Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
on
Condition Monitoring
Technology
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Presented
By
Engr. Md. Shahin Manjurul Alam
Saj Engineering & Trading Company
Company Profile
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Saj Engineering & Trading Company is established in 1998 to provide the NonDestructive Testing (NDT) and Condition Monitoring (CM) solution in Bangladesh industrial
Market. Since then we are providing the NDT and CM solution in different types of
industries like power generation, fertilizer, chemical, aviation shipbuilding, gas production
and distribution, cement, welding, paper, sugar, pharmaceuticals, research and
educational institutions. For the automobile and industrial market we are supplying
lubricants, filter, radiator and spark plug. For our products we represent the most
renowned manufacturers in the world.
As we have all sorts of latest NDT and CM products we have developed an industrial
inspection service provider under the name of Saj Industrial & Inspection Company.
And till now we have completed 40 Projects successfully and some projects is in our hand.
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Non
Destructive
Testing (NDT)
Products
Cold Welding
Materials &
Services
Condition
Monitoring
Products
MRO &
Packaging
Products
Different types
of Scientific
Equipments
Lubricants/En
gine Oil/
Motor oil
Automobile &
Heavy Duty
Filter
Predictive
Maintenance
Services
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Objective
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Types of machines
Motors
Pumps
Fans
Gearboxes
Engines
Compressors
Steam Turbines
Generators
Gas Turbines
Hydro Turbines
Rotating
Or
Reciprocating Machines
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Proactive
PP
Predictive
Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
on
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V aly
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M tras
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Select Suppliers
Supplier Specifications
Reactive
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ap
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rm y
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T
Th
D
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Equipment Performance
Metrics
Equipment Ranking
We are in
here
RCM
TPM
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H
el
e
F
i se
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N
RCA/FMEA
RCD
ll
e
Sm
ke
o
Sm
Training Programs
Written Procedures
Job Planning/Scheduling
CMMS
FF
Time
Machine Condition Chart
Condition Monitoring
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Condition Monitoring
Techniques
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1)
2)
3)
4)
Vibration Analysis
Oil Analysis
Thermal Analysis
Ultrasound Analysis
Vibration
Analysis
Thermal
Analysis
Condition Monitoring
For your Plant
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Oil Analysis
Ultrasound
Analysis
If you think this is your plant, then your plant is stand on this 4
technologies
Vibration Analysis
What Is Vibration ?
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Vibration Analysis
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Vibration Transducer
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SensorsTransducersProbesWhat is it?
Displacement
Shaft Riders
Proximity Probes
(Eddy Current Probes)
Velocity
Transducer
Accelerometer
Charge Type &
Line Drive
Constant Voltage &
Constant Current
How we Measure:
Probe Orientation
Vertical: A Transducer
Mounted Vertically "Sees
Only Vertical Movement
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Horizontal: A Transducer
Mounted Horizontally
"Sees" Only Horizontal
Movement
Mounting Direction
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Radial
Vertical
Vertical
Axial
Radial Horizontal
ial
x
A
Horizontal
Mounting Direction
Hori.
Vert.
Vert.
Axial
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Hori.
Axial
Turbines
Generators
Compressors
Motors
Pumps
Fans
Gears
~125 Machines
~1375 Machines
5%
Critical
25%
Essential
Wireless
Transmitters
30%
Important
~500 Machines
~500 Machines
20%
Secondary
20%
Non-Essential
Multi Technologies
Portable Solutions
Date Representation
Waterfall Plot
Orbit Plot
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Mass
Unbalance
Structural
Resonance
Misalignme
nt
Sleeve Bearing
Looseness/Rubs
X=RPM=CPM
minute=60Hz
1X=1xRPM=1xCPM
2X=2xRPM=2xCPM
Structural
Looseness
Gear Problem
Misalignment
CPM=Cycle per
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Bearing Looseness
Pump Cavitation
Oil Analysis
Oil Analysis
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Oil Analysis
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Blood Test
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No.
