Académique Documents
Professionnel Documents
Culture Documents
0
Condition Monitoring the intelligent Way
Lanco Date: 08.03.2011
Condition monitoring the intelligent Way
CONTENTS
1. GOAL 3
2. ABOUT US 3
INTRODUCTION
3. A) Importance of Condition Monitoring 4
B) Benefits of Condition Monitoring
4. METHODOLOGY 7
MACHINE DATA
a. Introduction 8
b. Applications 8
4.1
c. Flow Chart 8
d. Procedure 8
a. Introduction 10
b. Applications 10
4.2
c. Flow Chart 11
d. Procedure 12
e. Sample report 13
1
Condition Monitoring the intelligent Way
Thermal Image
a. Introduction 26
b. Applications 26
4.6 c. Flow Chart 27
d. Procedure 27
e. Sample report 28
Ferrography
a. Introduction 29
b. Applications 29
4.7 c. Flow Chart 29
d. Procedure 30
e. Sample report 31-32
Oil Analysis
a. Introduction 29
b. Applications 29
4.8 c. Flow Chart 29
d. Procedure 30
e. Sample report 31-32
2
Condition Monitoring the intelligent Way
1. GOAL
To provide full Time Services of Condition monitoring Experts to implement Predictive and
Proactive condition based maintenance system in your plant. The aim is to achieve, increased
Equipment / Plant Availability, Lesser Breakdowns, Decreased maintenance cost, and higher
amount of reliability.
2. ABOUT US
SPM INDIA is a Swedish Joint Venture Company having full-fledged World-class production
facilities to manufacture the latest Instruments in the field of Condition Monitoring at
Hyderabad.
We are Head Quartered at Hyderabad, having Branch Offices at Chennai, Mumbai, Baroda,
Kolkata and Delhi.
In addition to our Sales Activities for more than three decades, we also provide “Professional
Consultancy Services” with more than 40 engineers engaged in various projects all over India
delivering Condition Monitoring Services.
We have a Support Team with 20 engineers who are handling only Technical Presentation,
Installation & Commissioning & Training program.
We have a dedicated Training Center at Hyderabad where we conduct Training Program with
theory & practical for 4 days at very nominal charges.
3
Condition Monitoring the intelligent Way
3. INTRODUCTION
Condition Monitoring is the process of monitoring one or more specific Condition Parameters
in Machinery at regular intervals, such that a significant change becomes indicative of a
developing failure to identify impeding damages. It is a major activity of Condition Based
Predictive Maintenance.
The use of Condition Monitoring allows Maintenance to measure the deterioration of the
Machine Condition well in advance so that appropriate Correction Activity may be scheduled
to avoid the consequences of failure, before the failure occurs
4
Condition monitoring the intelligent Way
4. METHODOLOGY
The methodology is acronym for the step-by-step procedure for the Implementation of
different Condition Monitoring Techniques.
Condition Monitoring
Technique
Flow Chart
Created
Machine Data
Creation
Procedure
Described
Customer
Domain Inputs
Analyzing the
Measuring Results
Preliminary
Report
Generated
Correction Activities
Implemented
Final Report
Check the condition
After 3 Months
Document
Condition Monitoring the intelligent Way
a. Introduction:
The data, which identify as the equipment Technical data of the complete
equipment – both drive and driven details,
b. Application:
Gearbox and generator set for windmill – testing purpose.
c. Flow chart:
Machine Data
Insufficient Data
Data obtained /
Analysis to Start
1
Condition Monitoring the intelligent Way
d. Procedure:
The manufacturer / engineer in-charge will provide the complete data like;
• Equipment type
• Generator or motor Capacity – ratings (MW / KW)
• Class classification of the equipment as per ISO std
• Various rpm like Input-Output and intermediate speeds
• Gear box type
• Input speed & output speed
• Number of stages
• Bearing details like type and bearing number etc.
• Type of lubrication systems
• Type of cooling systems
• Other relevant details, If any.
All the machine data are tabulated and schematic diagram of equipment system is
framed as shown here under.
