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Presentation & Demonstration on

Condition Monitoring

By

Engr. Md. Shahin Manjurul AlamSaj Engineering & Trading Company

www.sajetc.comObjective

• Condition Monitoring (CM)• Condition Monitoring Techniques• Vibration Analysis • Oil Analysis

Types of machines

MotorsPumpsFansGearboxesEnginesCompressorsSteam TurbinesGeneratorsGas TurbinesHydro Turbines

Rotating Or

Reciprocating Machines

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Heat

Noise

Smell

Smoke

Feel

Equipment Perform

ance

TimeFF

PP

Mechanical

UltrasoundVibration

Analysis

Oil Analysis

Thermograp

hyNDT

Lubrication Excellence

Proactive

Precision Maintenance Alignment, Balance, etc.

Select SuppliersSupplier Specifications

MetricsEquipment Ranking

RCMTPM

RCA/FMEARCDTraining ProgramsWritten Procedures

Job Planning/SchedulingCMMS System

Predictive Reactive

We are in here

Machine Condition Chart

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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

Machine condition monitoring technologies

Industrial requirements for machine condition monitoring

•Non-intrusive measurements

•Early detection to reduce cost

•Multiple technologies for complete assessment

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Condition Monitoring For your Plant

Vibration Analysis Oil Analysis

UltrasoundAnalysis

ThermalAnalysis

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If you think this is your plant, then your plant is stand on this 4 technologies

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

Machine failures

…and the VIbration is a common cause of failure

are very costly… sometimes spectacular,

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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.

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www.sajetc.comCommon Problems that Generate

Vibration1. Misalignment2. Unbalance3. Worn belts & pulleys4. Bearing Defects5. Hydraulic Forces6. Aerodynamic Forces7. Reaction Forces8. Reciprocating Forces9. Bent Shafts10.Rubbing11.Gear Problems12.Housing Distortion13.Certain Electrical

Problems14.Frictional Forces

www.sajetc.comWhat we Measure for

Vibration Analysis

Amplitude: How Much Movement Occurs or severity of the vibration.

Amplitude measures as1. Displacement: mm, mils (0.001”)2. Velocity: mm/sec, in/sec3. 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

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

www.sajetc.comVibration Transducer Sensors…Transducers…Probes…What is it?

….It basically converts mechanical vibration to an electrical signal

AccelerometerCharge Type &

Line DriveConstant Voltage &Constant Current

VelocityTransducer

DisplacementShaft Riders

Proximity Probes(Eddy Current Probes)

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Radial Horizontal

Radial Vertical

Axial

Vertical

Axial

Horizontal

Mounting Direction

www.sajetc.comMounting DirectionVert.

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 whenThere is a thrust bearing or axial potential faults eg. misalignment

Machinery Health Monitoring Machinery Health Monitoring Strategy Strategy

~125 Machines

~1375 Machines

~500 Machines

~500 Machines

Total # Machines 2,500Typical Industrial Process Plant

5%5%CriticalCritical

25%25%EssentialEssential

30%30%ImportantImportant

20%20%SecondarySecondary

20%20%Non-EssentialNon-Essential

TurbinesGenerators

Compressors

MotorsPumps

FansGears

Application at Typical PlantApplication at Typical Plant

Online Solutions for Online Solutions for critical machinery critical machinery

WirelessWirelessTransmittersTransmitters

Multi TechnologiesMulti TechnologiesPortable SolutionsPortable Solutions

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By the Medical ECG we know the

condition of our Heart

By the CSI 2140 we check your Machinery

Health Condition

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www.sajetc.comData Representation

Wave Form Plot or Domain Plot

FFT Spectrum Plot

Orbit PlotWaterfall Plot

Unbalance Misalignment

Structural Looseness

Bearing Looseness

Structural Resonance Sleeve Bearing

Looseness/RubsGear ProblemMisalignment Pump Cavitation

FFT Spectrum Plot for some Problems www.sajetc.com

X=RPM=CPM CPM=Cycle per minute=60Hz1X=1xRPM=1xCPM2X=2xRPM=2xCPM3X=3xRPM=3xCPM

Demonstration on Vibration Analysis Technology

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CSI 2140 Machinery Health AnalyzerFive Inputs = Four Channels + Tacho

Five Inputs:Channel 1Channel 2Channel 3Channel 4

+Tachometer

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4 Channel Volts + Tach

Dual Orbits!