Element
Symbol
Readout
Range in PPM
Aluminum
Al
0-1,000
Barium
Ba
5-6,000
Boron
0-1,000
Cadmium
Cd
0-1,000
Calcium
Ca
0-6,000
Carbon
Reference
Chromium
Cr
0-1,000
Copper
Cu
0-1,000
Hydrogen
Reference
Iron
Fe
0-1,000
Lead
Pb
0-1,000
10
Magnesium
Mg
0-6,000
11
Manganese
Mn
0-1,000
12
Molybdenum
Mo
0-1,000
13
Nickel
Ni
0-1,000
14
Phosphorus
10-6,000
15
Potassium
0-1,000
16
Silicon
Si
0-1,000
17
Silver
Ag
0-1,000
18
Sodium
Na
0-6,000
19
Tin
Sn
0-1,000
20
Titanium
Ti
0-1,000
21
Vanadium
0-1,000
22
Zinc
Zn
0-6,000
23
Lithium
Li
0-1,000
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Elemental Analysis
426
427
428
430
11
430
12
430
12
R=Routine;L=LabRequested;B=SubmitSpecialSampleASAP
A=NoRecommendation,ContinueRoutineSampling
G=SampleAfterEachFlightDONOTFLYUNTILRESULTSAREKNOWN;
T=GROUNDUNIT,ExamineforDiscrepancy,AdviseLab
Failuredetectedbasedonincreasein
ironwearmetalconcentration
No.4Bearing
MissingParts
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ParticleShape
Analysis
ParticleCounting
Cutting
Cutting
Wear
Wear
Fatigue
Fatigue
Wear
Wear
Sliding
Sliding
Wear
Wear
Nonmetall
Nonmetall
ic
ic
Ferrography
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Oil Chemistry
Engine
Water (ppm)
Oxidation
(abs/mm2)
TAN (mg KOH/g)
TBN (mg KOH/g)
Alien fluid (%)
Anti-Oxidant
Additive (%)
Anti-wear
Additive (%)
Nitration
(abs/mm2)
Sulfation
(abs/mm2)
Soot (%)
Glycol (%)
Hydraulic
Synthetic
Gas Turbine
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Compressor/
transmissio
n
Gear/Turbine
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WDA Images
PLATELETS:
Two dimensional particles
produced by
metal to metal sliding.
SPHERICAL:
Produced by bearing fatigue or by
lubrication failure resulting in local
overheating.
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SPIRALS:
Similar in appearance to
machining swarf, and are
produced by a harder surface
abrading into a softer
CHUNCKY:
Produced by a fatigue mechanism
Infra-Red Thermography
Thermography
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Why Thermography?
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Non Contact
Rapid Scanning
Data can be recorded in differing formats
Images produced are comprehensive & reliable
Advantages
Non Contact
Non Intrusive
Can work at a distance
Fast and Reliable
Portable
Convincing Results
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Thermal Images
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Electrical
Switch Gear
Fuse boxes
Cable runs
Electrical
connectors
Insulation
Transformers
Fan
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37.4C
35
AR01
30
25
20
18.7C
Fuse Box
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38.1C
35
LI01
30
25
23.3C
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Electrical Connections
Used for the
detection of;
Corroded connections
Slack / loose
connectors
Connectors at too high
an operating
temperature
Hot spots
Electronics
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Electrical Motor
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Process Plant
Hot spots
Cold spots
(Cryogenics)
Damaged or
missing insulation
Tank levels
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Ultrasound Analysis
What is Ultrasound
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Advantages of Ultrasound
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Directional
Locatable
Multiple applications
Utilizable in all environments
Early warning failure indication
Supports other technologies
Application Groups
Leak detection
Compressed air
Specialty gasses
Vacuum
Steam traps / valves
Electrical Inspection
Mechanical Inspection
Slow speed bearings
Lubrication
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59
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VACUUM
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Electric Inspection
Switchgear
Transformers
Insulators
Relays
Breakers
*>28.4F
28.0
27.0
24.4
26.0
25.0
24.0
23.0
*<23.0F
26.8
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Electric inspection
Corona
Tracking
Arcing
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*>28.4F
28.0
27.0
24.4
26.0
25.0
26.8
24.0
23.0
*<23.0F
Bearing Inspection
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Very effective on S L O W S P E
ED!
3 Types of testing performed
Comparison
Historical Trending
Spectrum Analysis:
Fault frequency identification
Levels of Severity
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LUBRICATION
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