CONDITION MONITORING

THROUGH NON DESTRUCTIVE

TESTINGS OF MACHINES AND
PLANTS
INTRODUCTION
• CONDITION MONITORING

• SIGNATURE ANALYSIS

• NON-DESTRUCTIVE EVALUATIONS(NDE)

• IN-SERVICE INSPECTIONS (ISI)

• SAFTEY
 fig 1.c detection methods of failures
vibration
vibration
45% oil analysis

oil analysis temperature

23%

rotational speed
temperature
10%
torque

fluorescence
rotational speed
others 6%
4% acoustic emission
torque
acoustic emission 6%
3% fluorescence
others
3%
CONDITION BASED MAINTENANCE

2.PREVENTIVE

MAINTENANCE

1.BREAK DOWN 3.PREDICTIVE

NDE TECHNIQUES
1.VIBRATION MONITORING

2.ACOUSTIC EMISSION (AE)

3.INFRARED THERMOGRAPHY (IRT)

4.FERROGRAPHY

5.FIELD SIGNATURE MAPPING (FSM)

VIBRATION MONITORING INSTRUMENTATION

• VIBRATION MEASURING AND ANALYSIS SYSTEM

VIBROMETER CHANNEL FREQUENCY

MACHINE RECORDER
SELECTOR ANALYSER

fig,(1.a) SIGNAL FLOW DIAGRAM

• MINI COMPUTERS
• PROBABILITY DENSITY FUNCTION ANALYSIS (PDF)
• BY INSPECTION
 ANALYSIS OF RESULTS
1. VIBRATION CAUSE IDENTIFICATION

Sl DIRECTION OF
FAULT FREQUENCY
No VIBRATION

ROTATING
1 SAME AS RUNNING SPEED RADIAL
UNBALANCE

MISALIGNMENT RADIAL AND

2 2*SPEED
OF BEARINGS AXIAL

AT BALL OR ROLLER RADIAL AND

ROLLER BEARING AXIAL
3 SPEEED ULTRA SONIC
DEFECT
FREQUENCIES(20-60KHz)
OIL FILM WHIRL
4. IN HIGHSPEED 0.5*SPEED RADIAL
TURBO MACHINES

DAMAGED OR
5 No: OF TEETH* RPM RADIAL
WORN GEARS
VIBRATION METER (HAND HELD)

SPM VIB-11
by SKF

Vibration Meter : for imbalance, structural weakness, loose parts etc

INDUSTRIAL MACINERY CLASSIFICATION

Class 2: Medium size machines without special foundation
Class 3: Large machines on rigid foundations
Class 4: Large machines on soft foundations.
 fig 1.c detection methods of bearing failure
vibration
vibration
45%
oil analysis

oil analysis temperature

23%

rotational speed
temperature
10%
torque

fluorescence
rotational speed
others 6%
4% acoustic emission
torque
acoustic emission 6%
3% fluorescence others
3%
 APPLICATIONOF VIBRATION MONITORING IN
PLANTS
• MONITORING AT ‘ROURKELA STEEL PLANT’
• maintenance cost 10-15% of prod: cost

fig2. failure rate of different machineries of plant valve

valve sliding
others 6% sliding bearing bearing
6%
24% seal
seal
7%
gear

gear oil pump

7%

slide way
oil pump
8%
rolling
bearing
rolling bearing slide way others
29% 13%
 GROWTH THROUGH CBM ACTIVITIES AT RSP
BREAK DOWNS PREVENTED-10-102
EQUIPMENTS INCLUDED - 40-140
120

break
downsprevented
100

savings
80
No: of machines
60

insitu balancing
40

trend line
20
0

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

year
ACOUSTIC EMISSION MONITORING

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
ACOUSTIC-EMISSION METHOD

This method is based on the registration of the elastic compression waves that
are emitted by the defects developing in the stressed constructions.
ACOUSTIC EMISSION SYSTEMS

