Condition Monitoring

Most failures give some warning of that fact that they are about to occur. This warning is called a potential failure An identifiable condition which indicates that a functional failure is either about to occur or is in the process. Techniques to detect potential failures are known as on condition maintenance tasks condition monitoring techniques

THE P-F CURVE

FAILURE STARTS TO OCCUR

P
WHERE WE CAN FIND OUT THAT IT IS FAILING (POTENTIAL FAILURE)

WHERE IT HAS FAILED (FUNCTIONAL FAILURE)

TIME

Condition Monitoring

Have existed as long as mankind, in the form of the human senses ( sight,sound,touch & smell ) Disadvantage of Human
Inspection by Humans is relatively imprecise Associated P-F interval is very short

The effort is always to define potential failure conditions and develop techniques for detecting them which longest possible P-F interval.

Condition Monitoring Yields Great Reliability Information

The Principle of Condition Monitoring of machinery is straight forward : The goal is to identify changes in the condition of a machine that will indicate some potential failure. Physical characteristics are identified that collectively indicate the current condition of the machine. Each of these characteristics is measured, analyzed, and recorded so that trends can be recognized. Over a period of time, the progress of these represents the deterioration of machine condition and can be used to determine maintenance actions.

Condition Monitoring and Predictive Maintenance

Condition monitoring is carried out for two main reasons: To detect changes in condition that could lead to catastrophic failure, particularly for machinery that could represent a threat to the health and safety of people, or cause an environment incident. This is known as Machinery Protection or Protective Monitoring. To identify the early onset of incipient failures so that a prediction can be made about their most likely progress and suitable actions can be planned. This is known as Predictive Maintenance and is often abbreviated to PdM.

Condition Monitoring and Predictive Maintenance

What does condition monitoring do for the user? Condition monitoring provides users with a unique set of deliverable that allows them to organize maintenance activities more effectively than is possible using simple time or usage based scheduling: It clearly identifies machines that have potential problems. For a maintenance manager responsible for thousands of machines an important output of the system is a reliable exception report, which focuses attention each day on a small number of machines for which a possible early fault has been detected.

Condition Monitoring and Predictive Maintenance The system achieves this by testing measurements against a set of alarm thresholds. It identifies the nature of each problem. Continuing the medical analogy, this is known as the diagnosis stage. Since diagnosis often requires the comparison of results from several different types of measurement, the system allows the presentation of composite displays combining vibration, oil analysis, pressure changes, and thermo-graphy readings.

What does condition Monitoring do for the user?

Condition monitoring provides users with a unique set of deliverables that allows them to organize maintenance activities more effectively than is possible using simple time or usage based scheduling: It clearly identifies machines that have problems ( Exception Report ) It Identifies the nature of each problem. ( Fault Diagnosis ) It predicts the most likely outcome of each problem. (Fault prognosis )

What does condition Monitoring do for the user?

It

allows the user to make recommendations on the best course of action. ( Maintenance Actions) The objective of condition monitoring is to create reliability information. Condition Monitoring can only make recommendations about operating and maintenance actions.

Condition Monitoring Techniques

Condition Monitoring
Infrared Thermography

Infrared Thermography

Infrared thermography is the science of acquisition and analysis of thermal information by using non contact thermal imaging devices.

Infrared Thermography features

It is non-contact uses remote sensing -Keeps the user out of danger -Does not intrude upon or affect the target at all 2.It is two dimensional -Comparison between areas of the target is possible -The image allows for excellent overview of the target -Thermal patterns can be visualized for analysis 3.It is real time -Enables very fast scanning of stationary targets -Enables capture of fast moving targets -Enables capture of fast changing thermal patterns

Infrared Thermography applications

Electrical Maintenance Buildings Furnaces and boilers Mechanical, friction Fluid flow problems Tanks and vessels

Infrared Thermography
Electrical HT Substation

Infrared Thermography
Electrical Motor Winding

Infrared Thermography

Infrared Thermography
Loose or tight belt heats up abnormally

Infrared Thermography

Blocked Heat Exchanger

Infrared Thermography principle

An object when heated radiates electromagnetic energy. The amount of energy is related to the objects temperature. The Thermal Imager can determine the temperature of the object without physical contact by measuring the emitted energy.

Visible Spectrum

Infrared Thermography principle

The human eye responds to visible light in the range 0.4 to 0.75 microns. Infrared temperature measurement is made in the range 0.2 to 20 microns. Thermal Imager can focus this energy via an optical system on to a detector in a similar way to visible light. The detector converts infrared energy into an electrical voltage which after amplification and complex signal processing is used to build the thermal picture in the operators viewfinder on board the Thermal Imager.

Infrared Thermography principle

The amount of energy radiated from an object is dependant on its temperature and its emissivity. An object which has the ability to radiate the maximum possible energy for its temperature is known as a Black Body. In practice there are no perfect emitters and surfaces tend to radiate somewhat less energy than a Black Body. As energy moves towards the surface a certain amount is reflected back inside and never escapes by radiative means. 60% of the available energy is actually emitted. The emissivity of an object is the ratio of the energy radiated to that which the object would emit if it were a Black Body.

