CONDITION MONITORING

A K Darpe
Department of Mechanical Engineering
Indian Institute of Technology Delhi
Sound Maintenance Program: Need of the day

Periodic Measurements: Not foolproof

Predictive Maintenance (online continuous

monitoring):
# catches the fault early
# cost effective

Narora Atomic Power Plant failure: could have

been avoided

FDAS, OLES-OSBUDD for KAPS developed

Sound Maintenance Program: Need of the day

Periodic Measurements: Not foolproof

Predictive Maintenance (online continuous

monitoring):
# catches the fault early
# cost effective

Narora Atomic Power Plant failure: could have

been avoided

FDAS, OLES-OSBUDD for KAPS developed

 Definition of Expert System
• A computing system capable of representing and
reasoning about some knowledge rich domain, which
usually requires a human expert, with a view toward
solving problems and/or giving advice.
– The level of performance makes it “expert.”
– Some also require it to be capable of explaining its
reasoning.
– Does not have a psychological model of how the
expert thinks, but a model of the expert’s model
of the domain.
 Expert System Developed in IIT Delhi
• OLES (online expert system)
• OSBUDD (operator support and backup data
display).
• Uses knowledge base compiled by John S
Sohre.
• Continuous online vibration and process data
can be acquired from any machine.
• The diagnosis of the fault is almost
instantaneous.
• The important vibration data be trended over
any interval of time.
• Orbit plot, waterfall plot, can be plotted.
• An integrated signal analysis toolbox is
provided.
DEVELOPMENT OF AN ONLINE DIAGNOSTIC SYSTEM FOR
KAKRAPAR ATOMIC POWER PLANT

Schematic of the system

Frequency Domain Signal
TG Vibration
Signals

Diagnostic
Transducer
Signal
Conditioning
FDAS System
(OLES)

Process
Signals

Signal Flow for FDAS

 Signals received by FDAS

• Vibration Signals
– Bearing vibration signals - 12 Nos
– Shaft vibration signals - 8 Nos

• Important Process Signals

– Generator Power
– Condenser vacuum
Schematic of the system
 OSBUDD
(Operator Support and Back Up Data
Display)
Displays processed data in various
format

Trend of important vibration parameters

Expert system diagnostic results

Provision of reviewing past data

Demo and Help for operator assistance

Plots: Time Domain
Frequency Domain
Trend
Orbit
Waterfall

Analysis: Expert System Diagnosis

Signal Processing

Assistance: Demo
Help
Backup Data Loader
 Expert System
Each fault produces a typical frequency
pattern (signature)

Sohre’s Database as knowledge base

Direction and type (shaft/brg) of

predominant vibration taken into account

Expert system estimates probability of

each fault, lists five most probable ones.
 COMMERCIAL CONDITION
MONITORING SYSTEMS
Diagnostic tool from DSA International
• Automated diagnostic system called Check-mate
• Uses frequency spectrum of vibration from common
data collection systems (either offline or online)
• User can select from the list of vibration spectra
available at any particular point of the machine of
interest.
• After selection the expert system compares the
vibration levels of that particular point with alarm
levels and suitable remedial action can be taken
• In the latest version of check-mate up to 700 spectra
can be automatically analyzed in under 10 minutes.
 Check-Mate identifies
• Unbalance.
• Off-set misalignment.
• Angular misalignment.
• Bent shaft.
• Looseness.
• Unequal foundation stiffness.
• Coupling lock-up.
• Bearing problems-preload, looseness, inner race,
outer race, ball train defects.
• Gear defects-tooth wear, misalignment, eccentricity,
broken or worn tooth/teeth, hunting tooth faults.
Cont…
 Check-Mate identifies
• Sub-synchronous bearing instability.
• Electrical faults-cracked rotor bars, eccentric rotor.
• Rubs-rotor, axial.
• Belt problems.
• Cavitation.
• Oil whirl.
• Dry whirl.
• Check-mate identifies faulty readings caused by a
loose or damaged sensor.
 Unique Features of Check-Mate
• Model based, object oriented and data driven .
• Machines are quickly modeled with in built parts such
as gears, bearings, shafts and motors.
• Spectra are accessed simply by clicking on the
measurement locations.
• Frequencies associated with the typical generic faults
are easily displayed by clicking on that part's icon.
• Spectral peaks are quickly identified.
• The user can go the the part and ask for 1X, 2X, 3X
rotation speed or the BPFO (outer race ball pass
frequency) and multiples to be displayed on the
current spectra.
Cont…
                                         
