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PRESENTATION
ON
CONDITION MONITORING
By. A.BHAGAWATI
MAINTENANCE •ON FAILURE
•FIXED TIME(PREVENTIVE) •PREDICTIVE •DESIGN OUT
STRATEGY
Upto 1920s : On Failure maintenance 1920-1960s: Preventive Maintenance 1970s : Predictive Maintenance 1985 : TPM- Zero Defects - Zero Breakdown
STRATEGY On Failure Fixed time Predictive Design Out
Definition Fix it when it breaks
Conduct maintenance at regular intervals
Maintenance based upon known condition
Redesign to eliminate root cause of failure
Advantage (when implemented correctly)
Cheap, No pre care or management
Can be planned for spares, labour
Spot a potential failure
Less maintenance required
Disadvantage (when implemented wrongly)
High stock level, loss of production, Unsafe
Unnecessary replacement of parts, spares, can induce failure
Costly if implemented incorrectly.
Cold be highly expensive
Examples Headlights, Streetlights
Oil change Bearings M/c undergoing repetitive failure (Seal)
PREDICTIVE MAINTENANCE
• ADVANTAGEs • Impending equipment failure
can be detected • Can run equipment to near
failure • Maintenance can be planned • Root cause can be detected,
scope for redesign
• DISADVANTAGEs • Can be costly if
implemented wrongly
INTRODUCTION • Human Condition Monitoring - Heart beat, pulse, Pathology, Usg • Industrial Condition Monitoring Early Bearing Condition Analyzer- Screwdriver 1850: Railroad wheel tappers 1945: Oil Analysis, Canadian P. Railways 1970s: Established use of Vibration, Oil analysis, Thermal Imaging 1983: First PC based CM system
CM TOOLS
• VIBRATION ANALYSIS • WEAR DEBRIS MONITORING • THERMOGRAPHY
VIBRATION MONITORING
• Versatile Tool for CM for rotating and reciprocating equipments
• Wide range of techniques and instrumentation • Careful selection & application of techniques
essential for success.
PROBLEM IDENTIFICATION • Unbalance • Misalignment • Looseness • Defective Bearings • Resonance • Eccentricity • Bend shaft • Worn gears • Drive belt problem • Distortion (Soft-foot & Piping strain) • Motor Electrical Problem
VIBRATION • All machines vibrate. • An increase in vibration level is a sign
of trouble & amplitude of vibration depends upon the extent of defect in the machinery component
• Each trouble will create vibration with different characteristics
VIBRATION FUNDAMENTALS • What causes vibration: Induced force & freedom for
movement • It is the motion of mechanical parts back & forth from
its position of rest/neutral position • HARMFUL EFFECTS Increased load on BRGs, reduced BRG life Higher forces on mountings, foundation loosening &
damage of support structure Increased stresses of M/c; Risk of fatigue Decreased equipment efficiency Increased maintenance cost due to more component
failure & unplanned operation Reduced output quality-REJECTION BY QC Unsafe operating Environment
CHARECTERISTICS OF VIBRATION
• AMPLITUDE • FREQUENCY • PHASE Amplitude : Magnitude of Vibration - Displacement (Micron) - Velocity (mm/sec) - Acceleration (g) - Spike Energy (gSE)
AMPLITUDE • RMS: Energy contained in the time wave form • PEAK: 1.41 * RMS • PEAK-TO-PEAK: 2 * PEAK • AVERAGE: Area under curve
FREQUENCY • Period of Vibration is the Time required to
complete one full cycle • Frequency = 1/ time period • If the time required to complete one cycle is
1/60 th of a second, frequency : 60 cycles per second or 60 CPS or 60 Hertz (1 CPS=1 Hertz)
• Vibration frequency is measured in Cycles per minutes (CPM) as it is easier to relate this characteristic to rotational speed of the machine
Hence a vibration occuring at 60 Hz will be expressed occuring at 3600 CPM (1 * RPM)
PARAMETER SELECTION
• Frequency sensitivity Displacement up to 600 CPM Velocity 600-60000 CPM Acceleration > 60000 CPM Spike Energy Ultrasonic range
DISPLACEMENT vs VELOCITY vs ACCELERATION
DISPLACEMENT VELOCITY ACCELRATION
Sensitive to low frequencies. Good guide for imbalance & other low frequency faults
Has average sensitivity th’out frequency range, sensitive for imbalance, misalignment, looseness & later stage of rolling element bearing damage
Sensitive to high frequencies. Good guide for rolling bearing damage, gear related problems & cavitations etc.
BENDING OF A WIRE • Consider the example of repeatedly bending a piece of wire, there are two ways to
reduce the time required to achieve fatigue. One is to increase the distance (DISPLACEMENT) that the wire is bent. The farther the wire is bent each time, the less time it will take to reach fatigue. The other is to increase the number times per minute or second (FREQUENCY) the wire is bent. The more times per minute the wire is flexed, the less time it will take to reach fatigue failure. Thus the severity of vibration is dependent on both Displacement and Frequency.
