BE MECH SEM VII DLOC - 4

MEDLO7041:
Machinery Diagnostics

By Mr. Sanjay Lohar

Asst. Professor,
Dept. of Mechanical Engineering, VCET
Teaching Scheme (Theory)
Department Level Optional Course – 4

Course Course Teaching Scheme Credits Assigned

Code Name (Contact Hours)
Theory Pract Tut. Theory Pract. Tut. Total
MEDLO Machinery 3 -- -- 3 -- -- 3
7041 Diagnostics

Course Course Examination Scheme

Code Name
Theory Term Practical Total
Work
Internal Assessment End Exam
Sem Duration
Test 1 Test 2 Average
MEDLO Machinery 20 20 20 80 3 -- -- 100
7041 Diagnostics
Syllabus Theory
Module Contents

Module 1 1.1 Basics of Vibration

Periodic and random motion, Spectral Amplitude Scaling: RMS, Peak and
Peak-to-Peak Conversion and Selection, Time and frequency domain analysis,
Phase analysis, Orbit analysis, Understanding signal pattern, Importance of
speed in accurate diagnosis, Importance of side bands in frequency spectrums.

1.2 Introduction to Vibration based Condition Monitoring

Maintenance Principles, Vibration based fault Prognosis, Goal of Vibration
Monitoring, Steps in Vibration Monitoring, Benefits of Vibration based
condition monitoring.

Module 2 Vibration Measurement

Vibration measuring instruments: displacement, velocity, acceleration; Force
measurement, Laser based measurements: laser vibrometer
Sensor Selection Criteria , Sensor – Mounting Locations and Techniques
Syllabus Theory
Module Contents

Module 3 Data Acquisition & Signal Processing

Classification of signals, Signal analysis, Fast Fourier Transform (FFT),
Essential Settings in Data Acquisition System (Plot Formats, Frequency Span
and Frequency Resolution, Average Types and Number of Averages,
Windowing, Spectrum Scaling), Signal conditioning

Module 4 Machinery Fault Diagnosis I

Natural frequency and resonance tests (Practical approach), Time and
Frequency domain analysis to identify unbalance, bent shaft, Misalignment,
Soft foot conditions, Mechanical looseness
Syllabus Theory
Module Contents

Module 5 Machinery Fault Diagnosis II

Rolling element bearing and Journal Bearing fault diagnosis, Faults related to
Gearbox, vane defects in pumps, Fault in Fans and Blowers.

Module 6 Applications of Condition Monitoring

Case studies related Balancing Problems in Turbines, Condition Monitoring in
Sugar mills, Health Monitoring of Journal Bearing, Condition Monitoring of
Industrial Pumps. (Aspects to be covered : Selection of sensors, recommended
location of sensor, direction of measurement, selection of plot type, Data
validation and Identification of Faults)
M/c health monitoring techniques
o Thermography
o Wear Debris Analysis
o Ultrasonic testing
o Radiography
o Acoustic Emission
o Vibration Analysis ….. Mostly Prefered
M/c health monitoring techniques
• Vibration (Accelerometer)
• Wear Debris (Spectrophotometer)
• Oil (Particle count meter)
• Temperature (IR detectors)
• Electrical Current (Hall effect sensor)
• Process Parameters (Orifice, Pressure gage)
Benefits of Vibration Analysis
Vibration monitoring is one of the most effective ways to detect and prevent
equipment failure or downtime. 70% of trouble shooting of fault diagnosis
or fault identification is done by monitoring vibration produce by machine

It can screen most faults including imbalance, misalignment, looseness, and

late-stage bearing wear, providing precise warning of impending failure.

Top 5 benefits of vibration monitoring

•Screen quickly, act quickly. Expanding your maintenance program to include
condition monitoring tools gives you deeper, more actionable insights. ...
•Organize information for data-driven decisions. ...
•Identify potential failures early. ...
•Reduce maintenance spend.
Undesirable Vibration
• Fatigue failure
• Loosening of hardware or assembly
• Human discomfort in operating Jack hammer
• Vibration that cause noise

Desirable Vibration
• Ultrasonic Cleaning of precision components
• Jack Hammer
• A guitar string is a good example: When plucked it will vibrate at its
natural frequency.
• Response of machine to diagnose faults
Failure
What is Machine Failure
Types of Machine Failure
Sudden Machine Failure
Intermittent Machine Failure
Gradual Machine Failure
Cause of Machine Failure