2
Condition Monitoring the intelligent Way
a. Introduction:
In simple terms, the SPM method detects development of a mechanical shock wave
caused by the impact between two masses. At the instantaneous moment of impact,
molecular contact occurs and a compression
(shock) wave develops in each mass. The SPM
method is based on the events occurring in the
mass during the extremely short time period after
the first particles of the colliding bodies come in
contact.
b. Application:
3
10
Condition Monitoring the intelligent Way
c. Flow chart:
SPM
SPM
Measure LR Values
Measure HR Values
Collect Spectrum
LR/HR
Values YES
Within
SPM Std
Limits
Bearing
Condition
found to be Report
NO Preparation
Satisfactory
SPM
Spectrum YES
found Cleared for
Healthy Operation
NO
Recommendations
Check Lubrication
Check Brg. Condition
Check Mounting
Change Brg
Correction
Activity
Carried out
Recheck
4
11
Condition Monitoring the intelligent Way
d. Procedure:
Details of input like Shaft internal diameter and Bearing numbers are to be given as
input before starting the SPM measurements.
To measure the LR / HR Values.
To measure Cond values.
To collect SPM time wave and spectrum.
The measured values are to be compared with the std values.
View the colour codes like Green-Yellow-Red.
When the vibration amplitudes are crossing more than the satisfactory level, the
detailed analysis is conducted to identify the possible causes and root cause for
generating the higher vibration amplitudes.
Reports will be submitted for possible correction activities at site, are suggested to the
manufacturer / shop floor personnel.
Minor variations in the readings are normal. They can be caused by temperature and
load variations, time since re-greasing or other variations in the operating condition of
machine and bearing.
On damaged bearing, the sharp edges of fresh spallings will cause high readings which
drop when the damage is partly rolled out.
Important for the planning of bearing replacements in the trend of the readings and
the rate of change. Bearings with high readings (yellow and red zone) are measured
more frequently than bearings in good, stable condition.
After completing the correction activity, Vibration amplitude are re-checked. When
found satisfactory the final report is submitted for clearance as well as for future
references.
5
12
Condition Monitoring the intelligent Way
e. Sample Report:
6
13
Condition Monitoring the intelligent Way
a. Introduction:
b. Application:
Knowing the Severity of the problem necessary Corrective Action can be taken at the
most appropriate time, for any rotating equipment and critical operating equipment. The
equipment like Turbo generator, Pumps, Fans, Mills, Crushers, Compressors. The
components like Motor and gear boxes, generator are to be critically need to be
analyzed using vibration measurement and spectrum analysis.
Mechanical Rubbing
Antifriction Bearing Defects (Inner race, Outer race, Cage, Rolling elements).
Gear Problems (Tooth wear, Tooth load, Gear eccentricity, Backlash, Gear
misalignment, Cracked or broken tooth).
7
14
Condition Monitoring the intelligent Way
C. Flow Chart:
Vibration Analysis
Correction
Submission of report
for correction
Activities
Activities by SPM
Team
Corrective actions by
Laser Dynamic
Customer/manufacturer Alignment Balancing
Carried out
8
15
Condition Monitoring the intelligent Way
d. Procedure:
The equipment is operated at rated rpm and normal operating conditions are to be met. Using
the sophisticated vibration analyzer the basic and advanced vibration data to be collected.
The measured values are compared with ISO 10816 standard requirements as per the given
class, for example Class-4.
When the vibration limits are crossing than the satisfactory level the detailed analysis is
conducted to identify the possible causes and root cause for generating the higher vibration
amplitudes.
Reports will be submitted for possible correction activities at site are suggested to the
manufacturer / shop floor personnel.
Note: During analysis the root causes are like Misalignment and dynamically imbalanced, the
desired correction activities like Laser alignment and dynamic balancing using the
sophisticated analyzer like Leonova Infinity will be done SPM team.
After completing the correction activity, Vibration amplitude are re-checked. When found
satisfactory the final report is submitted for clearance as well as for future references.
9
16
Condition Monitoring the intelligent Way
e. Sample Report:
10
17
Condition Monitoring the intelligent Way
a. Introduction:
Misalignment is the deviation of the relative shaft position from collinear axis of rotation when
the equipment is running at normal operating condition. Alignment is a vital part in the daily
maintenance work. . Nearly 50% of all machine breakdowns are caused by misalignment.
