Contents

Introduction
Potential Failures and On-condition Maintenance Tasks
The P-F Curve/Diagram
Technical Diagnostics
Condition Monitoring Techniques
Categories of Condition Monitoring Techniques
Methodologies of Condition Monitoring Techniques
General Purpose Condition Monitoring Techniques
Introduction

The state of damage of a machinery or one of its

elements is the undesired deviation from the
required state fixed in the design.

Knowledge of the state of damage provides a

collection of data or information about the state of
machinery, which in turn can be used for setting the
date and kind of maintenance measures to be
taken. 3
 Cont.

The state of damage of an equipment

depends on:
 kind and conditions of damage, and
 duration of operation of equipment
 Determination of the state of damage is
part of Technical Diagnostics and
Maintenance Technique.

4
 Potential Failures and On-condition
Maintenance:
Most failures give some warning before they occur. This
warning is called potential failure.

Potential failure is defined as an identifiable physical

condition which indicates that a functional failure is
either about to occur or it is in the process of occurring.

A functional failure is defined as the inability of an

equipment in meeting a specified performance standard.

5
Cont.
 Techniques of detecting potential failures are known as
on-condition maintenance tasks. This is so because equipment is
left in service on the condition that they meet specified
performance standards

On-condition tasks entail checking for potential failures

so that action can be taken to prevent functional failure
or to avoid the consequences of the functional failure.
This is known as predictive maintenance (PDM) or
condition-based maintenance (CBM).
6
 Cont.
The four major categories of on-condition techniques
are as follows:
I. condition monitoring techniques, which involve
the use of specialized equipment to monitor the
condition of other equipment
II. techniques based on variations in product quality
III. primary effects monitoring techniques, which
entail the intelligent use of existing gauges and
process monitoring equipment
IV. inspection techniques based on the human
senses.
7
The P-F Curve/Diagram

8
Cont.
The P-F curve shows:
where failure in the equipment starts to occurs;

where equipment condition deteriorates to the point at which

the failure can be detected; and finally,

where the equipment has failed indicating functional failure.

P point at which it is possible to detect whether failure

is or is about to occur is known as potential failure.

F point where failure has taken place – functional

failure 9
 Cont.
 It is called the P-F curve, because it shows how
a failure starts, deteriorates to the point at
which it can be detected (point 'P') and then, if
it is not detected and corrected, continues to
deteriorate - usually at an accelerating rate
until it reaches the point of functional failure F.
Between points P and F it may be possible to
take action to prevent functional failure or to
avoid consequences of functional failure.
10
Cont.
Examples of potential failures include hot spots
showing deterioration of furnace refractories or
electrical insulation, vibrations indicating imminent
bearing failure , cracks showing metal fatigue, particles
in gearbox oil showing imminent gear failure, etc.

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 On-condition tasks are carried out at intervals less than
the P-F interval, where the P-F interval is the interval
between the occurrence of a potential failure and its
deterioration into functional failure.

12
 Cont.
 The P-F interval is the warning period, or the lead time to failure, or the
failure development period.

 The on-condition task is done at intervals which are less than the P-F
interval, usually at a frequency equal to half the P-F interval. This
ensures that the inspection will detect the potential failure before
functional failure takes place.

 In applying the P-F curve to condition monitoring, the sooner a

potential failure can be detected, the longer the P-F interval would be.

 Longer P-F interval would entail that the frequency interval for
inspection would be done less often. Hence there would be more time
to take appropriate actions to avoid the consequence of failure.
13
Technical Diagnostics
 Technical diagnostics is the determination of the technical state or
state of damage of an equipment, evaluation of the state and
collection of information for deciding the date and kind of
maintenance .

 Conclusions arrived at about the state of damage of an equipment

are probabilistic, and the accuracy of results obtained depends on
the accuracy of the method of investigation used, sampling
techniques and measuring techniques.

14
Schematic representation of technical
diagnostics

15
Measured Quantities for the State of Damage
Direct measured quantities
 The direct measuring technique determines the difference
between the initial state and the state after wear process.
 The measurements taken can be direct linear, volumetric
or mass quantities.
These measured quantities can be absolute or related
to duration of operation.
 Absolute measurement gives the amount of wear as an
average worn out thickness.
 Related measurement gives amount of wear per unit time
of operation.
16
 Cont.
 Direct measurement gives dimensions of parts. If the
wear is not constant over a surface, the measurement
should be done in different planes with different
orientations.

