Condition based Monitoring

 Introduction
Contents
 Methodology of CBM
 Objectives and advantages of CBM
 Condition signals and monitoring
 CM Techniques
 Performance Monitoring
 Visual Tactical and Aural Monitoring
 Temperature Monitoring
 Leakage Monitoring
 Vibration Monitoring
 Lubricant Monitoring
 Filter Debris Analysis
 Thickness Monitoring
 Crack Monitoring
 Corrosion Monitoring
 Noise/Sound acoustic Monitoring
 Smell and Odour Monitoring
 Motor Defect Detected by current monitoring
 Introduction
 Determining Health and condition of equipment
 Monitor the steady characteristics of the equipment and learn those
characteristics
 If these condition changes, then generate the alarm, investigate the
problem and correct it before failure.
 “If it is not broken, do not fix it”
 When we do not need failure as well as maintenance
 The non-invasive monitoring of systems to obtain knowledge of their
condition; to distinguish wear, impending failure or other deterioration
without disrupting the normal operation of those systems
 Human senses – sight, touch, smell, hearing, taste
 Fluid analysis – lubricants, greases, hydraulic oil
 Process parameter analysis –temperatures, pressures
 Vibration and acoustics –vibration analysis, shock pulse, acoustic
emission
 Technical Barrier
• Difficulty to accurately predict the remaining
useful life of the equipment
• Difficulty in continually monitor a equipment
• Difficulty of Maintenance system to learn and
identify impending failures for an equipment
and then recommend what action should be
taken
• Frequency of CM is difficult question
 Methodology of CBM
• Listing and codification of all equipments and
components
• Selecting critical equipment/machine and systems
(VED)
– Continuous monitoring – hazardous safety
– Periodic Monitoring
• Identify Components/items: Very critical, less critical,
critical – categorized as process components,
mechanical components, control components etc.
• Fixing Condition Parameter: i.e. vibration, temperature,
pressure flow, noise, strains ….
 Methodology (Cntd..)
 Fixing Monitoring Technique: for identified condition parameters,
relevant monitoring tools/instruments/implements are identified
and obtained /installed. The points from where these parameters
are to be monitored is a very important task in this process
 Monitoring Schedule and frequency – daily, weekly, monthly etc…
Some parameters are online and some are offline
 Trend Monitoring: the inspection records should be decoded,
analysed and compared with the maximum allowable limit or
earlier data. OEM – provides machine signature/record along with
test certificates
 Extent of deviation /defects to be identified from the inspection.
This is called as feature extraction
 Repair schedule and execution
 Follow-Up
 Aims/objective
• To intervene before the failure occurs, to do
maintenance only when needed.
• To reduce number of failures and number of
shutdowns
• To reduce cost of maintenance and production
loss
• To increase the operating life of the replacement
items.
 Condition Signals and Monitoring
 Machines Emanates – Primary Signal and Secondary signals
 Primary signals are Performance Signal which are to be
monitored. Performance Trend Monitoring
 Secondary signals – Loss output like vibration, sound,
thermal, chemical and physical change. Etc.
 Its essential to monitor both the signals to effectively
access the health of the machine.
 Every defect or malfunction in an equipment or system
indicates significant frequencies or signals which can be
easily identified , measured or compared with suitable
instruments. 70% of damages can be characterized by such
a signals. Such a signals are termed as a Dynamic Signals or
Tribological Signals
Condition Signals and Monitoring
• Dynamic Signals are Vibration, sound, leakage,
heat etc.
• Tribological signals are friction and wear
characteristics, lubricant contamination, and
chemical changes etc.
• Signals are compared with the severity charts
and the defects can be identified.
• Few defects are detected by feature extraction
and correlation techniques
 Condition monitoring techniques
• Based on these dynamic signals or tribological signals
condition
• Strategy to select technique to collect data
• Remain dependent on the conventional methods – P,
T, flow
• Supplement it with vibration analysis?
• Whether only the condition or status needs to be
identified?
• Do you want to know exact cause/fault to be
detected ?
• CM tool works use multivariate statistical process
control techniques
Visual, Tactical and aural Monitoring
• Direct Methods
– Human Eyes, ear and other senses
– Optical Probes
– Microscope, stroboscope, borescope etc.
• Indirect Methods
– Optical Probe with television etc.
– Photographs and videos
– Radiographs
– X Rays, Thermographs etc.
Visual Monitoring
• Borescopes are used for inspection work where the
area to be inspected is inaccessible by other means.
• Devices for use inside the human body are referred
to as endoscopes.
• Borescopes are commonly used in the visual
inspection of aircraft engines, aeroderivative industrial
gas turbines, steam turbines, diesel engines, and
automotive and truck engines. Gas and steam
turbines require particular attention because of safety
and maintenance requirements.
• Borescope inspection of engines can be used to
prevent unnecessary maintenance, which can become
extremely costly for large turbines.
•
• They are also used in manufacturing of
machined or cast parts to inspect critical
interior surfaces for burrs, surface finish or
complete through-holes.
• Other common uses include forensic
applications in law enforcement and building
inspection, and in gunsmithing for inspecting
the interior bore of a firearm.
• Flexible borescopes
• A flexible borescope includes a bundle of optical
fibers which divide the image into pixels.
• It is also known as a fiberscope and can be used
to access cavities which are around a bend, such
as a combustion chamber or "burner can", in
order to view the condition of the compressed
air inlets, turbine blades and seals without
disassembling the engine.
• Flexible borescopes suffer from pixelation and pixel
crosstalk due to the fiber image guide. Image quality
varies widely among different models of flexible
borescopes depending on the number of fibers and
construction used in the fiber image guide. For
flexible borescopes, articulation mechanism
components, range of articulation, field of view and
angles of view of the objective lens are also
important. Fiber content in the flexible relay is also
critical to provide the highest possible resolution to
the viewer. Minimal quantity is 10,000 pixels while
the best images are obtained with higher numbers of
fibers in the 15,000 to 22,000 range for the larger
diameter borescopes.
• Video borescopes
• A video borescope or "inspection camera" is similar to
the flexible borescope but uses a miniature video
camera at the end of the flexible tube. A display in the
handle shows the camera view. Because the complex
optical waveguide is replaced with an inexpensive
electrical cable, video borescopes can be much less
costly and potentially better resolution (depending on
the specifications of the camera). Digital models often
have an integrated recorder and can save images in
common digital formats.
• Rigid borescopes are similar to fiberscopes but
generally provide a superior image at lower
cost compared to a flexible borescope. Rigid
borescopes have the limitation that access to
what is to be viewed must be in a straight line.
• Rigid borescopes are therefore better suited
to certain tasks such as inspecting automotive
cylinders, fuel injectors and hydraulic manifold
bodies
•