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4 Channel Volts + Tach

4 Channel Accel+ Tach4 Channel Accel+ Tach

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Multiple Live Plots – Up to 8! www.sajetc.com

Oil Analysis www.sajetc.com

OIL . . . your engine’s lifeblood . . . can reveal its internal condition……

What 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

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• 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

Oil Analysis seeks to provide answers for…

Change Filter?Change Oil?Tear Down?

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Cost justification for industrial oil analysis

Documented case histories and cost savings on-site oil analysis to monitor a wide range of industrial machinery. Realistic Return on Investment: 500%+

Defer maintenanceProactive CONTAMINATION CONTROLKeeping oil clean, dry, and fit for use

Reduce oil consumptionLESS OIL USED

“Test it, don’t change it”

Eliminate reactive maintenanceTrend FAILURE PROGRESS

Predictive vibration & oil analysis

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All Test of Your Oil www.sajetc.com

1. Elemental Analysis (Spectral Analysis) 2. Particle count, 3. Particle Shape Analysis 4. Parts per million (PPM) distribution , 5. ISO codes and ASTM standard 6. Ferrography 7. Oil Chemistry ( Dielectric, TBN, TAN, Oxydation,

Nitration, Sulfations, Soot etc.)8. Water-in-oil, 9. Viscosity 10.Wear Debris Analysis (WDA)

Wear Metals and Possible SourcesEngine Bearing Gear Transmission Hydraulic

System

Heat Exchanger Compressor Turbine

Iron

Cylinder Liners, Piston Rings, Valve train, Crankshaft, rocker arms, spring gears, lock washers, nuts,

pins, connecting rods, Engine Blocks, Oil

pump

Rolling element Bearings: rollers

(tungsten alloyed steel), raceways and

cages, Journal Bearings:

Journal shaft, bearing Shoe backing

Locking keys

Bull gears, pinions, case

hardened teeth, locking

pins

Gears, bearings, Brake bands, clutch, shift spools, pumps, power take off (PTO)

Pump, motor, vanes, pump

housing, cylinder bores and rods,

servo valves, pistons

Rotary Screw, lobes, vanes, connecting rods, rocker arm,

bearings, cylinders, housing, shafts, roller bearings (see above)

oil pump, piston rings

Reduction gear, shaft, bearings,

piping, case

Copper

Valve train bushing, Wrist pin bushing, Cam bushings, Oil

Cooler core, Thrust washers, governor,

connecting rods bearings, valve gear train thrust buttons

Rolling element Bearings: alloyed element in cages, Journal Bearings:

journal bearing pads, slinger rings,

Locking keys

Bushings, thrust washers

Clutches, steering discs, bearings

Pump thrust plates, bushings,

cylinder gland guides, pump

pistons, oil coolers

Cooler tubes, baffles, plates

bearings, cylinder guides, wear plates,

thrust washers, bearings (see above) oil pump, oil coolers,

thermostats, separator filters

Bearings (see bearing section) piping, coolers

Tin

Valve train bushing, Wrist pin bushing, Cam bushings, Oil

Cooler core, Thrust washers, governor,

connecting rods bearings, valve gear train thrust buttons

Rolling element Bearings: alloyed element in cages, Journal Bearings:

journal bearing pads (babbited)

Bushings Clutches, steering discs, bearings

Pump thrust plates, bushings, Can be a residue from catalyst in

some oils (Quinto lubric series)

bearings, separator filters

Bearings (see bearing

section) piping, coolers

Aluminum

Engine blocks, pistons, blowers, Oil pump bushings, bearings

(some) Cam bushings(some) , Oil

coolers (some)

Rolling element Bearings: alloyed element in cages, Locking keys

Bushings, thrust washers, grease contamination

Bushings, clutches Cylinder gland (some) pump,

motor pistons, oil coolers.

Aluminum complex grease contaminant

Cooler tubes, baffles, plates

Housing, bearings, cylinder guides, wear

plates, thrust washers, bearings (see above), oil pump, oil coolers

Bearings(see above) piping, coolersEHC Systems: Residue from synthetic media (alumina) filters

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Wear Metals and Possible Sources (Cont.)