• Operator Error
• Wrong amount of Maintenance
• Physical wear and tear
• Reliability culture Failing
Operator Error
Wrong amount of Maintenance
Physical wear and tear
Reliability culture failing
Strategies to prevent Machine Failure
All over the world, plant operators adopt three different types of maintenance
techniques for machines, known as the reactive maintenance, preventive
maintenance, and predictive maintenance.
The benefits of planned maintenance
• Eliminate unnecessary maintenance
• Reduce rework costs
• Reduce lost production caused by failures
• Reduce repair parts inventory
• Increase process efficiency
• Improve product quality
• Extend the operating life of plant systems
• Increase production capacity
• Reduce overall maintenance costs
• Increase overall profit
Reactive Maintenance
Another name for reactive maintenance is breakdown maintenance. Obviously, in
this type of maintenance, no maintenance is done on the machine, and only when
the machine fails it is replaced by an entirely new machine. So, in a plant,
machines that are very critical and expensive obviously cannot be left to fail by
performing reactive maintenance. Usually, the less expensive and noncritical
machines can be good candidates for reactive maintenance.

For example, in a steel plant one obviously cannot afford to have the blast
furnace under a reactive maintenance program, but perhaps a water cooler in
the workers’ cafeteria may be a candidate for reactive maintenance
Attributes of a reactive maintenance program
High expenses involved
High spare parts inventory cost
High overtime labor costs
High machine downtime
Low production availability
Preventive Maintenance
In preventive maintenance, the maintenance on a particular machine is
done in a regular periodic manner at a fixed frequency. This type of
maintenance is also known as periodic maintenance

Preventive maintenance per the schedule mentioned in the service

manual of the vehicle supplied by the manufacturer at a fixed time
interval or distance covered by the vehicle

However, if this was a vehicle fleet owner having thousands of vehicles,

and if all the vehicles had to undergo preventive maintenance as per the
OEM schedule, there could be instances where the cost of service would
be very high and could have been avoided if only the vehicles whose
engine oils had gone bad were replaced and serviced.
Which Maintenance you will recommend???
In the armed forces, maintenance of weapons to fire , army vehicles and
naval vessels

In the armed forces, we would always like the weapons to fire whenever
required to do so, army vehicles and naval vessels to move immediately
on an order from the field commander, and so on. In such scenarios, cost
is not a major criterion, but functionality of the system is. Soldiers would
prefer that their gun not malfunction in front of an adversary because it
has not been maintained.
Predictive Maintenance

In predictive maintenance, maintenance is done on a machine depending on

its need.
The decision to conduct maintenance or not to conduct maintenance
depends upon the machine’s past and present condition. However, in order
to know a machine’s condition, additional instrumentation is required on
the machine to measure its “health” parameters. This instrumentation
includes transducers, signal conditioners, data acquisition units, computer-
based signal analysis systems, and software-driven diagnostic routines.

Preventive maintenance is a need-based maintenance that depends on the

condition of the machine. This type of maintenance is also known as
condition-based maintenance.
Predictive Maintenance
Once the machine’s condition is known, it becomes convenient, using simple
mathematical models, to determine the reasons behind any impending
failure of the machine or diagnose its fault condition .

Also, through simple mathematical regression models, the fault

prognosis can be done and the remaining useful life of the machine with
its present condition can be predicted.

Worldwide, it has been reported that over an extended time, predictive

maintenance is more economical than preventive maintenance, though it
is initially expensive because of the additional requirement of an
instrumentation system
Budget Head Predictive Preventive
Maintenance Maintenance

Capital Maintenance Equipment Rs. 5,00,000/- Zero

Cost

Machine Downtime, Repair & Labor Rs. 50,000/- Rs. 50,000/-

cost per shutdown for repair

Maintenance cost at end of 1st year Rs. 5,00,000/- Rs. 2,00,000/*-

Maintenance at end of 10 years Rs. 20,00,000/-

Maintenance cost at end of 20 years Rs. 7,50,000**/- Rs. 40,00,000/-

* Assuming four shutdowns a year

**Assuming there are 5 shutdowns between 1st and 20th Year.
The advantages of the predictive maintenance technique over the other two
are many. For instance, it is economic in the long run, it provides a scope for
fault prognosis, the maintenance schedule can be controlled according to the
availability of resources, the spare parts inventory can be reduced, and the
faults in a machine can be minimized. In the long run, this type of
maintenance leads to high production rates and increased profitability.

