CONDITION MONITORING THROUGH NON DESTRUCTIVE TESTINGS OF MACHINES AND

PLANTS

PRESENTED BY :

ANOOP GOPAL

ROLL NO: 09

S7 MECHANICAL

INTRODUCTION

• CONDITION MONITORING

• SIGNATURE ANALYSIS

• NON-DESTRUCTIVE EVALUATIONS(NDE)

• IN-SERVICE INSPECTIONS (ISI)

• SAFTEY

fig 1.c detection methods of failures

vibration45%

others4%

acoustic emission3% fluorescence

3%

torque6%

rotational speed6%

temperature10%

oil analysis23%

vibration

oil analysis

temperature

rotational speed

torque

fluorescence

acoustic emission

others

CONDITION BASED MAINTENANCE

2.PREVENTIVE2.PREVENTIVE

3.PREDICTIVE3.PREDICTIVE1.BREAK DOWN 1.BREAK DOWN

MAINTENANCEMAINTENANCE

NDE TECHNIQUES

1.VIBRATION MONITORING1.VIBRATION MONITORING

2.ACOUSTIC EMISSION (AE)2.ACOUSTIC EMISSION (AE)

3.INFRARED THERMOGRAPHY (IRT)3.INFRARED THERMOGRAPHY (IRT)

4.FERROGRAPHY4.FERROGRAPHY

5.FIELD SIGNATURE MAPPING (FSM)5.FIELD SIGNATURE MAPPING (FSM)

VIBRATION MONITORING INSTRUMENTATION

• VIBRATION MEASURING AND ANALYSIS SYSTEM

VIBROMETER CHANNEL SELECTOR

FREQUENCYANALYSER

RECORDER

fig,(1.a) SIGNAL FLOW DIAGRAM

MACHINE

• MINI COMPUTERS

• PROBABILITY DENSITY FUNCTION ANALYSIS (PDF)

• BY INSPECTION

ANALYSIS OF RESULTS1. VIBRATION CAUSE IDENTIFICATION

Sl No

FAULT FREQUENCYDIRECTION OF VIBRATION

1ROTATING UNBALANCE

SAME AS RUNNING SPEED RADIAL

2MISALIGNMENT OF BEARINGS

2*SPEEDRADIAL AND AXIAL

3ROLLER BEARING DEFECT

AT BALL OR ROLLER SPEEED ULTRA SONIC FREQUENCIES(20-60KHz)

RADIAL AND AXIAL

4.OIL FILM WHIRL IN HIGHSPEED TURBO MACHINES

0.5*SPEED RADIAL

5DAMAGED OR WORN GEARS

No: OF TEETH* RPM RADIAL

VIBRATION METER (HAND HELD)

Vibration Meter : for imbalance, structural weakness, loose parts etc

INDUSTRIAL MACINERY CLASSIFICATIONClass 2: Medium size machines without special foundation Class 3: Large machines on rigid foundations Class 4: Large machines on soft foundations.

SPM VIB-11 by SKF

fig 1.c detection methods of bearing failure

vibration45%

others4%

acoustic emission3% fluorescence

3%

torque6%

rotational speed6%

temperature10%

oil analysis23%

vibration

oil analysis

temperature

rotational speed

torque

fluorescence

acoustic emission

others

fig2. failure rate of different machineries of plant

others24%

rolling bearing29%

slide way13%

valve6% sliding bearing

6%

seal7%

gear7%

oil pump8%

valve

slidingbearingseal

gear

oil pump

slide way

rollingbearingothers

APPLICATIONOF VIBRATION MONITORING IN PLANTS

• MONITORING AT ‘ROURKELA STEEL PLANT’

• maintenance cost 10-15% of prod: cost

GROWTH THROUGH CBM ACTIVITIES AT RSPN

o:

of

ma

chin

es0

20

40

60

80

100

120

94-95 95-96 96-97 97-98 98-99 99-00

breakdownsprevented

savings

insitu balancing

trend line

year

BREAK DOWNS PREVENTED-10-102

EQUIPMENTS INCLUDED - 40-140

ACOUSTIC EMISSION MONITORING

AE sensors respond with amazing sensitivity to motion in the low ultrasonic frequency range (10 kHz - 2000 kHz).  Motions as small as 10-12 inches and less can be detected

ACOUSTIC-EMISSION METHOD

This method is based on the registration of the elastic compression waves that are emitted by the defects developing in the stressed constructions.