Engine Bearing Gear Trans-mission Hydraulic System

Heat Exchanger

Compressor Turbine

Chrome Rings, Liners, exhaust valves, zinc chromate from cooling system inhibitor

Rolling element Bearings: alloyed /coated element in rollers, tapers

Bearings(some), shaft coatings, some special gears are chrome plated

Bearings, water treatment

Cylinder liners, rods, spools

Housing, bearings, cylinder guides, wear plates, thrust washers, bearings (see above), oil pump, oil coolers

Shaft coating (some) bearings

Lead Main Bearings, connecting rod bearings.Lead can be present as a contaminant from Gasoline (Leaded gas) (Octane improver, anti-knock compound)

Rolling element Bearings: alloyed element in cages, Journal Bearings: Major alloying element in Babbitt bearings, alloying elements

Bearings, can also be red lead paint flakes from gear case walls

Bearings Bearings Bearings

Silicon Engine blocks (alloying element with aluminum parts), ingested dirt from breathers, external sources. Can also be from defoamant additive in lubricant

Rolling element Bearings: alloyed element with aluminum in cages

Bushings, thrust washer, silicone sealant, defoamant additive

Brake shoes, clutch plates, ingested dirt

Elastomeric seals (some) pump, motor pistons, oil coolers

Ingested dirt, silicone sealant, bearings, cooler (alloyed with aluminum)

Ingested dirt, silicone sealant, defoamant additive

Silver Bearings (alloying element) wrist pins, turbochargers (EMD railroad engines)

Bearings, oil coolers

Baffle & tube solder

Nickel Valves, Valve guides, Cylinder liners, Bearings. Can also be from heavy fuel contamination

Rolling element Bearings: alloyed element in rollers, races

Alloying element for tool steel gears

Bearings, servo valve plating pumps, pistons

Bearings Bearings, shaft, reduction gears

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Other Wear Metals and Metallic Additives

Element Possible Sources in Additives

Sodium Corrosion inhibitor additive, also indicates coolant leak into oil, can also be road Salt, Sea water, Ingested Dirt

Boron Corrosion Inhibitor additive, Antiwear/Antioxidant additive, can indicate coolant leak, grease contamination

Magnesium Detergent/dispersive additive, can also be alloying element in steels

Calcium Detergent/dispersant additive, Alkaline reserve additive for high sulfur fueled engines, can be grease contamination,

Molybdenum Solid/liquid antiwear additive, alloy in bearing and piston rings

Barium Corrosion inhibitors, Detergents, Rust inhibitors

Zinc Anti-wear, Corrosion inhibitors, Anti-oxidants, alloying element for bearings, thrust washers, galvanized cases

Phosphorus Anti-wear, Corrosion inhibitors, Anti-oxidants additives, EP additives

Element Possible Wear Sources

Titanium Wear metal for aircraft engines, bearings, Can also be contaminant from paint (titanium dioxide)

Vanadium Fuel Contaminant, can also be alloying element for steel

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www.sajetc.comFerrography

Optical Particle Counting Techniques

Readout & Control

Laser

View Volume

PhotoDiode

Laser Beam

Light Blocking

Oil Flow

Readout & Control

Light Scattering

Laser

Scattered Light

Lens

PhotoDiode

Laser Beam Trap

Oil Flow

Laser

Oil Flow

Direct Imaging

CCDLens Display

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Particle Counting Classifications• The count is compared to known standards

• ISO 4406 • NAS 1638(out of service, but still widely quoted)• AS 4059• MIL-STD-1264• and many other internal industry methods

• Two types of counting method • Cumulative• Differential

MOST POPULAR

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Particle Counting Reporting Codes

• A particle counting code is simply an arbitrary number given for a sample that represents a particle count range for a given size range

• In ISO 4406, code increases when the particle population is ~ doubled from the previous range

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• 60+ Brands, 400+ oils, 30+ fine tuned calibration algorithms and growing• Synthetic, Mineral Fluid, Biodiesels, etc• Comprehensive oil match algorithm to expand new oil library in the field

Engine Hydraulic Synthetic Gas Turbine

Compressor/ transmission

Gear/Turbine

Water (ppm)

Oxidation (abs/mm2)