 Direct measurement is usually done after disassembly.

But it can also be made without disassembling provided
there is easy access to the measured quantities

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 Indirect measured quantities
 During the operation of a machine or parts

of it, certain signals are produced which are

related to the state of operation of the machine.
For example, mechanical vibrations, noise signals, acoustic and
thermal emissions, change in chemical compositions, smell,
pressure, relative displacement, and so on
 These signals, which are known as the diagnostic parameters,
if properly analyzed provide some information regarding the
state of the machine.
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 Categories of Condition Monitoring
Techniques
Condition monitoring techniques are designed to detect
specific symptoms which are related to the state of
damage of the equipment.

Depending on how the monitoring is done, the

techniques can be classified as:
A. On-load monitoring techniques

B. Off-load monitoring techniques

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A. On-load monitoring techniques: mostly carried out
without interruption of operation
 visual, aural, tactile inspection of accessible components

 temperature monitoring

 lubricant monitoring

 leak detection

 vibration/sound monitoring

 corrosion monitoring

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B. Off-load monitoring Techniques:

Off-load monitoring techniques require shutdown of the

unit. These include:
 visual, aural and tactile inspection of normally inaccessible
or moving parts

 crack detection

 leak detection

 vibration testing

 corrosion monitoring
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Methodologies of Condition Monitoring
Techniques
Today, there exists a large and growing variety of forms
of condition monitoring techniques for machine
condition monitoring and fault diagnosis. Here we
briefly introduce six main techniques

1. Dynamic effects monitoring

2. Particle effects monitoring
3. Chemical effects monitoring
4. Physical effects monitoring
5. Temperature effects monitoring
6. Electrical effects monitoring
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 1. Dynamic Monitoring
 Dynamic monitoring detects potential failures which cause
emission of abnormal energy in the form of waves such as
vibration and noise.
 Equipment which contain moving parts that vibrate are
monitored dynamically. This is done by measuring how much
the system vibrates.
 Techniques employed
 Broad band vibration analysis
(changes in vibration characteristics are
monitored)
 Constant bandwidth analysis
(changes in vibration characteristics are
monitored by using accelerometers)
 Real time analysis
(measurement of vibrational signals;
shock analysis)
 Ultrasonic analysis
(changes in sound pattern are monitored)
23
 2. Particle Monitoring
 Particle monitoring detects potential failures which cause
particles of different sizes and shapes to be released into the
environment in which the component is operating.

 These include wear particles and corrosion particles.

 Examples of equipment employed in particle monitoring are:

 Ferrography

 Real time ferromagnetic sensors

 Graded filtration

 Sedimentation

24
 3. Chemical Monitoring
 Chemical monitoring detects potential failures which cause traceable quantities
of chemical elements to be released in to the environment.
 This technique is used to detect elements in the lubricating oil which indicate
occurrence of potential failure elsewhere in the system.
 They are employed to detect wear, corrosion, leakage.

 Some of equipment are :

 Atomic emission spectroscopy

 X-ray fluorescence spectroscopy

 Infrared spectroscopy

 Electro-chemical corrosion monitoring

 Exhaust emission analyzers

 Colour indicator
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 4. Physical Effects Monitoring
 Physical effects monitoring includes changes in the physical appearance or structure of
equipment which can be detected directly.
 The monitoring techniques involved detect potential failures in the form of cracks,
wear, corrosion, etc.
 Some of the techniques employed are:
 Liquid dye penetrants

 Magnetic particle inspection

 Ultrasonic techniques

 X-ray radiography

 Light probes

 Deep-probe endoscope

 Oil odor

 Strain gauge

 Viscosity monitoring
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 5. Temperature Monitoring
These techniques look for potential failures which cause
rise in temperature of an equipment itself.

Monitoring techniques included in here, among others,

are:
 Infrared scanning

 Temperature indicating painting

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 6. Electrical Effects Monitoring

These techniques look for changes in resistance,

conductivity, etc. The techniques includes the following.
 Electrical resistance monitoring

 Potential monitoring

 Power factor testing

 Breaker timing testing

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 General Purpose Monitoring Techniques
 Lubricant, thermal and vibration monitoring techniques are
considered to be general purpose monitoring techniques.