 Unique Features of Check-Mate
• Trends for specific fault frequencies are extracted
from waterfall diagrams.
• Trends will also accurately track harmonics and wide
band frequencies.
• Alert levels are set for individual fault frequencies,
harmonics and wide-band modulations.
• Actual frequencies for alerts are automatically
recalculated for machine speed of each spectrum.
• Diagnostics include clear advice on appropriate
operation or maintenance actions.
• DSA international can supply customized rules or
machine parts to meet one’s special requirements.
DSA International Corporation
4580 Marineview Crescent
North Vancouver, BC V7R 3P5
Canada
phone:  604-986-0936
fax:       604-986-0935
email:   alees@dsaint.com
 A Fault Diagnosis and Maintenance
Expert System for Rotating Machinery
• The FDMES for rotating machinery has its own
distinguishing feature in both the rules and reasoning
mode.
• Knowledge based rules of FDMES are compiled from
diagnostic tables of mechanical faults.
• The FDMES can diagnose 58 kinds in 10 categories of
mechanical faults give the second reasons: design
and manufacture, installation and maintenance,
operation and control, machine deterioration and
give the methods of prevention and cure.
• FDMES is used in 18 large enterprises in China.
 BENTLY NEVADA’ Data Manager
• Bently Nevada’s data manager (DM2000) with
continuous, online data acquisition, archiving, and
display capabilities.
• Static and dynamic data under steady-state and
transient operating conditions can be collected.
• Data acquisition modes can be both automatically and
manually initiated.
• Data display stations can be located where desired in
LAN,WAN or RAS.
• MMS(Machinery Management Services) engineers are
available for help. The MMS engineers may be able to
determine the condition of machinery from the
remotely transmitted data alone.
 Display plots available
• Current values, bar graph, machine train diagram,
trend, fast trend, high resolution trend , multivariable
trend, acceptance region, time base, shaft average
centerline, spectrum/full spectrum, alarm list, system
list, waterfall, bode, polar, cascade, plus orbit and
plus spectrums.
• Along with expert system, Bently Nevada provides
hardware and software products primarily designed
for online acquisition and presentation of data and
information.
• Bently Nevada provides portable condition monitoring
solutions.
 BENTLY NEVADA’ System 1TM
• System 1™ is a patented modular and scalable
software platform for managing plant asset data and
information.
• Increases asset availability and reliability by providing
a single, integrated tool for storing, accessing, and
managing plant production assets with information,
rather than simply data.
• System 1™ replaces previous Bently Nevada stand-
alone online software programs such as
Trendmaster® 2000, data manager® 2000, and
machine condition manager™ 2000 by combining the
functionality of these products into a single platform.
Cont…
• Accepts data from any data source, not just Bently
Nevada condition monitoring hardware.
• Provides tools to capture and use condition data,
historical data, baseline data, nameplate data, asset
properties, lessons learned, and other relevant
information.
• Provides tools to link documents and files, write
reports, and to exchange data with other systems.
• High-end data analysis tools for diagnostics and root
cause analysis are also part of System 1™
• SYSTEM 1TM is designed to be modular and scalable.

Cont…
• Using this platform, a solution can be built to
support a wide range of user scenarios in many
industries such as
– Power generation
– Pipelines
– Refineries
– Marine
– Oil and gas
– Waste water treatment
– Food and pharmaceutical
– Semiconductor manufacturing
– Petrochemical
– Pulp and paper
– Metals and mining
 MasCon/ ProCon
• NAIDEN’S (an SKF group Company) MasCon/ ProCon
online system monitors and diagnoses various process
and machine component conditions, and provides
automatic advice for correcting existing or impending
conditions.
• MasCon’s in-built hardware auto-diagnosis system
continuously checks all sensors, cabling and
electronics for any faults, signal interruption,
shortcuts, or power failure.
• Any malfunctions triggers an alarm, and in the case of
system power failure the system will automatically
restart when the power returns.
Cont…
 MasCon/ ProCon
• Data is transferred via TCP/IP. It can be sent to
company for quick help and action.
• 32 different sensors, signal and measurement
configuration can be accommodated.
• Individual conditions for warning and alarm may be
set for each point.
• By using expert guide, in-built software, One can add
the new machines using simple mouse clicks.
• The frequency bands, resolution, defect frequencies,
machine diagnosis are generated automatically.
• Damaged machine components are identified
independently of the measurement point position.

