3/27/2019

Training Course
on
Vibration Analysis Level-1
Centre for Vibration Analysis & Condition Monitoring (CVCM)
N-Block, Opp.: National Achieve Centre,
Pak Secretariat, Islamabad

Condition Monitoring

“Monitors the condition of the machine, if you

know the condition you can plan your response”

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Condition Monitoring (2)

• Your rotating machine is trying

to tell you its condition via:

 Vibration

 Temperature

 Oil samples

 Sound

 Motor voltage/current
• You have to choose the
technologies required to
assess the condition

Condition Monitoring = Health Monitoring

Vibration: Oil: Thermography: Motor Current:

The ‘pulse’ of the The ‘life blood’ of ‘Taking its The ‘brain waves’
machine the machine temperature’ of the machine

Total
Picture

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Why monitor the condition?

• Its all about money!

• When a machine fails:
 Production may stop.
 There may be secondary damage.
 There may be safety or environmental issues.
 Repair/labour costs can increase.

Condition Monitoring Benefits

• If we can assess the risk of failure we can plan the

repair at most cost effective time. Parts can be ordered
and labour organized.
• We do not need to perform expensive preventive
maintenance.
• We can reduce number of parts held in store

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Condition Monitoring: Early warning system

• Some technologies can tell us that a

problem exists now, and they help to
assess the severity.
• Some tests will also tell us if a situation
exists that could cause a problem in
future:
 Contamination in lubricant
 Resonance
 Misalignment

Condition Monitoring: Watch for a change

• We do not always know what levels are acceptable

• Instead we watch for change in level
 We trend levels over time
 We can use statistics to set alarms

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Condition Monitoring: The whole picture

• Each technology tells you something about the machine.

• Select the technologies and test frequency carefully.
• Best results are achieved when results from multiple
technologies are integrated into one report .

Overview of Technologies

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Condition Monitoring Technologies

• Oil Analysis

• Thermography

• Acoustic Emission

• Wear Particle Analysis

• Motor Testing

• Vibration Analysis

Role of Condition Monitoring Technologies

Thermography
19 %

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Overview of Technologies

Oil Analysis is a non-destructive test used to assess the condition of lubricants and
determine the type and amount of contamination present.

Criticality of lubrication to most industrial equipment, oil analysis trending over time is
one of the most powerful predictive tools for identifying potential failures.

3 basic categories of elements affecting the lubrication effectiveness: wear metals,

contaminants, and additives.

Oil Analysis – What does it offer ?

• Designed to keep track of the health of lubricants as well as
the equipment.
• Detecting and avoiding Contamination
• Detecting and avoiding lubricant degradation
• Detecting and avoiding Wear
Therefore
• Extending Lubricant Life
• Extending equipment life
• Improving Uptime performance
• Improving Profitability

Oil Analysis is not a tool for blaming someone !

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Benefits of Oil Analysis

– Reduce maintenance costs

– Reduce unexpected downtime

• Indication of component failure

• Locations of the damage

• Identify type of damage (chemical, abrasion, fatigue, or other)

– Increase equipment availability

Potential Cost Saving from Oil Analysis

– Lubricant consolidation

– Extended oil change intervals

– Extended machine life

– Power consumption

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8 Steps to Oil Analysis Success

1. Benchmark 2. Correctly Located 3. Consistent & Correct

the New Oil Sampling Points Sampling Procedure

4. Clean & Appropriate 5. Correct Selection of 6.. Immediate dispatch

Sampling Bottles Appropriate Tests of samples to Lab

8. Quality Interpretation &

7.Quality testing by the
immediate action to any
Lab
abnormal feedback

Oil Analysis Program – What should be included ?

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Strengths & Weaknesses of Oil Analysis

• Detects normal wear particles up to 6-10 microns.
• Determines lubricant additive depletion
• Detects fluid contamination
• Does not detect the onset of abnormal wear – wear particles
in excess of 10 microns
• Does not detect the sources of wear ( bearings, gears, seals,
rings, etc)
• Does not provide information regarding machine condition

Overview of Technologies
Wear Particle Analysis
– Wear particle analysis is a machine condition analysis technology
that is applied to lubricated equipment.
– It provides an accurate insight of a machine’s lubricated
components by examining particles suspended in the lubricant.
– By trending the size, concentration , shape and composition of
particles contained in a systematically collected oil samples,
abnormal wear related conditions can be identified at an early
stage.