• An example: a vibration of 6 mils at 120 CPM would be in the GOOD range where as the same vibration at 3600 CPM is considered VERY ROUGH. Hence severity of vibration not only depends on displacement but also on frequency.
• Benefits of Vibration Velocity Measurement over displacement: Vibration velocity is a direct indicator of fatigue since it takes into account both
displacement and frequency. It is not necessary to know the frequency of vibration in order to evaluate the severity
of vibration velocity since frequency is already a part of velocity. A measurement of overall vibration velocity is a valid indicator of the overall
condition of a machine whether the vibration is simple (one frequency) or complex (multiple frequency).
SUMMATION-1 Low Displacement & very high frequency
Accln=d*f*f is very high. Failure is due to applied force
Monitor acceleration
Medium velocity & medium frequency
Velocity= d * f Failure is due to fatigue
Measure velocity
High displacement & low frequency
Vel. is moderate, no fatigue Accln is Low, no failure due to applied force. Failure is due to Stress.
Measure displacement
FREQUENCY ANALYSIS • Characteristics of the Oscillating force caused by individual M/c defect is the
frequency of the oscillating force. • Frequency of vibration is equal to the frequency of this force. • Frequency of vibration is therefore indicative of the type of m/c defects. • Normally any m/c undergo different kinds of defects at a time. • Only the severity of different defects are of different extent. • Vibration components of different frequencies (which is characteristics of the defect)
therefore are present in the m/c simultaneously. • Overall vibration is therefore the resultant of the vibration components of different
frequencies. • In frequency analysis, the overall vibration is sensed.. • Does mathematical calculation to find out the individual vibration components. • Calculate amplitude & frequency of the individual vibration components & display
the information in graphical manner. • The technique is sometime referred to as Spectrum analysis/signature analysis. • FFT TRANSFORM (FAST FOURIER TRANSFORM) • The process of transforming time domain signal to frequency domain. • Time domain signal must first be sampled and digitalized.
SPIKE ENERGY • A measurement parameter designed to detect low amplitude
transient impacts generated within the audiosonic/ultrasonic frequency range by microscopic surface flaws in rolling element bearing and gears.
• The acceleration signal is processed via a high pass filter& a peak detection circuit to produce a numerical value which is the product of : The number and amplitude of the impacts in a unit of time.
• The value is expressed in gSE (IRD) dB (Shock Pulse-SPM) • It is primarily bearing condition monitoring parameter
PHASE • The position of a vibrating part at a given instant w.r.t. a fixed point or
another vibrating object. • The part of a vibration cycle through which one part of object moves relative
to another part. • The unit of phase is degree where one complete cycle of vibration is 360
degree. • Phase analysis Applications: Conforms m/c defect Distinguishes misalignment Vs Bent shaft Distinguishes unbalance Vs eccentricity Detects mechanical looseness Detects resonance Detects type of unbalance Used for balancing.
ADVANCED TECHNIQUES
• Phase Analysis • Time wave analysis • Amplitude Vs Time analysis • Amplitude Vs Phase Vs RPM • Bode Shape analysis • Orbit analysis
CHART Frequency in Terms of RPM
Most Likely cause
Other possible reason
1 * RPM Unbalance
2 * RPM Looseness
3 * RPM Misalignment
<1 * RPM Oil whirl
Synchronous Electrical Prob
2 * syn Fr Torque pulse
Harmonics Bad gears
Very High Fr Bad Bearing(AF
VIBRATION STANDARD
• Published Standard-ISO 2372 • Manufacturer’s guidelines • Comparison • Trending
WEAR DEBIS ANALYSIS • All machines wear out • To predict internal condition of machine in a non intrusive way
by the study of worn particle or debris • SCOPE:Determines: When abnormal wear has begun Root cause of wear/failure Which component is failing Requirement of lubricant replacement Suitability of lubricants Seal/Filter condition CAN PROVIDE EARLIEST DIAGNOSTIC WARNING_
BEFORE VIBRATION CAN SENSE DANGER
7 STEPS FOR WDA
• Sample collection • Codification • Physical & Chemical Test • Incubation • Slide preparation • Microscopic examination • Report Preparation
WDA METHODS • Spectroscopy • Ferrography • Magnetic Plug FERROGRAPHY -Particle Quantifier -Analytical Ferrography- severity of wear Mode of wear size of wear concentration of wear component under wear
THERMOGRAPHY
• Thermography (Thermal imaging) is a methode of redefining the appearance of an object in terms of temperature
• An infrared camera generates only B & W image. By using a complicated algorithms this is converted to colored image.
• A colored thermogram gives immediate feeling of temperature
THANK YOU
A. Bhagawati
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