TAN (mg KOH/g)

TBN (mg KOH/g)

Alien fluid (%)

Anti-Oxidant Additive (%)

Anti-wear Additive (%)

Nitration (abs/mm2)

Sulfation (abs/mm2)

Soot (%)

Glycol (%)

FT-IR Oil Analyzerwww.sajetc.com

Wear Debris Analysis www.sajetc.com

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 Imageswww.sajetc.com

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 WearSevere Sliding with Lubrication Starvation

Severe Sliding Wear

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Three Body Abrasive Wear

“Soft” Surface

“Hard”Surface

Hard abrasive contamination

Cutting wear particle

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Surface Damage due to Hard Particles

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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 microns46

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Demonstration on Oil Analysis Technology

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FluidScan Viscosity Meter

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FluidScan

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.

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www.sajetc.comWhy Thermography?

• Non Contact• Rapid Scanning• Data can be recorded in differing formats• Images produced are comprehensive & reliable

Advantages• Non Contact• Non Intrusive• Can work at a distance• Fast and Reliable• Portable• Convincing Results

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SEE THE IMAGE, SEE THE TEMPERATURE

SEE THE TEMPERATURE, SEE THE PROBLEM

www.sajetc.comThe Motto of Thermal Imaging

Thermal Images

Electrical

• Switch Gear• Fuse boxes• Cable runs• Electrical connectors• Insulation• Transformers

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Fan

18.7°C

37.4°C

20

25

30

35

AR01

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Fuse Box

23.3°C

38.1°C

25

30

35

LI01

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Electrical Connections

Used for the detection of;

• Corroded connections• Slack / loose connectors• Connectors at too high an

operating temperature• Hot spots

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Electronics www.sajetc.com

Electric Motor Bearing www.sajetc.com

Electrical Motor www.sajetc.com

High Voltage Substation www.sajetc.com

Process Plant

• Hot spots• Cold spots (Cryogenics)• Damaged or missing

insulation• Tank levels

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What’s In Your PDM Toolbox?

• One Technology CAN NOT do Everything!!!!!!

• Successful Integration is the key to getting the most out of your resources:– Awareness – Proper training – Documentation

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Ultrasound Analysis

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What is Ultrasound

High frequency (ultrasound) sound Waves range in size from 1/8” (0.34 cm) To 5/8” (1.7 cm)(Assuming ultrasound range from 20 khz-100khz)

Low frequency sound waves range in size from 3/4” (1.88 cm) to 56’ (16.9 m)(Assuming the average hearing range from 20Hz to 20KHz)

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Advantages of Ultrasound

•Directional•Locatable•Multiple applications•Utilizable in all environments•Early warning failure indication•Supports other technologies

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Application Groups

• Leak detection– Compressed air– Specially gasses– Vacuum– Steam traps / valves

• Electrical Inspection• Mechanical Inspection

– Slow speed bearings– Lubrication

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Ultrasonic Leak Detector

• Locate the leak• Measure the Leak• Calculate costs• Calculate Greenhouse Gas

emission reduction

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How Leaks Develop

• Fluid: Liquid or gas• Turbulent Flow

Produces Ultrasound

PRESSURE

VACUUM

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Good Valve – Bad Valve www.sajetc.com

Electric Inspection• Switchgear• Transformers• Insulators• Relays• Breakers

26.8

24.4

*>28.4°F

*<23.0°F

23.0

24.0

25.0

26.0

27.0

28.0

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Electric inspection

• Corona• Tracking• Arcing

• Good for medium and high voltage

26.8

24.4

*>28.4°F

*<23.0°F

23.0

24.0

25.0

26.0

27.0

28.0

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Bearing Inspection

• Very effective on S L O W S P E E D !• 3 Types of testing performed

– Comparison– Historical Trending– Spectrum Analysis:

• Fault frequency identification

UE SYSTEMS INC. All Rights Reserved

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Levels of SeverityDb levels over baseline

8 db LUBRICATION

12 db minor damage-microscopic faults

16 db damage-visual faults

35+ db catastrophic failure imminent

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What’s In Your PDM Toolbox?

• One Technology CAN NOT do Everything!!!!!!

• Successful Integration is the key to getting the most out of your resources:– Awareness – Proper training – Documentation

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