Condition

Monitoring

KSHITIJA HINGE
M F G - I T D E P T.
Index
1. Failure Process and Cost to Repair
2. From Regular Inspections to Condition Monitoring
3. Identify Potential Failure
4. Condition Monitoring
5. Condition Monitoring Measurements
6. Condition Based Maintenance (CBM) Strategy
7. Condition Monitoring Techniques
1. Oil Analysis
2. Vibration Analysis
• Factors Causing Vibrations
• Vibration Analysis Sensor
• Vibration Analysis Sensors Advantages
• Dynamic Vibration Analysis
• Vibration Data Plotting
• Process Vibration Alarms ISO API Standards
• Conclusion – Vibration Analysis
8. Reliability Spectrum
9. Condition Monitoring Applications
10. Condition Monitoring Global Market
11. Summary – Condition Monitoring
Failure Process and Cost to Repair

• A functional failure might cause a complete line

stop.

• If you know the condition of the equipment, you

can reduce maintenance costs as well as the risk of
an unexpected breakdown.

• Using this knowledge to schedule repair and

replacement is called predictive maintenance.
From Regular Inspections to Condition Monitoring

• How often do you check for signs of potential failure?

• Have you missed to check when it was actually

necessary because you were adhere to the schedule?

• Was your inspection accurate enough to avoid future

breakdown?

Potential Failure to Functional Failure

Identify Potential Failure

• The earlier you can detect a potential failure, the

more time you have to react, plan and execute
equipment maintenance

• Early Indicators
•Oil analysis (months).
•Ultrasound Analysis (months).
•Vibration (weeks, months).
•Thermal image (weeks).
•Audible noise (days, weeks).
•Heat (days).
Condition Monitoring
• What is Condition Monitoring?
Continuous evaluation of the health of equipment throughout its serviceable life

• Which Assets need to be monitored? • A Criticality Assessment

Based upon the likelihood of failure and consequences of
failure, the equipment inclusion within the condition
monitoring program is decided.

In Reliance we divide all the assets in 3 categories

Vital, Essential and Desirable.
Condition Monitoring Measurements
To carry out condition monitoring, it is necessary to take measurements at regular intervals.

• What are Condition Measurements? • The collection and analysis of these measurements will
reveal results that enable the accurate diagnosis of the
equipment’s state.

• There can be no condition monitoring without condition

measurements.
Condition Based Maintenance (CBM) Strategy
Is developed to focus on condition monitoring activities of business and safety critical machinery.

• A Criticality Assessment
Based upon the likelihood of failure and consequences of
failure, the equipment inclusion within the condition
monitoring program is decided.

• Fault Matrices
Are utilized to identify detectable machine faults (for each type
of critical machinery) and the parameters that can be
monitored which are sensitive.

• The Condition Monitoring Strategy

Is then defined based upon the critical machine list
and failure modes which can be realistically identified
through condition monitoring.
Condition Monitoring Techniques
Installed vibration sensors monitor axial, vertical,
or horizontal movement and send notifications
when it becomes excessive.

The goal is to prevent Malfunctioning

recurrence by equipment generates
addressing the root a sound that
cause of a problem. ultrasonic sensors can
detect.

Lubricant/Oil analysis
Thermal images, are
analyses the number
visual displays of the
and size of particles
amount of infrared
such as iron, silicon,
energy emitted,
aluminum silicate, etc.
transmitted and
in collected oil
reflected by an object.
samples to determine
asset wear. “Undetected failure is not an option!”
Oil Analysis
Lube oil analysis serves two main purposes:

• To assess oil quality to ensure the oil is fit for further

• To assess machine condition by examining the oil for signs of mechanical wear
Lube Oil Analysis – Laboratory Analysis
Total Acid Number (TAN) – is used to measure the acidic content of the oil.
Total Base Number (TBN) – indicates the ability of an oil to neutralise acid.
Water Content – is a standard test used to assess the percentage of water within the oil sample.
PQ Index (Particle Quotient) – gives an indication of ferrous wear debris in the oil sample.
Ferrographic Analysis (also known as Wear Debris Analysis) – It is used to assess the size, shape and number of wear
particles suspended in the oil sample.
Spectrographic Analysis - measures the concentration (normally in parts per million (ppm)) of elements
Viscosity - low viscosity reduces oil film strength, weakening its ability to prevent metal-to-metal contact
Vibration Analysis
Vibration is simply a back and forth movement or oscillation of components in rotating equipment.