The types of misalignment can be Parallel or offset, Angular and Skew (combination of both).
b. Applications:
All equipment need to be aligned across the shaft & coupling, few types of coupling are;
A flexible coupling can handle some misalignment but it will generate heat and it will increase
forces on the shafts.
This will crease vibrations and coupling elements, seals, bearing will fail prematurely.
Shaft alignment can be performed with a lot of tools. The easiest way is to use a ruler or a
straight edge over the two coupling halves and align by eyesight. The result is not very
accurate and it is operator dependent. To achieve a better result is to use dial indicators. A
skilled and experienced user can achieve good and reliable result, but it takes time. The
easiest way and most accurate is to use laser based alignment systems. They do not require
special skill and delivers very accurate and repetitive results.
11
18
Condition Monitoring the intelligent Way
c. Flow chart:
Laser Alignment
Laser Alignment
Fixing of TDs
Dimensional measurement I/P
NO
Alignment found
satisfactory (within YES
the Tolerance Limit)
in both Horizontal &
Vertical
Report
Preparation
NO
Alignment process
Calculate shims and foot Alignment
Select suitable shims checking/correction
completed and
cleared for operation
Horizontal correction
Vertical correction
12
19
Condition Monitoring the intelligent Way
d. Procedure:
13
Condition Monitoring the intelligent Way
e. Sample report:
14
21
Condition Monitoring the intelligent Way
a. Introduction:
There are several types of unbalance conditions; the most important of which are called static
and dynamic. Static unbalance is a condition where the center of rotation of a rotor does not
correspond to its center of mass, or in other words, its center of gravity does not lie on its
axis of rotation. This result in a centrifugal force applied to the bearing at the 1X frequency.
This 1X force is proportional to the square of the speed of the rotor, meaning that high-speed
machines require much more accurate balancing than low speed ones.
Unbalance forces in machines will always produce vibration at the bearings where the radial
and tangential 1X components are 900 out of phase. This is a sure test of unbalance and can
be used to help distinguish unbalance from misalignment.
b. Applications:
Rotors which can be treated as having a single large mass along their length and that have
access to the main mass. Examples are Fans, Single Stage Centrifugal Pumps, Single Sage
Centrifugal Compressors, Flywheels, etc… The Main requirement is that there is access to the
plane that requires balancing, if there is no access to this plane then the rotor will need to be
removed to be balanced. Occasionally, when it is known that the balance problem is mainly
due to a coupling hub as opposed to the main impeller or wheel, then balancing can be
carried out on the coupling along with acceptable results.
15
Condition Monitoring the intelligent Way
c. Flow chart:
Dynamic Balancing
Vibration FFT
General
imbalance NO Check for other
conditions & sources of vibration
Phase Shift ≅ problems
900 found
YES
Carryout Static
NO Balancing
Carryout Dynamic
Balancing
YES
Vibration Amplitudes &
Balancing Tolerances
Found within Limit
Report
Preparation
NO
Trim Balancing
Equipment Cleared
for Operation
NO
16
23
Condition Monitoring the intelligent Way
d. Procedure:
There are two ways of giving phase information, as ‘Phase Lagging’ or ‘Phase
Leading’. In ‘Phase Lagging’ the keyphasor point is 00 and the phase angle increases
in the opposite direction to the direction of rotation i.e. if the rotation is clockwise
then the phase angle increases in an anticlockwise direction. In ‘Phase Leading’ the
keyphasor point is again 00 but the phase angle increases in the direction of rotation
i.e. if the rotation is clockwise the phase angle increases in a clockwise direction. The
instruments in use at JTPCL Refinery are all ‘Phase Lagging’ so this is the method we
will concentrate on.
To get the phase information we require a ‘tacho’ signal. This can either be from a
permanently mounted system such as a ‘Bently Nevada KeyPhasor’ or from a
temporary system such as an optical or electro-magnetic tacho.
The set-up of the instruments varies so each will need to be set-up according to the
relevant instruction manual.