AE data collection systems

•Laptop based AE system

•DiSP Systems (any number of channels can be used)
• Portable AE test system (lunch box)
CASE STUDY
AE DURING HYDROTESTING OF A
HORTON SPHERE
MAX: PRESSURE 22 Kg/cm2

Pressurization (Stage 1)
Random AE activity due to
1. Mechanical rubbing between support
structure and vessel
2. Paint layer peel-off .
Re pressurization (Stage 2)
No significant AE activity

•AE SIGANLS FROM NEWER AREA

Fig.2(f) AE monitoring during hydro
( local plastic deformation )
testing of Horton sphere
•NO SIGNAL DURING SUBSEQUENT
PRESSURIZATION
 IR THERMOGRAPHY

• Infrared thermography is based on the principle of detection and measurement

of infrared radiations QR) arising from the natural or stimulated thermal radiation
of an object21
 I R MEASURING SYSTEMS

ThermaCAM S60 : Real-Time Thermal

VARIOSCAN
Type
3021 ST •highly sensitive thermal imaging,
Spectral range
8 ... 12
•precision temperature measurement,
[µm] •enhanced connectivity options including
Detector •high speed data transfer
Hg, Cd, Te
material •extensive thermal analysis capabilities
Detector cooling Stirling-cooler
 CASE STUDY

raw thermo graphic data.

data after removing the noise and vertical

gradient.

correspond to low
strength welds.
high strength welds

data processed for the local gradient in

surface temperature. Fig setup for infrared testing of lap joints
FERROGRAPHY
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 AND

FREQUENCY.

•SPECTROMETERS TRANSLATES THE INTENSITY OF THIS RAINBOW OF

COLORS INTO A COMPUTERIZED READOUT.
 HOW IS THE TEST PERFORMED
Conditions Detected
Tests
Abnormal Fuel Incorrect Additive
# Dirt Water Coolant Oxidation
Wear Dilution Oil Depletion
Glycol Test         *      
Viscosity   *       *    

Appearance/Odor   * * * *   *  

Spectrometric
*   *   * *    
Analysis

Alkaline Reserve           *   *

Blotter Spot Test     * *     *  

Water Content       *        

Distillation   *            
Flash Point   *            
WEAR METAL ORIGIN TABLE

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.
 MEASURING INSTRUMENT

ModelT2FMAnalytical Ferrograph.
This measure the effects Bi chromatic microscope.
of Contamination and Video camera.
electro-chemical changes Video capture card.
that occur in synthetic Image capture software.
and petroleum based oils industrial standard personal computer.
FIELD SIGNATURE MAPPING
• The FSM Inspection Tool (FSM) is a new
technology for monitoring and inspection
of metallic pipes and structures, pipelines
and storage vessels

• Reduce life cycle inspection costs

• Reduce inspection time

FIELD PATTERN Sensing pins (electrodes) in an
Graphical plots indicating the array over the monitored
severity and location of corrosion, area to detect changes
in the electrical field pattern.
and calculates actual corrosion The voltage = the signature.
and metal loss
INDUSTRIAL ARRANGEMENT

A typical refinery monitors high temperature

areas such as heater bends in the
distillation unit.
CONCLUSION
 SUMMARY OF APPLICABILITY AND CAPABILITY OF VARIOUS
NDT TECHNIQUES

NON
NDT DETECTION AUTOMATED DEFECT
CONTACT
TECHNIQUE CAPABILITY INSPECTION SIZING
INSPECTION

VIBRATION VOLUMETRIC POSSIBLE POSSIBLE POSSIBLE

ACOUSTIC NOT
VOLUMETRIC POSSIBLE POSSIBLE
EMISSION POSSIBLE

I R THERMO- SURFACE ,
POSSIBLE POSSIBLE POSSIBLE
GRAPHY NEAR SURFACE

POSSIBLE
FERROGRAPHY VOLUMETRIC POSSIBLE POSSIBLE

SURFACE,
FSM NEAR SURFACE
POSSIBLE POSSIBLE POSSIBLE