SEMINAR BY VISHNU P 1BD11MDE13

CONDITION MONITORING
SIGNATURE ANALYSIS NON-DESTRUCTIVE EVALUATIONS(NDE)

Change in Machine components parameters like vibration, noise, temperature, oil contamination, wear debris etc... , called signatures,would dictate a change in the condition poor health of the machine.

2.PREVENTIVE

MAINTENANCE

1.BREAK DOWN

3.PREDICTIVE

1.VIBRATION MONITORING
2.ACOUSTIC EMISSION (AE)

3.INFRARED THERMOGRAPHY (IRT)

4.FERROGRAPHY 5.FIELD SIGNATURE MAPPING (FSM)

VIBRATION MEASURING AND ANALYSIS SYSTEM

MACHINE

VIBROMETER

CHANNEL SELECTOR

FREQUENCY ANALYSER

RECORDER

fig,(1.a) SIGNAL FLOW DIAGRAM

MINI COMPUTERS
PROBABILITY DENSITY FUNCTION ANALYSIS (PDF) BY INSPECTION

1. VIBRATION CAUSE IDENTIFICATION

Sl No FAULT ROTATING UNBALANCE MISALIGNMENT OF BEARINGS ROLLER BEARING DEFECT FREQUENCY DIRECTION OF VIBRATION

SAME AS RUNNING SPEED

RADIAL
RADIAL AND AXIAL

2*SPEED

AT BALL OR ROLLER SPEEED RADIAL AND AXIAL ULTRA SONIC FREQUENCIES(20-60KHz) RADIAL

4.

OIL FILM WHIRL IN HIGHSPEED 0.5*SPEED TURBO MACHINES

DAMAGED OR WORN GEARS No: OF TEETH* RPM

RADIAL

MONITORING AT ROURKELA STEEL PLANT

maintenance cost 10-15% of prod: cost

BREAK DOWNS PREVENTED-10-102 EQUIPMENTS INCLUDED - 40-140

120

break downsprevented savings

No: of machines

60

80

100

insitu balancing

40

20

trend line

94-95

95-96

96-97

97-98

98-99

99-00

year

AE sensors respond with amazing sensitivity to motion in the low ultrasonic frequency range (10 kHz - 2000 kHz). Motions as small as 10-12 inches and less can be detected

This method is based on the registration of the elastic compression waves that are emitted by the defects developing in the stressed constructions.

AE data collection systems Laptop based AE system DiSP Systems (any number of channels can be used) Portable AE test system (lunch box)

CASE STUDY
AE DURING HYDROTESTING OF A HORTON SPHERE
MAX: PRESSURE 22 Kg/cm2

Pressurization (Stage 1) Random AE activity due to 1. Mechanical rubbing between support structure and vessel 2. Paint layer peel-off . Re pressurization (Stage 2) No significant AE activity
AE SIGANLS FROM NEWER AREA

(
Fig.2(f) AE monitoring during hydro testing of Horton sphere

local plastic deformation )

NO SIGNAL DURING SUBSEQUENT PRESSURIZATION

Infrared thermography is based on the principle of detection and measurement of infrared radiations QR) arising from the natural or stimulated thermal radiation of an object21

I R MEASURING SYSTEMS

Type Spectral [m] Detector material Detector cooling range

VARIOSCAN 3021 ST 8 ... 12 Hg, Cd, Te Stirling-cooler

ThermaCAM S60 : Real-Time Thermal highly sensitive thermal imaging, precision temperature measurement, enhanced connectivity options including high speed data transfer extensive thermal analysis capabilities

CASE STUDY

raw thermo graphic data.

data after removing the noise and vertical gradient.

correspond to low strength welds.

high strength welds

data processed for the local gradient in surface temperature.

Fig setup for infrared testing of lap joints

1.WEAR DEBRIS ANALYSIS

MODE: ABRASION, IMPACT, FATIGUE, EROSION, CORROSION RATE : CONCENTRATION OF WEAR DEBRIS SEVERITY : SIZE OF DEBRIS INDICATES LOCATION : COLOUR OF THE PARTICLES

2.SPECTROMETRIC ANALYSIS
OIL ELECTRICALLY EXCITED TO THE POINT WHERE LIGHT IS EMITTED. ELEMENT EMITS A LIGHT OF ITS OWN PARTICULAR COLOR AND FREQUENCY. SPECTROMETERS TRANSLATES THE INTENSITY OF THIS RAINBOW OF COLORS INTO A COMPUTERIZED READOUT.

HOW IS THE TEST PERFORMED

Tests # Glycol Test Viscosity Appearance/Odor Spectrometric Analysis Alkaline Reserve Blotter Spot Test Water Content Distillation Flash Point * * * * * * * * * * * * * * * * * Conditions Detected Abnormal Wear Fuel Dilution Dirt Water Coolant * * * Incorrect Oil Oxidation Additive Depletion

METAL WEAR POSSIBLE ORIGIN.

ALUMINIUM CHROMIUM COPPER IRON SILVER
BEARINGS,BLOCKS,BLOWERS,BUSHINGS, CLUTCHES,PISTONS. BEARINGS,PUMPS,RINGS,RODS. BEARINGS,BUSHINGS,CLUTHES,WASHERS. BLOCKS,CRANK SHAFTS, CYLINDERS,DISCS. SOLDERS.

TIN

PISTONS.

ModelT2FMAnalytical Ferrograph.
This measure the effects of Contamination and electro-chemical changes that occur in synthetic and petroleum based oils Bi chromatic microscope. Video camera. Video capture card. Image capture software. industrial standard personal computer.

The FSM Inspection Tool (FSM) is a new technology for monitoring and inspection of metallic pipes and structures, pipelines and storage vessels
Reduce life cycle inspection costs Reduce inspection time

Graphical plots indicating the severity and location of corrosion, and calculates actual corrosion and metal loss

Sensing pins (electrodes) in an array over the monitored area to detect changes in the electrical field pattern. The voltage = the signature.

A typical refinery monitors high temperature areas such as heater bends in the distillation unit.

NDT TECHNIQUE

DETECTION CAPABILITY
VOLUMETRIC

NON CONTACT INSPECTION

POSSIBLE

AUTOMATED INSPECTION
POSSIBLE

DEFECT SIZING
POSSIBLE

VIBRATION
ACOUSTIC EMISSION I R THERMOGRAPHY FERROGRAPHY

VOLUMETRIC SURFACE , NEAR SURFACE VOLUMETRIC SURFACE, NEAR SURFACE

POSSIBLE

POSSIBLE

NOT POSSIBLE

POSSIBLE

POSSIBLE

POSSIBLE

POSSIBLE

POSSIBLE

POSSIBLE

FSM

POSSIBLE

POSSIBLE

POSSIBLE

The implementation of condition monitoring methodologies to components and plants is very essential for ensuring safety and reliability and for increasing productivity of plants. Nondestructive evaluation techniques which aim at detection and characterization of defects, fatigue, stresses, corrosion, dimensional changes and micro structural degradations in materials, bear unique potential for applications related to the condition monitoring of components and plants.