17
Condition Monitoring the intelligent Way
e. Sample report:
18
25
Condition Monitoring the intelligent Way
a. Introduction:
A Typical Thermography camera detects radiant energy or heat in the infrared range of the
electromagnetic spectrum, generally between 800 to 20000 nanometers of wavelength. By a
non-contact mode the infrared energy (heat) is detected and after converting the same into
an electronic signal, it is processed to produce a Thermal Image or Heat Picture (Thermo
gram), with indication of Temperatures.
b. Applications:
1. Hot spot/ Cold Spot Detection for Maintenance Intervention (Electrical, Mechanical &
Process Equipments).
2. Condition Monitoring of Refractory Lining of Blast Furnace, Petrochemical Process
Heaters and others type of Furnaces, Ladles, Chimney.
3. Condition Monitoring of Insulation Lining of Boiler, Steam Pipeline, Hot air duct & other
Process Equipments.
4. Detection of Cold spots in Rotary Kilns to assess Deposition.
5. Calculation of Heat Loss.
6. Identification of anomalies in Cooling Systems.
7. Detection of Thermal abnormalities (due to loose contact/ joint) in Outdoor Switch
Yards & Transformers, in Switch Gears and Electrical Panels.
1. Control Panels
2. Switch gears
3. Transformers
4. Motor body, bearing and coupling temperatures etc
5. Furnaces
6. Industrial thermal imaging applications
7. Building Thermography applications
8. Application in Leakage Location
9. Appliance in Research and Development
19
26
Condition Monitoring the intelligent Way
c. Flow Chart:
Thermography
Thermal Imaging
captured
Report
Preparation
d. Procedure:
The relative motion / vibration or motion of atoms and molecules in the object causes
Infrared.
The thermal images are captured and analysis is done based on the temperature
levels and hot spots etc.
27
20
Condition Monitoring the intelligent Way
e. Sample report:
21
28
Condition Monitoring the intelligent Way
4.7. Ferrography:
a. Introduction:
b. Application
c. Flow chart
Ferrography
Quantitative Analysis
WPC found within Report
YES
acceptable Limits Preparation
NO
Qualitative Analysis:
1. Ferrogram Prepared
2. Image Captured & Compared
3. Analysis Done
22
29
Condition Monitoring the intelligent Way
c. Procedure
Step-2 – Qualitative Analysis to identify the type of wear & sources of wear.
Result:
23
30
Condition Monitoring the intelligent Way
d. Sample report
24
31
Condition Monitoring the intelligent Way
25
Condition Monitoring the intelligent Way
a. Introduction:
Oil Analysis involves Sampling and Analyzing Used Oil to identify the presence of
Metals, Non-Metals and Contaminants. Sampling and Analyzing on a Regular Basis
establishes a Baseline of Normal Level and helps to identify Onset of Abnormality.
Oil Chemical Condition Monitoring and Particle Measurement in Oil Samples are
important Monitoring Elements for Predictive Maintenance Program.
b. Application
c. Flow chart
Oil Analysis
Test
Check Oil
Characteristics
like Viscosity, NO
TAN/TBN, Change Oil
Moisture etc
found within the
Limit
YES
29
26
Condition Monitoring the intelligent Way
c. Procedure
The Oil analysis tests are conducted for following characteristics as per ASTM
standard:
1. Viscosity
2. Water by Karl Fischer (Moisture)
3. Oxidation stability
4. TAN / TAB Titration
5. FTIR Spectrography
6. Flash Point
7. Fire point
8. Foaming Characteristics
9. Emulsion Characteristic
Result:
The health condition of the used oil will be tested for the above characteristics and will
be declared whether the oil be continue to be useful or to be changed / replaced.
27 30
Condition Monitoring the intelligent Way
d. Sample report
TEST-1
Kinematic Viscosity @ 40
1 41.5 42.6 41.4-50.6 ASTM D 445
deg.C,cst
Kinematic Viscosity @ 100
2 6.8 6.6 6.9 ASTM D 445
deg.C,cst
4 Moisture Content ppm 79.75 234.9 500 PPM MAX ASTM D 1744
TEST-2
TEST-4
Recommendations:
Used oil test results shows normal condition of oil.
28