Industrial vibration analysis is often used on:

• Motors
• Pumps
• Gear Boxes
• Compressors
• Conveyors
• Rollers
• Engines
• Turbines (Steam/Gas/Water/Wind)
• Other machine tools that have rotational elements

• The amplitude of the vibration indicates the performance or quality

• An increase in the vibration amplitude is a direct result of deterioration or failure of rotational elements
Factors Causing Vibrations
The most common factors causing Vibration - Unbalance, Misalignment, Looseness etc.

Unbalance Bent Shaft

Looseness Misaligned
couplings
Vibration Analysis Sensors
Vibration analysis requires measurement and analysis of rotating machines utilizing different vibration sensors

• Accelerometers
• Accelerometers are case mounted using a permanent
bolt or portable magnet to hold them in place.
• Accelerometers are used for higher frequency
measurement like Bearing, Gear Box.

• Displacement Probes
• Displacement probes are used to measure the actual
movement of the shaft.
• These are generally known as proximity probes, these
transducers are limited in application but wherever
applicable they are extremely useful and important.

• Velocity Probes
• Velocity probes are used to measure the actual speed
of the shaft.
 Vibration Analysis Sensors Advantages
Advantages
Accelerometer Velocity Transducer Displacement/Proximity Probe
1. Surface Mounted. 1. Surface mounted and portable. 1. Direct measurement of shaft of shaft motion/position within journal bearing.
2. Small, Portable and Robust. 2. Self-generating no complex signal conditioning. 2. Very sensitive to low frequencies down to DC.
3. Large Dynamic Frequency Range.
4. Relatively Inexpensive.
5. Signal can be integrated to measure velocity or displacement.
Disadvantages
Accelerometer Velocity Transducer Displacement/Proximity Probe
1. Requires amplifier electronics. 1. Bulky 1. Limited frequency range(0 to 10 kHz). Practical range 0 to 2 kHz.
2. Limited Frequency Range (<1.5 kHz). 2. Permanently mounted (not portable) often diffi cult to replace.
3. Moving parts potentially wear over time. 3. Conditioning electronics required and interface panel must be housed in non-
hazardous area.
Applications
Accelerometer Velocity Transducer Displacement/Proximity Probe
1. Machines with rolling element bearings. 1. Portable transducer for measurement of low 1. Machines with journal bearings.
speed machines.
2. Gearbox Fault Diagnosis. 2. Machines with lightweight high speed rotors in heavy casing/foundations.
3. Heavy rigid rotors with light casing/foundations. 3. Measurement of radial shaft vibration and axial shaft position.
4. Highly utilised with portable handheld data collectors 4. Keyphasor (phase reference device).
Dynamic Vibration Analysis1
Fast Fourier Transform is most commonly used for vibration analysis.

The plots of amplitude vs. time (time waveform) and amplitude vs. frequency (FFT) are required for the trained technician
or engineer to analyze and determine the machine fault.
Dynamic Vibration Analysis2
Analysing the frequency disturbances will identify the faulty element.

Quantifying The Amplitude of Vibration

• Peak-to-Peak = 2 x Peak
• Peak =1.414 x RMS
• RMS = 0.707 x Peak
• (Average = 0.9 x RMS = 0.637 x Peak)
 Dynamic Vibration Analysis3
Dynamic vibration analysis can be accomplished in several different manners

• Portable sensors and portable data collection

Following a predetermined route of
machinery measurements

• Permanent sensors and portable data collection

Following a predetermined route of
machinery requirements

• Permanent sensors and permanent data collection

That provides machinery protection 24
hours per day, 7 days per week, 52 weeks per year
Vibration Data Plotting1
Orbit Plot
The Orbit display uses two data channels in the
time domain.

A well balanced shaft with no movement in any

direction would produce a dot in the middle of the
plot.

The shaft movement can give an indication of the

vibration source e.g. if there is a lot of up/down
movement it may be that the machine feet are not
bolted down tightly enough.

To create an orbit plot you need to take a dual

channel simultaneous measurement to capture
data at the horizontal and vertical axes at the
same time.

The displacement or acceleration sensors must

be placed 90° apart from each other.
The Orbit display uses a pair of measurements in
the time domain.
Vibration Data Plotting2
Orbit Plot

Shaft orbits must be taken from XY vibration transducers mounted orthogonally (90o apart).

