Professional Documents
Culture Documents
Oil Analysis/Tribology:
This technique involves collecting and testing machine oils, equipment lubricants or other
fluid samples to ascertain the condition of either/both the fluids and the machines. As
machines wear, overheat or trend toward failure, contaminants are deposited in lubricating
oils and other operating fluids. Careful analysis of oil samples reveals these
contaminants. Data from these studies can then be interpreted to indicate impending failures.
Data from these studies can then be interpreted to indicate impending failures.
Techniques include:
• Ferrography
• Presence of water
• Viscosity/kinematic viscosity test
• ICP or atomic emissions spectroscopy to identify presence of contaminants
• Dielectric strength test
• Microbial analysis
• Particle quantification index (iron content)
• Fourier transform infrared spectroscopy
• Ultraviolet spectroscopy
• Potentiometric titration/total acid number and total base number
• Sediment test
Vibration Analysis/Dynamic Monitoring:
Equipment and parts respond to vibrations in a variety of ways that can be used to identify
defects due to misalignments, imbalances or design flaws. Wear on machine parts, bearings,
rotors and shafts, causes these parts to vibrate with specific patterns that can be recorded and
analyzed. Different parts vibrate in different ways, and worn or out-of-balance parts have
unique vibration signatures that can be tracked and used to predict parts failures.
Techniques include:
• Shock pulse analysis
• Fast fourier transforms
• Broadband vibration analysis
• Ultrasonic analysis
• Power spectral density (PSD)
• Time waveform analysis
• Spectrogram/spectrum analysis
Techniques include:
• Comparative thermography
• Testing of electrical, pipe-works and machinery
• Comparative quantitative thermography
• Comparative qualitative thermography
• Paint stickers (colour change with out of spec temperatures)
• Fluids that change colour at out-of-spec temperatures
• Lock-in thermometry
• Pulse phase thermometry
• Pulse thermometry
Almost all areas of manufacturing processes can benefit from ultrasonic monitoring UM. It provides
an early warning for machine parts deterioration that might otherwise be masked by ambient plant
noises and temperatures.
Techniques include:
• Airborne ultrasonics
• Ultrasonic backscatter technique
• Backwall echo attenuation
• Ultrasonic thickness and gauging (pipe walls, etc.)
• Phased array testing
• Automatic and continuous ultrasonic inspection
• Internal rotating inspection systems
• Acoustic emissions testing
• Dry-coupled ultrasonic testing
• Long-range ultrasonic testing
• Acoustic ranging
• Time-of-flight diffraction
Techniques include:
• Neutron backscatter
• Computed radiography
• Computed tomography (CT)
• Direct radiography
• Positive material identification (PMI)
• Neutron radiography
Laser Interferometry:
Laser interferometry measures changes in wave displacement based on a laser-generated,
highly accurate wavelength of light. This technique is used to identify surface and subsurface
defects in composites and other materials. It is based on the interference of light waves
generated by a laser. (Sound and radio/electromagnetic waves are also used.) The interference
pattern is then captured and measured by a device called an interferometer.
The various interference patterns can be analyzed to show differences in material
characteristics such as the presence of corrosion, surface defects or cavities in the material.
Techniques include:
• Laser shearography
• Laser ultrasonics
• Strain mapping
• Electronic speckle pattern interferometry
• Digital holography (used worldwide to test turbine blades and surgical parts)
• Holographic interferometry (still in laboratory testing/not currently used in general
widespread condition monitoring)
Electrical Monitoring:
This approach applies the principles of deviations in electrical parameters to identify faults
and defects. Characteristics such as resistance, induction, capacitance, pulse response,
frequency response and others are used to detect potential maintenance issues. Central to this
methodology is the measurement of degradation trends in an electrical system so that
preventative action can be taken in advance of any system failure.
Techniques include:
• Megohmmeter testing
• High potential testing
• Power signature analysis
• Battery impedance testing
• Surge testing
• Motor circuit analysis
• Alternating current field measurement (ACFM)
Electromagnetic Measurement:
This category of test measures magnetic field distortions and eddy current changes to identify
cracks, corrosion, weaknesses and other defects. A magnetic field is applied to surface walls,
setting up magnetic fields. These fields interfere with one another causing patterns. Eddy
current reporting over an extended period is used to identify gradual deterioration in material
quality and surface features.
Similarly, electromagnetic testing induces an electromagnetic field or electric current inside
the tubing or test object. Defects will create disturbances, which can be measured and
analyzed. A variety of techniques have been developed to take advantage of these properties.
Techniques include: