[TYPE THE COMPANY NAME]

ASSINGMENT
NO;2
Submit by ; Ahmad Raza(1848)4th
Mechanical
Submit to ; Sir Usman Amin
Date
TOPIC ;

Explain condition monitoring techniques

with industrial practical example.

.What is Condition Monitoring?

Condition monitoring (CM) is the process of monitoring a parameter of conditions
in machinery (vibration, temperature, etc.), in order to identify a significant
change which is indicative of a developing fault. It is a major component of
predictive maintenance. The use of conditional monitoring allows maintenance to
be scheduled, or other actions to be taken to prevent failure and avoid its
consequences. Condition monitoring techniques are normally used on rotating
equipment and other machinery such as pumps, electric motors, internal
combustion engines and presses.

1.Explanation of CM techniques;
The following list of condition monitoring techniques, grouped by several
category types, shows the extent technology has moved monitoring ahead.
The various methods listed may or may not currently be linked within an
IoT network, but most are suitable for automatic data collection and
analysis.

1.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 .

Technique include:
• Ferrography ;

Ferrography is a specialized type of oil analysis used to study particle

wear on machine components through analysis of contaminants
in lubricating oil. It can be used to predict and diagnose errors occurring on
machinery. Ferrography is related to tribology, which is the study of friction
between interacting surfaces. Since the advent of ferrography in the 1970s
it has been used in many industrial settings as a form of preventative
maintenance.

Working;

Analytical ferrography works through magnetic separation of contaminant

particles and a professional analysis of the particles. A sample of the
machine's lubricating oil is taken and diluted, then run across a glass slide.
This glass slide is then placed on a magnetic cylinder that attracts the
contaminants. Non-magnetic contaminants remain distributed across the
slide from the wash. These contaminants are then washed, to remove
excess oil, heated to 600 °F for two minutes, and the slide is analyzed
under a microscope. After analysis, the particles will be ranked according to
size. Particles over 30 microns in size are considered "abnormal" and
indicate severe wear.

ANALYTICAL FERROGRAPHY - TestOilTestOil

2.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:

• Ultrasonic analysis

Ultrasonic methods of NDT use beams of mechanical waves (vibrations)

of short wavelength and high-frequency, transmitted from a small probe
and detected by the same or other probes. Such mechanical waves can
travel large distances in fine-grain metal, in the form of a divergent wave
with progressive attenuation.

Working;

A high frequency sound wave from a transducer is induced into material

where anomalies in the material create echoes that are sensed for
evaluation by specialized ultrasonic testing instrumentation. Inspections
can be performed by manually moving a transducer over a component or
by connecting it to an encoded scanning mechanism.

Ultrasonic Testing
3.Motor Circuit Analysis;
(MCA) is a battery of computerized tests on an electric motor to ascertain
the motor’s overall condition and possible sources of potential failures.
Electrical imbalances and degradation of insulation are the chief causes of
motor failure and are the focus of MCA testing. Some tests are go/no-go
tests, while test results for others must be tracked over time to identify
failure development. These tests are generally grouped into voltage-based
or current-based tests.

Techniques include:

• Insulation

The Insulation Resistance Test is the second test required by the electrical

safety testing standards. The Insulation Resistance Test consists in
measuring the Insulation resistance of a device under test, while phase and
neutral are short circuited together.

Working;

In a short time/spot reading test, the tester is connected across

the insulation of the motor windings. A test voltage is then applied for a
fixed period of time, usually 60 seconds. The most important aspect of
this test is that it remains consistent in duration from test to test.

Insulation Testing
4.Thermography/Temperature Measurements/Infrared
Thermography;
Thermography is the study of heat patterns in machines and objects.
Images capture thermal radiation patterns emitted from equipment. Data
analysis is used to identify potential failures or degradation of equipment

parts. Generally, equipment and parts will heat as parts failure is

developing. Thermal anomalies and temperature differences can indicate
misalignment, imbalances, improper lubrication, worn components,
undesirable mechanical stresses and electrical overheating.
Thermographic inspection helps identify safety issues such as overheated
electrical connections, pipe leaks and pressure vessel weaknesses. Many
infrared techniques based on the principles of IR radiation have been
developed to fit specific industrial applications.

Techniques include:

• Comparative thermography • Lock-in thermometry • Pulse phase

thermometry • Testing of electrical, pipe-works and machinery.

5.Ultrasonic Monitoring/Acoustic Analysis/Airborne

Ultrasonics;
Ultrasonic monitoring of equipment, bearings and rotating parts uses high-
frequency sound waves to detect part defects such as leaks, parts seating
and cavitations. In many cases, tiny changes in friction forces can be
detected with ultrasonic monitoring. These small changes may be missed
with IR or vibration analysis. Because of this, UM can be an excellent
companion testing technique along with IR and vibration analysis. 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 • Phased array testing