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Overview of Technologies
Particle Sources
– Bearing
– Gears
– Seals
– Interior surfaces
– External particulates (contaminants)
– Chemical corrosion
– Additives degradation

Overview of Technologies
Wear Metals

Wear Metal Possible Origin

Aluminum Bearing, Blocks, Blowers, Bushings,
Clutches, Pistons, Pumps, Rotors
Chromium Bearing, Pumps, Rings, Rods
Copper Bearing, Bushings, Clutches, Pistons, Pumps
Iron Bearing, Blocks, Crankshafts, Cylinders,
Discs, Gears, Pistons, Pumps, Shafts
Tin Bearing, Bushings, Pistons

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Overview of Technologies
Acoustic Emission:
– Rotating equipment and other assets emit high-frequency sound that
provides clues to potential problems:

• Excellent tool for finding air leaks

• Good tool for finding bearing problems
• Lubrication problems can be detected and corrected
• Good tool for finding steam leaks in steam traps
• Can be used to detect electrical faults and many others

Overview of Technologies
What is ultrasound:
– The human ear can only detect sound in the sonic range 20 to 20,000 Hz

– Any sounds that are above the human hearing capabilities are referred to
as “ultrasounds”

– A few facts:
• The sounds are directional
• The volume depends on distance from the source
• Sound travels through air and solids

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Overview of Technologies
How do you use it:
– An Ultrasonic Gun is required to measure the signal and then heterodyne
the signal to an audible signal

Air leak Steam leak Steam Trap

Overview of Technologies
What do you do with it:
– There are two ways to use the ultrasound data.
 You can listen to it
 Search for leaks, search for faults etc.

– You can measure it

 The units are displayed in dB
 You can also view a time waveform and spectrum

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Overview of Technologies
Thermography:
– Thermography is the study of radiated energy using a thermal infrared
imaging system
– Heat can indicate a fault condition
– Temperature can be measured at a point but we will focus on thermo
graphic image

Overview of Technologies
Infrared Thermography
– The camera detects the radiated energy and displays the temperature
gradients. A scale indicates the relationship between colour and
temperature

– The radiated energy is interpreted by the camera to display a

temperature at a point or area
 The actual temperature indicated may be incorrect
 Surface type, wind condition and other factors effects accuracy

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THERMOGRAPHY SURVEY

What can Thermography find?

What you see What thermography sees

Overheating electrical connection indicates a serious fire hazard.

THERMOGRAPHY SURVEY

Can you afford not to have a

Thermography Survey?

Fire damaged electrical system

Cruise Ship Fire
Damage

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Applications of Infrared Thermography

– Mechanical
 Machines, pipes, bearing and belts

– Electrical
 Overhead lines, transformers, motors and control panels

– Steam Systems

– Security Systems

– And many others!

Thermal Comparison to Photographic Image

– Comparing the visual image to thermo-
graphic image reveals the nature of fault
condition

– The temperature scale indicated severity

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A few thing to know

– The source of heat may comes from inside the object (tank, machine,
cabinet), but the detector only see the energy emitted from the
surface.

– It is therefore necessary to open cabinets to detect electrical faults

Electric Motor Bearing

8 1 ,

8 0

7 0

6 0

5 0 ,

Overheated motor bearing

Over 80 °C on bearing housing

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Belt Drives

2 0 2 .3 °F
Hot v-belt 200
stressed due
to wear and/or 180

misalignment 160

140

120

100

80

6 6 .9 °F

Belt Drives

• Over-heating due
to:
 Belt wear
 Pulley wear
 Pulley misalignment

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Overview of Technologies
Motor Testing
– Motor Current Signature Analysis (MCSA) is a condition
monitoring technique used to diagnose problems in induction
motors.
– It was first proposed for use in nuclear power plants for
inaccessible motors and motors placed in hazardous areas.
– MCSA can be used as predictive maintenance tool for detecting
common motor faults at early stage and as such prevent
expensive catastrophic failures, production outages and extend
motor lifetime.

MCSA – Motor Current Signature Analysis

• Used to generate analyses and trend of electric
machines dynamically.
• They aim to detect predictive problems in a rotating
electric machine, such as:

Static eccentricity ( Stator)

Dynamic eccentricity (Rotor)
Broken rotor bar problems
Voltage unbalance
Shorted stator turns
Problems on the windings

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Motor Current Signature Analysis

Induction
Motor Fault

Electrical Fault Mechanical Fault

Stator fault Rotor fault Bearing fault Eccentricity

Winding Broken rotor

external faults bars, end rings

Motor Testing
– Current spectra can be collected on each power leg at the panel
using a current clamp.
– One general comparison that can be made is the amperage draw
from each leg.
– These should be approximately the same for proper load
balancing.
– An exceptionally high or low load indicates problems.
– The flux coil is used on the motor rather than on panel. It collects
data from the flux field generated by the motor. The data can be
viewed on a spectrum.
– Flux measurement Indicate Potential problems in windings.

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Overview of Technologies

Vibration Analysis
– Can tell us a great deal
about a machine.

Overview of Technologies

Vibration Analysis
– Used to Detect, Analyse and Confirm plant machinery problems. This can
be done in three ways:
• On-line for automated and continuous monitoring and protection of
critical plant items
• Portable route based data collection and analysis
• Wireless used for remote monitoring of moving or inaccessible
equipment

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Overview of Technologies
Typical Machinery Problems that Can Be Found Using Vibration Analysis:

• Unbalance
• Misalignment
• Mechanical looseness
• Structural problems
• Bent shaft
• Bearing faults

Overview of Technologies
Typical Machinery Problems that Can Be Found Using Vibration Analysis:

• Gear faults
• Belt problems
• Lubrication problems
• Electrical motor faults
• Cavitation and turbulence
• others

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Which Technology is Applicable?

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