They do not need to be true vertical and true horizontal but must be 90o apart in the radial plane.
Process Vibration Alarms – ISO Standards
Leverage the investment already made in process control systems (PLC, DCS, and SCADA).

• American Petroleum Institute (API) and International Standards Organization (ISO) have produced guidelines as
to acceptable levels of vibration based upon generic machine types.
Process Vibration Alarms – API Standards
The American Petroleum Institute (API) has produced numerous standards to satisfy the specific needs of the
petroleum, chemical and gas industries. These standards closely specify the detailed design, inspection and
testing of generic machine types

 API 610 – Centrifugal Pumps

 API 611 – General Purpose Steam Turbines
 API 612 – Special Purpose Steam Turbines
 API 613 – Special Purpose Gear Units
 API 616 – Gas Turbines
 API 617 – Axial and Centrifugal and Expander Compressors
 API 618 – Reciprocating Compressors
 API 619 – Rotary-Type Positive Displacement Compressors
 API 670 - Vibration, Axial Position and Bearing Temperature
Monitoring Systems
 API 674 – Positive Displacement Pumps – Reciprocating
 API 676 – Positive Displacement Pumps – Rotary
 API 677 – General Purpose Gear Units
 API 681 – Liquid Ring Pumps
Conclusion – Vibration Analysis
Vibration analysis is not a new technology. The Piezo effect and charge output of certain materials was discovered in
1880 by the Curies, and the first accelerometer was built in 1923.

Over the last 100 years, this technology has been refined for today’s industrial market to provide fast and efficient
measurements of rotating machinery vibration.

• Sensors are designed to withstand harsh industrial environments and provide critical measurements year after year.
• Cables and connectors are constructed of the most rugged materials available, and provide the critical link from the sensor to the
data collector.
• Mounting hardware is available for a broad range of applications. Measurements are accomplished quickly with portable magnet
mounts or quick disconnects.
• Permanent sensor installation can be accomplished with epoxy, stud mounting, or an array of special mounts designed for
permanent applications.
• Junction boxes are extremely useful in collecting multiple cables and organizing them in a manner that protects them and makes
them accessible to the user. They prevent tangling cables and identify each measurement point.

Dynamic vibration analysis or process vibration alarms will provide a proven technology to predict failures in rotating
machinery and improve machine reliability
Reliability Spectrum
Reliability spectrum – Essential steps in the reliability improvement process
Condition Monitoring Application
Condition Monitoring Global Market
The global machine condition monitoring market size is estimated to be USD 2.6 billion in 2019 and is projected to reach
USD 3.9 billion by 2025, at a CAGR of 7.0%.

Key Market Players By Industry

General Electric (US), Emerson Electric •Oil & Gas •Aerospace & Defense
(US), Honeywell International (US), •Power Generation •Food & Beverages
National Instruments (US), and SKF •Metals & Mining •Marine
(Sweden) •Chemicals •Others (Healthcare, Cement, Paper & Pulp,
•Automotive and Semiconductor & Electronics)

By Monitoring Technique By Geography By Deployment Type

•Vibration Monitoring •North America •On-premises
•Thermography •Europe •Cloud
•Oil Analysis •APAC
•Corrosion Monitoring •Rest of the World (RoW) By Monitoring Process
•Ultrasound Emission •Online Condition Monitoring
•Motor Current Analysis •Portable Condition Monitoring

https://www.youtube.com/watch?v=TxTJvshoZJk&feature=youtu.be
 Summary - Condition Monitoring
A method of maintaining optimum equipment performance by monitoring parameters of condition of equipment

• Why do we do it? • How do we do it?

• Positive impact on Sustainability, Safety & Quality Using the basic senses
• Increases Reliability and plant uptime • Visual: Eccentric, heat damage, looks different
• Places issues into planned shutdowns • Audible: Squeals, rumbles or change in sound
• Increased reliability • Touch: Vibration and heat with caution
• Reduces waste • Smell: Burnt oil, rubber or electrical systems
• Benefits multiple KPIs
• Advanced Monitoring methods
• Who does CM? • Visual: daily running inspections and routes
• Front line operators with daily checks • Audio: Acoustic Emission & Ultrasound
• Technicians & Engineers constantly • Odor: Daily Inspections & Oil Sampling
• CM specialists with data logging • Vibration: Meters, Handheld or Permanent
• Heat: Infrared Meter and Thermal Imager