~125 Machines ~1375 Machines ~500 Machines ~500 Machines Total # Machines 2,500 Typical Industrial Process Plant 5%5% CriticalCritical 25%25% EssentialEssential 30%30% ImportantImportant 20%20% SecondarySecondary 20%20% Non-EssentialNon-Essential Turbines Generators Compressors Motors Pumps Fans Gears Application at Typical PlantApplication at Typical Plant Online Solutions forOnline Solutions for critical machinerycritical machinery WirelessWireless TransmittersTransmitters Multi TechnologiesMulti Technologies Portable SolutionsPortable Solutions www.sajetc.com
- 20. By the Medical ECG we know the condition of our Heart By the CSI 2130 we check your Machinery Health Condition www.sajetc.com
- 21. www.sajetc.comDate Representation Wave Form Plot or Domain Plot FFT Spectrum Plot Orbit PlotWaterfall Plot
- 22. 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
- 23. Oil Analysis www.sajetc.com OIL . . . your engine’s lifeblood . . . can reveal its internal condition……
- 24. 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
- 25. www.sajetc.com • 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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- 30. CSI 5200 Minilab “The Oil Analyzer” The Complete Minilab with 1.CSI 5200 Main Unit 2.52DV Digital Viscometer 3.52ZM Stereo Zoom Microscope 4.51CV Camera 5.Video Capture kit 6.AMS Machinery Manager www.sajetc.com
- 31. CSI 5200- Oil Analyzer www.sajetc.com
- 32. 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.
- 33. Wear Debris Analysis www.sajetc.com
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- 35. 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 Wear Severe Sliding with Lubrication Starvation Severe Sliding Wear 35
- 36. 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
- 37. Three Body Abrasive Wear “Soft” Surface “Hard” Surface Hard abrasive contamination Cutting wear particle 37
- 38. 38 Surface Damage due to Hard Particles 38
- 39. Rolling Element Bearing Failures Surface initiated cracks propagate at acute angles to the surface Cracks initiated in subsurface by high shear stress 39
- 40. 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
- 41. 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. 41
- 42. 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
- 43. 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 microns 43
- 44. 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. 44
- 45. Fatigue Particles from Combined Rolling and Sliding Irregularly shaped smooth surface fatigue particle. 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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- 50. 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
- 51. 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
- 52. www.sajetc.com Why Thermography? • Non Contact • Rapid Scanning • Data can be recorded in differing formats • Images produced are comprehensive & reliable
- 53. 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
- 54. Aerospace Applications 1. Water ingress in airplane control surfaces and radomes 2. Tire and brake system diagnosis 3. Windshield and wing surface deicing system diagnosis 4. Stress crack and corrosion identification and location 5. Jet and rocket engine analysis 6. Composite materials delamination and disbanding location 7. Target signature analysis Thermography Applications in Aircraft www.sajetc.com
- 55. Advantages • Non Contact • Non Intrusive • Can work at a distance • Fast and Reliable • Portable • Convincing Results www.sajetc.com
- 56. CSI 9830 (HOT SHOT) IR Thermal Image Camera www.sajetc.com
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- 58. SEE THE IMAGE, SEE THE TEMPERATURE SEE THE TEMPERATURE, SEE THE PROBLEM www.sajetc.com The Motto of CSI 9830
- 59. Thermal Images of Aircraft www.sajetc.com
- 60. Water ingress in airplane control surfaces and radomes www.sajetc.com Thermal image showing water ingress (dark areas) on illustrated section of aircraft
- 61. Boeing 737. The cockpit of a Boeing 737 when being boarded as shown by the Thermal Image Camera. www.sajetc.com
- 62. Boeing 737 Turbine. Shows the heat pattern in the turbine of this jet. www.sajetc.com
- 63. Boeing 737 front wheel. Thermal imaging provided by the Camera shows no uneven wear or heating on this plane wheel. www.sajetc.com
- 64. Tire and brake system analysis www.sajetc.com
- 66. Electrical • Switch Gear • Fuse boxes • Cable runs • Electrical connectors • Insulation • Transformers www.sajetc.com
- 69. Electrical Connections Used for the detection of; • Corroded connections • Slack / loose connectors • Connectors at too high an operating temperature • Hot spots www.sajetc.com
- 74. Process Plant • Hot spots • Cold spots (Cryogenics) • Damaged or missing insulation • Tank levels www.sajetc.com
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Notas del editor
- Steel Surface after Abrasive Polishing. The smallest black dot on a white background that a person with good vision can see is about 40 µm. The abrasive scratches left on this piece of steel after polishing are therefore too fine to be seen without magnification. To the unaided eye, the surface has a matte finish. It is a dull finish, not the mirror finish achieved when a metal surface is polished to a much higher degree. Formation of Break-In Wear Particles. When a steel surface with micro-scratches is subjected to sliding wear in an oil-lubricated contact, the top most surface plastically deforms. The high points on the surface are smeared over the troughs and fine strips of metal are broken away. These strips tend to be long with straight-edges and may be recognized as break-in wear particles. Many larger, randomly shaped particles usually accompany break-in wear. Scanning Electron Photomicrograph of High Hardness Steel Undergoing Break-In Wear. The top-most surface of even extremely hard steel plastically deforms to a great extent when subjected to load in an oil-wetted sliding contact. This top most layer is sometimes referred to as the shear mixed layer, so-called because of the lack of long range crystalline order that otherwise gives the material rigidity. Surface material is not constrained on its open face so the mechanical properties are entirely different from the bulk material where the crystalline structure is constrained in all directions. The top surface layer, perhaps a few tenths of a micrometer in thickness, can be plastically deformed with ease, much like spreading peanut butter.
- Cutting wear particles are curved, forming loops and spirals, much like miniature machining swarf. Another Scanning Electron Photomicrograph of Cutting Wear Particles. In this view some large, abrasive contaminant particles may also be seen.
- Rolling contact fatigue particles are rather thick with smooth surfaces, more-or-less equal length and width, and irregular edges. Laminar wear particles indicate metal particles have been extruded through a rolling contact. When a metal particle is flattened in a rolling contact, the subsurface of the bearing undergoes higher than normal tensile stress. This may initiate subsurface cracking, which after thousands or millions of subsequent passes over the same area , will cause the crack to grow until it reaches the surface at which time a large spall particle will be generated.
- Metal spheres may be generated by welding and grinding. Fly ash from coal fired power plants contain large numbers of both ferrous (magnetic) spheres and glass (nonmetallic and transparent) spheres. Metal spheres are generated in large numbers at steel mills and foundries. Scanning Electron Photomicrograph of Ferrous Spheres. On rare occasions, ferrous spheres may be generated by the surfaces of rolling element bearings as a precursor to fatigue spalling. Spheres generated by this wear mode are all of the same approximate size and are small, less than 5 µm.
- Fatigue particles from gear pitch line have much in common with rolling element bearing fatigue particles. They generally have a smooth surface and are frequently irregularly shaped. Depending on the gear design the particles may have a major dimension-to-thickness ratio between 4:1 and 10:1. The chunkier particles result from tensile stresses on the gear surface causing the fatigue cracks to propagate deeper into the gear tooth prior to spalling. Scuffing of gears is caused by too high a load or speed causing excessive heat generation which breaks down the lubricant film causing adhesion of the mating gear teeth. The particles tend to have a rough surface and a jagged circumference. Some of the large particles will have striations on there surface indicating a sliding contact. Because of the thermal nature of scuffing quantities of oxide will be present and some particles will show signs of partial oxidation, that is tan or blue temper colors . Notice these particles are longer than they are wide, have relatively straight edges and show surface striations.