ACOUSTIC EMISSION SYSTEMS

AE data collection systems

•Laptop based AE system •DiSP Systems (any number of channels can be used)• Portable AE test system (lunch box)

Pressurization (Stage 1)Random AE activity due to1. Mechanical rubbing between support

structure and vessel2. Paint layer peel-off .Re pressurization (Stage 2) No significant AE activity

CASE STUDY

AE DURING HYDROTESTING OF A HORTON SPHERE

MAX: PRESSURE 22 Kg/cm2

Fig.2(f) AE monitoring during hydro testing of Horton sphere

•AE SIGANLS FROM NEWER AREA ( local plastic deformation )

•NO SIGNAL DURING SUBSEQUENT PRESSURIZATION

IR THERMOGRAPHY

• Infrared thermography is based on the principle of detection and measurement of infrared radiations QR) arising from the natural or stimulated thermal radiation of an object21

TypeVARIOSCAN 3021 ST

Spectral range [µm]

8 ... 12

Detector material

Hg, Cd, Te

Detector cooling Stirling-cooler

I R MEASURING SYSTEMS

ThermaCAM S60 : Real-Time Thermal

•highly sensitive thermal imaging,•precision temperature measurement, •enhanced connectivity options including •high speed data transfer •extensive thermal analysis capabilities

raw thermo graphic data.

data after removing the noise and vertical gradient.

data processed for the local gradient in surface temperature.

CASE STUDY

high strength welds

Fig setup for infrared testing of lap joints

correspond to low strength welds.

FERROGRAPHY1.WEAR DEBRIS ANALYSIS

MODE: ABRASION, IMPACT, FATIGUE, EROSION, CORROSION RATE : CONCENTRATION OF WEAR DEBRIS SEVERITY : SIZE OF DEBRIS INDICATES LOCATION : COLOUR OF THE PARTICLES

2.SPECTROMETRIC ANALYSIS

•OIL ELECTRICALLY EXCITED TO THE POINT WHERE LIGHT IS EMITTED.

•ELEMENT EMITS A LIGHT OF ITS OWN PARTICULAR COLOR AND FREQUENCY.

•SPECTROMETERS TRANSLATES THE INTENSITY OF THIS RAINBOW OF COLORS INTO A COMPUTERIZED READOUT.

HOW IS THE TEST PERFORMED

TestsConditions Detected

#AbnormalWear

FuelDilution

Dirt Water CoolantIncorrectOil

OxidationAdditiveDepletion

Glycol Test         *      

Viscosity   *       *    

Appearance/Odor   * * * *   *  

Spectrometric Analysis

*   *   * *    

Alkaline Reserve           *   *

Blotter Spot Test     * *     *  

Water Content       *        

Distillation   *            

Flash Point   *            

WEAR METAL ORIGIN TABLE

METAL WEAR POSSIBLE ORIGIN.ALUMINIUM BEARINGS,BLOCKS,BLOWERS,BUSHINGS,

CLUTCHES,PISTONS.

CHROMIUM BEARINGS,PUMPS,RINGS,RODS.

COPPER BEARINGS,BUSHINGS,CLUTHES,WASHERS.

IRON BLOCKS,CRANK SHAFTS, CYLINDERS,DISCS.

SILVER SOLDERS.

TIN PISTONS.

MEASURING INSTRUMENT

ModelT2FMAnalytical Ferrograph. Bi chromatic microscope.Video camera.Video capture card.Image capture software.industrial standard personal computer.

This measure the effectsof Contamination and electro-chemical changes that occur in synthetic and petroleum based oils

FIELD SIGNATURE MAPPING

• The FSM Inspection Tool (FSM) is a new technology for monitoring and inspection of metallic pipes and structures, pipelines and storage vessels

• Reduce life cycle inspection costs

• Reduce inspection time

FIELD PATTERN Sensing pins (electrodes) in an array over the monitored area to detect changes in the electrical field pattern. The voltage = the signature.

Graphical plots indicating the severity and location of corrosion, and calculates actual corrosion and metal loss

INDUSTRIAL ARRANGEMENT

A typical refinery monitors high temperature areas such as heater bends in the distillation unit.

CONCLUSION

SUMMARY OF APPLICABILITY AND CAPABILITY OF VARIOUS NDT TECHNIQUES

NDT TECHNIQUE

DETECTION CAPABILITY

NON CONTACT INSPECTION

AUTOMATED INSPECTION

DEFECT SIZING

VIBRATION VOLUMETRIC POSSIBLE POSSIBLE POSSIBLE

ACOUSTIC EMISSION

VOLUMETRIC POSSIBLE POSSIBLENOT POSSIBLE

I R THERMO- GRAPHY

SURFACE , NEAR SURFACE

POSSIBLE POSSIBLE POSSIBLE

FERROGRAPHY VOLUMETRIC POSSIBLE POSSIBLEPOSSIBLE

F S MSURFACE, NEAR SURFACE

POSSIBLE POSSIBLE POSSIBLE