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SEMINAR BY

VISHNU P

1BD11MDE13

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CONDITION MONITORING

SIGNATURE ANALYSIS

NON-DESTRUCTIVE EVALUATIONS(NDE)

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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.

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2.PREVENTIVE

3.PREDICTIVE1.BREAKDOWN

MAINTENANCE

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1.VIBRATION MONITORING

2.ACOUSTIC EMISSION (AE)

3.INFRARED THERMOGRAPHY (IRT)

4.FERROGRAPHY

5.FIELD SIGNATURE MAPPING (FSM)

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VIBRATION MEASURING AND ANALYSIS SYSTEM

VIBROMETER CHANNELSELECTOR

FREQUENCY

ANALYSER RECORDER

fig,(1.a) SIGNAL FLOW DIAGRAM

MACHINE

MINI COMPUTERS

PROBABILITY DENSITY FUNCTION ANALYSIS (PDF)

BY INSPECTION

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Sl

NoFAULT FREQUENCY

DIRECTION OF

VIBRATION

1ROTATING

UNBALANCESAME AS RUNNING SPEED RADIAL

2MISALIGNMENT

OF BEARINGS

2*SPEEDRADIAL AND

AXIAL

3ROLLER BEARING

DEFECT

AT BALL OR ROLLER SPEEED

ULTRA SONIC

FREQUENCIES(20-60KHz)

RADIAL AND

AXIAL

4.

OIL FILM WHIRL

IN HIGHSPEEDTURBO MACHINES

0.5*SPEED RADIAL

5DAMAGED OR

WORN GEARSNo: OF TEETH* RPM RADIAL

1. VIBRATION CAUSE IDENTIFICATION

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MONITORING AT ROURKELA STEEL PLANT maintenance cost 10-15% of prod: cost

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No:

ofmachines

0

20

40

60

80

100

120

94-95 95-96 96-97 97-98 98-99 99-00

break

downsprevented

savings

insitu balancing

trend line

year

BREAK DOWNS PREVENTED-10-102

EQUIPMENTS INCLUDED - 40-140

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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

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This method is based on the registration of the elastic compression waves that

are emitted by the defects developing in the stressed constructions.

http://www.eltest.ru/video/pip.mpg

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AE data collection systems

Laptop based AE system

DiSP Systems (any number of channels can be used)

Portable AE test system (lunch box)

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Pressurization (Stage 1)

Random AE activity due to

1. Mechanical rubbing between supportstructure and vessel

2. Paint layer peel-off .

Re pressurization (Stage 2)

No significant AE activity

CASE STUDY

AE DURING HYDROTESTING OF A HORTON

SPHERE

MAX: PRESSURE 22 Kg/cm2

Fig.2(f) AE monitoring during hydro

testing of Horton sphere

AE SIGANLS FROM NEWER AREA (local plastic deformation )

NO SIGNAL DURING SUBSEQUENT

PRESSURIZATION

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Infrared thermography is based on the principle of detection andmeasurement of infrared radiations QR) arising from the natural orstimulated thermal radiation of an object21

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TypeVARIOSCAN

3021 ST

Spectral range

[m] 8 ... 12

Detector

materialHg, Cd, Te

Detector cooling Stirling-cooler

I R MEASURING SYSTEMS

ThermaCAM S60 : Real-Time Thermal

highly sensitive thermal imaging,precision temperature measurement,

enhanced connectivity options including

high speed data transfer

extensive thermal analysis capabilities

http://news.thomasnet.com/images/large/2002/12/17793.jpg

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raw thermo g raphic data.

data after remo ving the noise and v ert ical

gradient .

data processed for the loc al gradient in

surface temperature.

CASE STUDY

high strength welds

F ig setup for inf rared testing of lap joints

correspond to low

strength welds.

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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 ANDFREQUENCY.

SPECTROMETERS TRANSLATES THE INTENSITY OF THIS RAINBOW OFCOLORS INTO A COMPUTERIZED READOUT.

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HOW IS THE TEST PERFORMED

Tests Conditions Detected

#Abnormal

Wear

Fuel

DilutionDirt Water Coolant

Incorrect

OilOxidation

Additive

Depletion

Glycol Test *

Viscosity * *

Appearance/Odor * * * * *

Spectrometric

Analysis* * * *

Alkaline Reserve * *

Blotter Spot Test * * *

Water Content *

Distillation *

Flash Point *

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METAL WEAR POSSIBLE ORIGIN.

ALUMINIUM BEARINGS,BLOCKS,BLOWERS,BUSHINGS,CLUTCHES,PISTONS.

CHROMIUM BEARINGS,PUMPS,RINGS,RODS.

COPPER BEARINGS,BUSHINGS,CLUTHES,WASHERS.

IRON BLOCKS,CRANK SHAFTS, CYLINDERS,DISCS.

SILVER SOLDERS.

TIN PISTONS.

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ModelT2FMAnalyticalFerrograph.Bi chromatic microscope.

Video camera.

Video capture card.

Image capture software.

industrial standard personal computer.

This m easure th e effects

of Contaminat ion and

electro-chem ical changes

that occur in syn thet ic

and petro leum based oi ls

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The FSM Inspection Tool (FSM) is a newtechnology for monitoring and inspection ofmetallic pipes and structures, pipelines andstorage vessels

Reduce life cycle inspection costs

Reduce inspection time

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Sensing pins (electrodes) in an

array over the monitored

area to detect changes

in the electrical field pattern.

The voltage = the signature.

Graphical plots indicating theseverity and location of corrosion,

and calculates actual corrosion

and metal loss

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A typical refinery monitors high temperature

areas such as heater bends in the

distillation unit.

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NDTTECHNIQUE

DETECTIONCAPABILITY

NON CONTACTINSPECTION

AUTOMATEDINSPECTION

DEFECTSIZING

VIBRATION VOLUMETRIC POSSIBLE POSSIBLE POSSIBLE

ACOUSTIC

EMISSIONVOLUMETRIC POSSIBLE POSSIBLE

NOT

POSSIBLE

I R THERMO-

GRAPHY

SURFACE ,

NEAR

SURFACE

POSSIBLE POSSIBLE POSSIBLE

FERROGRAPHY VOLUMETRIC POSSIBLE POSSIBLEPOSSIBLE

F S M

SURFACE,

NEAR

SURFACE

POSSIBLE POSSIBLE POSSIBLE

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The implementation of condition monitoringmethodologies 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.

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