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Condition Monitoring
Adam AdgarSchool of Computing and Technology
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Why is it needed?
► Improve industrial plant performance► Provide early warning of potential
failure► Continuous drive for improved
efficiencies► Reducing unexpected plant downtime► Removing need for routine maintenance
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How does it improve things?
►Maintenance performed on a 'just-in-time' principle rather than on a routine basis Reduction in replacement-parts holding
► Reduces or eliminates unscheduled shut-down of plant or equipment lead to additional costs, usually out of all
proportion to the cost of the repairs subsequently found to be necessary
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What is it?
► Dynamic systems (electrical, hydraulic, mechanical or thermal) possesses a normal characteristic 'signature' when operating in the desired state
► Changes in this signature may indicate the onset of a failure
► Small differences between normal and abnormal signatures may be hidden by 'noise' in the system
► Modern transducers and associated signal-analysis techniques can now discriminate between truly random variations and significant trends which, with knowledge of the system parameters and normal characteristics, can be used to predict time to failure
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How is it done?
► Need to identify changes in the condition of a machine that will indicate some potential failure
► Physical characteristics are identified that collectively indicate the current condition of the machine
► Each of these characteristics is measured, analysed, and recorded so that trends can be recognised
► Over a period of time, the progress of these trends represents the deterioration of machine condition and can be used to determine maintenance actions.
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Where is it done?
► Originally developed to anticipate failure in high-speed gearboxes in the aerospace industry
► Now being applied to an ever-growing range of industries
► If process variables such as vibration, speed, pressure, temperature, voltage, current etc. can be measured, then it is likely that a process signature can be identified which can lead in turn to the application of Condition Monitoring techniques
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Example
►Different types of monitoring systems are used according to the criticality and condition of the individual asset
►Data: Body Temperature 99°F►Diagnosis: Appendicitis► Prognosis: Bad► Action: Appendectomy
tomorrow
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Technologies Applied
1. Vibration analysis2. Thermographic analysis3. Oil analysis4. Ultrasonic analysis5. Motor current signature analysis
(MCSA)6. Performance trending/visual
observations
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1. Vibration Analysis► Involves measuring the forces created from vibrations.► 50 to 70% of rotating component failures are
attributable to misalignment► Non-intrusive.► Foundation of rotating machinery predictive
maintenance.► Limited analysis on reciprocating machinery now
possible.
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2. Thermographic Analysis► Involves the use of infrared scanners to detect
differences in surface temperatures.► Based on the principle that machinery failures will be
preceded by changes in temperature.► Foundation of electrical component predictive
maintenance► Can be used to analyze patterns of heat loss or gain► Non-intrusive► Non-contact
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3. Oil Analysis
► Identifies the condition of the hydraulic fluid or lubricant
Viscosity analysis Contamination analysis Acid/Base number Oil additive analysis
► Identifies the conditionof the machine.
Wear particle analysis
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4. Ultrasonic Analysis
► Measures the sonic sound patterns of machines being monitored
► Airborne ultrasounds (20 kHz - 100kHz) Cannot penetrate solid surfaces Can penetrate cracks Radiate in a straight line
therefore the source is easy to locate
Travel a short distance
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5. Motor Current Signature Analysis
► Detects mechanical and electrical problems in motor driven rotating equipment.
► Based on the concept that an electrical motor driving a mechanical load acts as an efficient transducer.
Motor senses mechanical load conditions and translates variations in these conditions into variations in electrical current conditions.
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6. Performance Trending
►Monitoring the performance of a machine through the trending of process data. Pressure Temperature Flow Amperage
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Visual Observations
►Oldest and most common technique► Involves looking, listening, touching► Virtually all equipment
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Benefits / Summary
►Opportunity to organising avoidance strategies to minimise lost time and unexpected costs
► Provides information on presence of a fault condition indication of fault type diagnosis of the cause of a fault level of severity of fault prediction of time-to-failure