Advantages of the predictive maintenance technique

• Lower maintenance costs
• Fewer machine failures
• Less repair downtime
• Reduced small parts inventory
• Longer machine life
• Increased production
• Improved operator safety
Attributes by which a predictive maintenance
• User-friendly hardware and software
• Automated data acquisition
• Automated data management and trending
• Flexibility
• Reliability
 A successful maintenance program in a plant must have the following

• Clearly defined objectives and goals

• Measurable benefits
• Management support
• Dedicated, accountable personnel
• Efficient data collection and analysis procedure; viable database
• Communication capability
• Evaluation procedures
• Verification of new equipment condition
• Verification of repairs
• Overall profitability
Bath Tub Curve
Bath Tub Curve
The infant mortality zone with high failure rates occurs in the early stages of
the machine. There could be several reasons for such high failure rates; some
of them are faulty installation at the site, ignorance and unfamiliarity of the
machine operator, improper electrical power supply, nonavailability of a user
or training manual, improper specifications, and choice of the machine.
Once the above reasons are sorted out, the machine’s failure rate reduces
significantly; this state of the machine continues for a considerable time,
which is known as the Useful life of the machine.

Finally, toward the end of the useful period, the failure rate of the machine
again increases, which can be due to excessive wear and tear on the machine
and fatigue failure of the machine component. Though by maintenance the
failure rates can be controlled and reduced, a time comes when the cost of
maintenance or upkeep is so high that it is better to completely replace the
machine with a new one.
The availability of the machine is defined as the ratio of the useful period
(also known as uptime) to the total lifespan of the machine.
Maintenance engineers strive to increase the availability of a machine by
decreasing the machine’s downtime. The total lifespan of a machine is the
summation of the uptime and downtime of the machine.
Failure Modes Effects and Criticality Analysis
(FMECA)
FMECA is a methodology widely used in the industry to identify and
analyze all potential failure modes of the various parts of a system,
determine the effects these failures may have on the system, and how to
avoid the failures or mitigate the effects of the failures on the system.
FMECA can be used for the following
objectives:
• Assist in selection of design alternatives with high reliability
• Ensure that all conceivable failure modes and their effects on
operational success of the system have been considered
• List potential failures and identify the severity of their effects
• Develop early criteria for test planning and test equipment requirement
• Provide historical documentation for future reference
• Provide a basis for maintenance planning
• Provide a basis for quantitative reliability and availability analysis
Implementation of FMECA for Machinery
Maintenance
In a large plant, it would be economical or logical to have all equipment
under reactive maintenance or predictive maintenance. A FMECA
analysis early in the planning stage of maintenance lets one determine the
critical machines that will require more attention than the rest
Risk Priority Number for FMECA
Risk matrix or a risk priority number (RPN). The RPN is defined as the
product of the following three numbers:

O: The rank of occurrence of a failure mode

S: The rank of severity of the failure mode
D: The rank of ease of not detecting the failure

Risk Priority Number = O × S ×D

The ranks of O, S, and D can be anywhere from 1 to 10.
So, the minimum value of the RPN is 1 and the maximum value is 1000.
Machines with a high RPN may undergo predictive maintenance and the
machines with a low RPN may undergo reactive maintenance.
 The advantages of permanent, or online, monitoring are:

• It reacts very quickly to sudden change and gives the best potential for protecting
critical and expensive equipment.
• It is the best form of protection for sudden faults that cannot be predicted. An
example is the sudden unbalance that can occur on fans handling dirty gas, where
there is generally a build-up of deposits on the blades over time. This is normally
uniformly distributed but can result in sudden massive unbalance when sections of the
deposits are dislodged
• It is sometimes more economical to have permanently mounted transducers on widely
distribute and difficult-to-access machines, such as wind turbines, and automated
manufacturing machines, and then the additional cost of transmitting the collected
signals back to a centralized monitoring system is economically justified
The disadvantages of permanent monitoring are:

• The cost of having permanently mounted transducers is very high, so previously could
only be justified for the most critical machines in a plant, or where it is difficult for
operators to access the machines

• Where the transducers are proximity probes, they virtually have to be built into the
machine at the design stage, as modification of existing machines would often be
prohibitive

• Since the reaction has to be very quick, permanent monitoring is normally based on
relatively simple parameters, such as overall RMS or peak vibration level, and the phase
of low harmonics of shaft speed. In general, such simple parameters do not give much
advance warning of impending failure.
The advantages of intermittent monitoring are:

• Much lower cost of monitoring equipment.

• The potential (through detailed analysis) to get much more advance warning of
impending failure, and thus, plan maintenance work and production to maximize
availability of equipment.

• It is thus applied primarily where the cost of lost production from failure of the
machine completely outweighs the cost of the machine itself.
The disadvantages of intermittent monitoring are:

• Sudden rapid breakdown may be missed, and in fact where failure is completely
unpredictable this technique should not be used.

• The lead time to failure may not be as long as possible if the monitoring intervals
are too long for economic reasons. This is in fact an economic question, balancing
the benefits of increased lead time against the extra cost of monitoring more
frequently.