Cont…
• Warnings and alarms are indicated in machine
picture by yellow or red color measurements.
• Measurements are made by mouse click over desired
point with overdue measurement indicators.
• Remote access via modem or internet is available.
• Selected reference spectra may be fixed and
automatically matched with new or earlier
measurements.
• Early detection of bearing faults using DPE (digital
peak enveloping).
• Triggering alarm levels may be set to adjust
automatically to load level and rotational speed.

Cont…
• Advanced turbine fault diagnostics system:
• Detection of eccentricity change in coupling,
• Blade failure,
• Bearing instability,
• Steam whirl,
• Rotor crack,
• Rotor rubbing,
• Temporary rotor bow,
• Loose bearing pedestal,
• Inclined position of bearing,
• Electrical run-out,
• Mechanical run-out,
• Loose stator core in generator,
• Change of imbalance at shutdown,
• Radial bearing damage,
• Inter turn short circuit in generator rotor, etc.
 Korea Institute of Science and
Technology .
• Development of integrated diagnostic system for
rotating machinery.
• Development of a portable vibration monitoring
system, which can transfer data on USB port.
• Diagnostic algorithm based on Sohre¡’s chart and a
rule base.
• Monitoring test for various fault case by using
integrated simulator.
• Tele-monitoring system by internet.
• Pre-step of new technology commercialization
through a small-size and integration.
• Integrated machine health monitoring system.
 CONDITION MONITORING
SENSORS
Signal Acquisition
Vibratory system

Knowledge base

Residual Life
Signal Processing
Loading History

Fault Identification
Data Analysis
Damage Severity And Representation
Identification
Gear Teeth Mesh Forces
 Gear blank digs into pinion and
withdraws once in one rotation
Second gear
xcos(t) xacos(at)
teeth mesh

Time for 1 revolution of gear

First gear
teeth mesh
Time for 1 revolution of gear
Time (sec)

Time (sec) x(t )  [ x  xa cos(a t )] cos t

First gear
teeth mesh
Time for 1 revolution of gear

Time (sec)
 Amplitude Modulation in Gear Pair

x(t )  [ x] cos t With perfect gearing condition

modulation frequency i.e., rotational

speed of the gear - a

carrier frequencies i.e.,gear mesh

frequency - 

x(t )  [ x  x a cos( a t )] cos t With imperfect gearing condition

xa x
x(t )  [ x cos t  xa cos t cos(a t )]  x cos t  cos(  a )t  a cos(  a )t
2 2
 Time domain information:
mostly rich in content, little in information
 User defined
software for
further
processing
Accelerometer

Charge I/P Charge AID card Lab view

Amplifier Voltage
software
loaded on
PC
Vibration being
sensed

Computer

VIBRATORY SYSTEM

ITEMS COST IN RUPEES

(Rs)
a) Charge based accelerometer 20,000 to 50,000
(piezoelectric)
b) ICP type Accelerometer 15,000 to 40,000
c) Charge Amplifier (required only for charge type accelerometer) 1,00,000 to 2,00,000
d) Analog to Digital Converter Card 25,000 to 1,20,000
(depending upon number of channels & sampling
rate)
e) Labview Software for acquisition & subsequent signal 80,000 onwards
processing. (basic version could cost
more for pvt industry.
 Lapto
p

Charge
Amplifier
Portable data
acquisition
system
Channel Tach
Acceleromet s o
er

Vibratory structure

ITEMS COST IN RUPEES

(Rs)
Portable Data Acquisition system 18,00,000 roughly
(OROS, PULSE (B&K), Pimento with Virtual Lab (LMS), etc. for 8 channel Data
Acquisition System
 Summary

• Knowledge about the system

• Selection of transducers, acquisition
system
• Features of signal processing and
problems/issues associated with it
• Data representation techniques
• Interpretation
• Experience – knowledgebase – update