 In each of these three techniques, the parameter being

monitored contains information that has been transmitted
through the machine.

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 1. Lubricant monitoring

 The oil which circulates through a machine carries with it evidence

of the condition of parts encountered.

 Examination of the oil and any particles it has carried with

allows monitoring of the machine on-load or at shut-down.

 Lubricant examination covers

 debris deposited,

 debris in suspension, and

 condition of oil.

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 a. Examination of debris collected
 Debris deposited are the larger particles carried along by the
lubricant which can be collected by filters or magnetic collectors.
 Examination of the debris under the microscope to establish size
and shape provides a good information regarding the state of
damage of the machine.

 Debris in suspension are the smaller particles collected by the

lubricant which remain in suspension.
 Examination of the debris in suspension gives the earliest warning of

component damage.

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 Cont.
 A change in the rate of debris collection indicates the change in
the condition of the machine as related to wearing out.

 Shape of debris collected carries information as to the wear

mechanism taking place.

Example:-

 Normal shape of wear particles tends to be flat;

 cutting or abrasive wear results in spiral shaped debris;

 surface fatigue failures produce larger angular particles.

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 b. Condition of oil used
Condition of used oil itself can be examined for indication of
other malfunctions.
 foaming of oil: cause is excessive churning or passage under pressure

through restrict

 darkened colour of oil: caused by oxidation of oil, excess temperature,

combustion or other chemical products reacting with the oil used.

Malfunctions that can be detected by lub monitoring

 damages of transmission components like gears, shafts, bearings, etc.

 blockage of ducts, pipes, etc.

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 2. Thermal monitoring
 Monitoring the temperature of a component in a machine is
undertaken for one of three purposes:
I. To enable temperature control of a process

II. To detect increase in heat generation due to some malfunction

such as damage of bearings

III. To detect changes in the heat transmitted through and out of the
body of the machine caused by a change in some component such
as failed coolant circulation or ash build-up in boilers, etc.

34
 Cont.
Temperature monitoring can be carried out

 at a point within the body of the plant (eg. measurement of

water temperature in a boiler),

 or at the surface of a component (eg. bearing housing).

Temperature monitoring devices are diverse and can be

classified as:
 contact sensors, and

 non-contact sensors (pyrometers)

35
 Malfunctions monitored thermally
 Possible areas where thermal monitoring can be applied.
 Bearing damages which result in heat generation and heating of the

bearing unit and other units that come in contact with the bearing unit.

 Failure of coolant or lubrication can be detected by a temperature rise of

appropriate bodies; such failures could result from pump failure, drive fault,
blockage in piping, valves or filter, or damaged heat exchanger.

 Incorrect heat generation like in internal combustion engines.

 Build-up of unwanted materials such as sediment in pipes, ash in boilers or

ducts, etc.

 Damage of insulating materials.

 Faults of electric components.

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 3. Vibration/noise monitoring
 Changes in vibration characteristics are indicative of trouble.

 The causes of vibration are

 unbalanced rotating and reciprocating parts,

 looseness in the fit between components,

 deflection of load carrying members,

 misalignment,

 damages in transmission components, etc.

 The equipment employed for vibration monitoring are vibro-

meters and accelerometers of wide variety.
37
 Cont.
Possible faults that can be detected by vibration
monitoring include:
 wear or failure of bearings;

 presence of unbalance in moving parts;

 changes in clearances;

 cracks in shafts and other moving components subjected

to cyclic loads.

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39
 CONDITION MONITORING SYSTEM (CMS)
CONDITION BASED MAINTENANCE (CBM)
CONDITION MONITORING SYSTEM
Impressions
(human senses) Vibration monitors
Maintenance
I&C channels
operators
Chemical Electrical
analysis consumption
Others Thermograph

CONDITION BASED MAINTENANCE

Cumulated
DECISIONS Experience
MAINTENANCE MANAGEMENT
COMPUTER MAINTENANCE MANAGEMENT SYSTEM
(CMMS)
CONDITION MONITORING

- Store data
CMMS
- Data management
- Experience database - Trends
- “Analysis”
- Alerts

Cumulated
Experience
DECISIONS
MAINTENANCE MANAGEMENT