Condition Monitoring

YANBU INDUSTRIAL COLLEGE/ MET DEPARTMENT
MET 213
CONDITION MONITORING
Eng.M.Ajmal & Eng. Osamah Ali

Department of Mechanical Engineering technology
YANBU INDUSTRIAL COLLEGE
EQUIPMENT MAINTENANCE
Failure Definitions:
A failure is an unsatisfactory condition. It may be catastrophic or merely
out-of-tolerance.
A functional failure is the inability of an item or system to meet a
specified performance standard.
A potential failure is an identifiable and quantifiable physical condition
which indicates a functional failure is imminent.
Failure is defined as a loss of ability to function normally
YIC/ MET 213 / Dr.Kassab 2 CONDITION MONITORING

The Perception of Equipment Life is...
Standard “Bathtub” Curve
Infant Mortality Wear-Out Zone

Failure Rate
Constant Wear-Out Rate
Time
The
Thetraditional
traditionalapproach
approachto
tomaintenance
maintenanceisisbased
basedononaamisunderstanding
misunderstandingof offailure
failure
distributions. Only a small percentage of equipment follows this curve
distributions. Only a small percentage of equipment follows this curve

Run to Failure
Timeline to Failure
Stressor
Applied Noticeable Performance Degradation Failure
If it ain’t broke don’t fix it…..

Now it’s broken,
so fix it!
6 Months
Simple, but expensive

The Preventive Approach
Timeline to Failure
Stressor
Preventive Maintenance Zone
PM Interval PM Interval
24 Months
Time-Directed Tasking: Proven to save 12% - 18% over “Run to Failure”

Predictive O&M
Timeline to Failure
Stressor
Preventive Maintenance Zone
phy ysis
gra nal sis
o A al y Predictive Maintenance Zone
m n
her tio An
T bra stic
Vi ou
Ac
48 Months
Additional 8% - 12% savings over a good preventive maintenance program

What is Condition Monitoring?

Simply stated, Condition Monitoring CM, also known as Predictive Maintenance, is the continuous or periodic monitoring
and diagnosis of equipment and components in order to forecast failures.
Condition Monitoring has been emerging within the last few years as more people have become aware
of its benefits and as the costs associated with monitoring the condition of systems and equipment have
decreased.


BENEFITS OF CM:
Allow the early detection of potentially catastrophic
faults, which could be extremely expensive to repair.
Increase equipment availability.
Reduce costs.
More effective utilization of maintenance resources
Increase reliability, without sacrificing safety.
Avoid premature overhaul or replacement.
Extending service life.

CONDITION MONITORING TECHNOLOGIES

TYPICAL CONDITION MONITORING TECHNOLOGIES
Infrared thermography,
Oil analysis,
Ultrasonic noise detection
Vibration analysis,
Visual Inspection (VI)
Flow and process analysis, and
Electrical circuit analysis.

Why Condition Monitoring?







Infrared Thermography (IRT)
Pictures of temperature difference ( Thermogram)

It is non-contact, line-of-sight and full-field image
based on thermal difference or thermal information
QUANTITATIVE OR QUALITATIVE
23 24 56 21 67 11
33 43 23 32 41 21
22 32 33 42 43 33
51 55 54 45 44 43
31 22 11 12 15 21
23 43 34 32 33 53
Temperature matrix Temperature difference

Applications of IRT
 Flow conditions in heat exchangers,
condensers, radiators and pipes
 Insulation conditions on pipes and
electrical cables
 Energy efficiency of houses
 Water or oil level in tanks
 Phase imbalance of electric current
 Degraded refractory in boilers, furnaces
and kilns
 Bearing problems
 Lubrication problems
 Motor overheating problems





Infrared Thermography: A Versatile Monitoring Tool
/ Generator Room / Main Distribution Panel Residence / Pantry
Elevated
temperature on a
neutral wire caused
by loose connection. Blocked drain pipe underneath concrete floor.
IR image on right is Blockage was located through thermal contrast
after repair - minimizing excavation area.
tightening of
connection




Ultrasonic Testing (UST)

Used to detect leakage of gases and liquids (high pressure/vacuum)
When pressure difference is more the leakage produce ultrasonic
noise due to turbulent flow
Ultrasonic
Ultrasound Audible
Translators
Audible range
Hi-frequency 20 – 20,000 hrtz

Applications of UST:
 Detect steam leaks
 Analyze steam traps
 Locate gas leaks
 Determine Bearing Faults
 Determine electrical faults

Leak Detection

Screening - find the leaks

 Soap bubble screening
 Electronic screening (sniffer)
 Toxic Vapor Analyzer (TVA)
 Organic Vapor Analyzer (OVA)
 Ultrasound Leak Detection
 Acoustic Leak Detection
 Optical Leak Imaging
Toxic Vapor Analyzer
Acoustic Leak Detection

Mechanical inspection

Oil Analysis
Lubricating oil analysis is performed for three reasons:
 To determine the machine mechanical wear condition,

 To determine the lubricant condition, and
 To determine if the lubricant has become contaminated.