Infrared Thermography application

Infrared Thermography application

Measuring the average temperature within several rectangles in the scene

Infrared Thermography electrical circuit

Joints & connections have contact resistance. Temp rises when current flows (Ohmic heat). Looseness (constriction resistance) & oxidation (film resistance) create HOT SPOT & resistive imbalance. Cause open circuit, energy loss & fire hazards. Implementation of a PdM programme based on IRT can certainly minimize sudden failures, energy loss & prevent fire hazards.

Case Study-1: Switchyard-Isolator

Case Study-2: Switchyard-Isolator

Case Study-3: Switchyard-CT

Case Study-4: Switchyard-Jumper

Case Study-5: Switchyard-Conductor

Case Study-6: Switchyard- Breaker

Case Study-7: Switchyard- Breaker

Case Study-8: Switchyard- Transformer

Case Study-9: Switchyard- Transformer

Case Study-10: Switchyard

Before

After

Case Study-11: Electrical Panel

Case Study-12: Electrical Panel

Case Study-13: Electrical Panel

Case Study-14: Electrical Panel

Case Study-15: Electrical Panel

Case Study-16: HT Panel

Case Study-17: HT panels

Case Study-18: HT panels

Case Study-19: HT panels

Case Study-20: HT panels

Case Study-21: Motors

Case Study-22: Motors

Case Study-23: Motors

Case Study-24: Motors

Case Study-25: Motors

Higher temp towards coupling

Higher temp towards motor bearing

Fault Evaluation & Categorization

SEE THE HEAT. Rise in temperature w.r.t ambient temperature. Rise in temperature w.r.t. that of similar component under similar operating conditions. Absolute temp w.r.t. load ( % of full load ). Available standards & OEMs data sheet.

Condition Monitoring
53

MOTOR MONITORING

Condition Monitoring and Predictive Maintenance For Electrical Equipments

Insulation Resistance / PI Surge Comparison Motor Current Signature Analysis

Broken Rotor bars, High resistance between bars & rings, Shorted stator / rotor laminations

Power Signature analysis

All the above + resistive & inductive unbalance, torque variations

Hi Voltage Testing Partial Discharge In all these cases the PF interval is from several weeks to months

MOTOR MONITORING
55

Diagnostic

testing to evaluate/ troubleshoot circuit faults Trending through periodic testing of motor condition Quality Assurance testing on new or reworked motors (Baseline Test)

Fault Zones
Power

56

Quality Power Circuit Stator Rotor Air Gap

Summary of Motor Failures

57

Current Analysis Fault Zones

58

Rotor
In-Rush/Start-Up (peak in-rush current and time to

start motor) Low and High Resolution (CSA) (pole pass Frequency [FP] sideband amplitude)
Air

Gap

Eccentricity (eccentricity peaks)

In-Rush/Start-Up Broken Bars

59

Rotor Evaluation Evaluating the FFT Spectrum

60

(From the previous slide) Diagram on the left indicates a motor (rotor) in good health This can be determined by the difference in amplitude between the line frequency and the pole pass frequency sideband immediately to its left (>60 dB) Diagram on the right 61

Low/High Resolution Test Broken Bars

62

Power Analysis
Power Quality Voltage and Current Waveforms Voltage and Current Total Harmonic Distortion Harmonic Voltage Factor (for motor derating) Power Circuit Voltage and Current Imbalances NEMA derating, based on voltage imbalance Stator Condition Impedance Imbalance

63

Effects of Imbalanced Voltages and Currents

64

Imbalanced

voltages seen by the motor are equivalent to introducing negative sequence currents having a rotation opposite to that of the positive sequence currents Negative sequence currents reduce motor torque

Effects of Imbalanced Voltages and Currents

65

small voltage imbalance produces a much larger current imbalance

Increases the temperature of an operating motor at a

given load (compared to that of a motor operating with balanced voltages)

Do

not operate a motor with voltage imbalance greater than 5% (per NEMA)

Voltage Imbalance Derating Curve

With imbalanced voltages, rated horsepower of an induction motor should be multiplied by the derating factor.

66

Consequences of Harmonics
67

Harmonic

currents tend to travel upstream, away from the nonlinear loads that produced them and towards the utility source. Adverse affects can be
Voltage distortion within facilities Excessive neutral return currents

High levels of neutral-to-ground voltage

Overheated transformers Large magnetic fields emanating from transformers Decreased distribution capacity Power factor rate penalties

Consequences of Harmonics
68

Harmonics

also interfere with vital electrical

processes
Programmable microprocessor controls and

monitoring devices Variable speed drives for motorized equipment on the assembly line are, like all electric equipment, sources and victims of voltage harmonics

Derating
Harmonic

69

currents increase the temperature of an operating motor at any given load

[compared to a motor operating with only fundamental voltage (50 Hz signal)]

Condition Monitoring
Category
1 Dynamic Monitoring 1

Nos of available techqs 17 15 15 24 4 15

Particle Monitoring Chemical Monitoring Physical Effect Temperature Electrical Effect