Technology of OA
Ferrography is a technique that provides microscopic
examination and analysis of wear particles separated from
all type of fluids.
Two of the major types of equipment used in wear

particle analysis are:
 Direct-Reading (DR) Ferrograph (no. of particles)
 Ferrogram Scanner (microscope) (type or shape)

Types of Wear Particles
Six types of wear particles are generated through wear process

(ferrous+non-ferrous)
1.Normal Rubbing Wear

2.Abrasive Wear (dirt, variety of metals )
3.Adhesive Wear (improper viscosity, contamination)
4.Cavitation (foaming of oils)
5.Corrosive Wear (acidic oxidation, random elect current)
6.Cutting Wear (imbalance, misaligment)

Types of Equipment
Analysis equipment that can be used on-site to characterize oil
condition, wear particles, and contamination.
Types of test equipment including:
 viscometers, spectrometers, oil analyzers, particle counters, and

microscopes.
 On-site testing can provide quick verification of a suspected oil problem

associated with critical components such as water contamination.

Typical oil analysis equipment

Direct Reading (DR) Ferrograph
Particle Counter

VIBRATION ANALYSIS
Vibration can be defined as the to and fro motion of a body around its mean position
caused by the influence of variable force vector.



Analysis Techniques
 Trend Analysis: ( 2D graph for future prediction of m/c condition)
 Pattern Recognition: ( like finger prints, eye recognition)

Analysis Techniques
 Test Against Limits (for calibration)
 Relative Comparison of data (from similar machines)
 Statistical Process Analysis

(previous data when machine was good)
 Correlation Analysis
(verify the data from different sources)
 Performance Analysis
(Temp., pressure, flow, displacement, speed, power)

Trend Analysis (TA)

This technique typically uses two-dimensional
graphs in order to visually display trends. The
graph may have alert or alarm levels to aid in the
analysis.

SHUTDOWN LIMIT
ALARM LIMIT
TIME

Condition Monitoring

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YANBU INDUSTRIAL COLLEGE/ MET DEPARTMENT

Eng.M.Ajmal & Eng. Osamah Ali

A functional failure is the inability of an item or system to meet a

specified performance standard.

A potential failure is an identifiable and quantifiable physical condition

which indicates a functional failure is imminent.

Failure is defined as a loss of ability to function normally

YIC/ MET 213 / Dr.Kassab 2 CONDITION MONITORING

The Perception of Equipment Life is...

Standard “Bathtub” Curve

Infant Mortality Wear-Out Zone

Constant Wear-Out Rate

YIC/ MET 213 / Dr.Kassab 3 CONDITION MONITORING

If it ain’t broke don’t fix it…..

Simple, but expensive

YIC/ MET 213 / Dr.Kassab 4 CONDITION MONITORING

The Preventive Approach

Time-Directed Tasking: Proven to save 12% - 18% over “Run to Failure”

YIC/ MET 213 / Dr.Kassab 5 CONDITION MONITORING

Additional 8% - 12% savings over a good preventive maintenance program

YIC/ MET 213 / Dr.Kassab 6 CONDITION MONITORING

What is Condition Monitoring?

YIC/ MET 213 / Dr.Kassab 7 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 8 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 9 CONDITION MONITORING

CONDITION MONITORING TECHNOLOGIES

YIC/ MET 213 / Dr.Kassab 10 CONDITION MONITORING

TYPICAL CONDITION MONITORING TECHNOLOGIES

YIC/ MET 213 / Dr.Kassab 11 CONDITION MONITORING

Why Condition Monitoring?

YIC/ MET 213 / Dr.Kassab 12 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 13 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 14 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 15 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 16 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 17 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 18 CONDITION MONITORING

Infrared Thermography (IRT)

Pictures of temperature difference ( Thermogram)

Temperature matrix Temperature difference

YIC/ MET 213 / Dr.Kassab 19 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 20 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 21 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 22 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 23 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 24 CONDITION MONITORING

Infrared Thermography: A Versatile Monitoring Tool

/ Generator Room / Main Distribution Panel Residence / Pantry

YIC/ MET 213 / Dr.Kassab 25 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 26 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 27 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 28 CONDITION MONITORING

Ultrasonic Testing (UST)

YIC/ MET 213 / Dr.Kassab 29 CONDITION MONITORING

 Detect steam leaks

 Analyze steam traps

 Locate gas leaks

 Determine Bearing Faults

 Determine electrical faults

YIC/ MET 213 / Dr.Kassab 30 CONDITION MONITORING

YIC/ MET 213 / Dr.Kassab 31 CONDITION MONITORING

Screening - find the leaks

YIC/ MET 213 / Dr.Kassab 32 CONDITION MONITORING