CONDITION MONITORING THROUGH NON DESTRUCTIVE TESTINGS OF MACHINES AND PLANTS

INTRODUCTION CONDITION MONITORING SIGNATURE ANALYSIS NON-DESTRUCTIVE EVALUATIONS(NDE) IN-SERVICE INSPECTIONS (ISI) SAFTEY

CONDITION BASED MAINTENANCE MAINTENANCE2.PREVENTIVE3.PREDICTIVE 1.BREAK DOWN

NDE TECHNIQUES 1.VIBRATION MONITORING 1.VIBRATION MONITORING 2.ACOUSTIC EMISSION (AE) 3.INFRARED THERMOGRAPHY (IRT) 4.FERROGRAPHY 5.FIELD SIGNATURE MAPPING (FSM)

VIBRATION MONITORING INSTRUMENTATION VIBRATION MEASURING AND ANALYSIS SYSTEM VIBROMETER CHANNEL SELECTOR FREQUENCY ANALYSER RECORDER fig,(1.a) SIGNAL FLOW DIAGRAM MACHINE MINI COMPUTERS PROBABILITY DENSITY FUNCTION ANALYSIS (PDF) BY INSPECTION

ANALYSIS OF RESULTS 1. VIBRATION CAUSE IDENTIFICATION Sl No FAULTFREQUENCY DIRECTION OF VIBRATION 1 ROTATING UNBALANCE SAME AS RUNNING SPEEDRADIAL 2 MISALIGNMENT OF BEARINGS 2*SPEED RADIAL AND AXIAL 3 ROLLER BEARING DEFECT AT BALL OR ROLLER SPEEED ULTRA SONIC FREQUENCIES(20-60KHz) RADIAL AND AXIAL 4. OIL FILM WHIRL IN HIGHSPEED TURBO MACHINES 0.5*SPEEDRADIAL 5 DAMAGED OR WORN GEARS No: OF TEETH* RPMRADIAL

VIBRATION METER (HAND HELD) Vibration Meter : for imbalance, structural weakness, loose parts etc INDUSTRIAL MACINERY CLASSIFICATION Class 2: Medium size machines without special foundation Class 3: Large machines on rigid foundations Class 4: Large machines on soft foundations. SPM VIB-11 by SKF

APPLICATIONOF VIBRATION MONITORING IN PLANTS MONITORING AT ‘ROURKELA STEEL PLANT’ maintenance cost 10-15% of prod: cost

GROWTH THROUGH CBM ACTIVITIES AT RSP No: of machines year BREAK DOWNS PREVENTED EQUIPMENTS INCLUDED

ACOUSTIC EMISSION MONITORING AE sensors respond with amazing sensitivity to motion in the low ultrasonic frequency range (10 kHz kHz). Motions as small as inches and less can be detected

ACOUSTIC-EMISSION METHOD This method is based on the registration of the elastic compression waves that are emitted by the defects developing in the stressed constructions.

ACOUSTIC EMISSION SYSTEMS AE data collection systems Laptop based AE system DiSP Systems (any number of channels can be used) Portable AE test system (lunch box)

Pressurization (Stage 1) Random AE activity due to 1.Mechanical rubbing between support structure and vessel 2. Paint layer peel-off. Re pressurization (Stage 2) No significant AE activity CASE STUDY AE DURING HYDROTESTING OF A HORTON SPHERE MAX : PRESSURE 22 Kg/cm 2 Fig.2(f) AE monitoring during hydro testing of Horton sphere AE SIGANLS FROM NEWER AREA ( local plastic deformation ) NO SIGNAL DURING SUBSEQUENT PRESSURIZATION

IR THERMOGRAPHY Infrared thermography is based on the principle of detection and measurement of infrared radiations QR) arising from the natural or stimulated thermal radiation of an object21

Type VARIOSCAN 3021 ST Spectral range [µm] Detector material Hg, Cd, Te Detector coolingStirling-cooler I R MEASURING SYSTEMS ThermaCAM S60 : Real-Time Thermal highly sensitive thermal imaging, precision temperature measurement, enhanced connectivity options including high speed data transfer extensive thermal analysis capabilities

raw thermo graphic data. data after removing the noise and vertical gradient. data processed for the local gradient in surface temperature. CASE STUDY high strength welds Fig setup for infrared testing of lap joints correspond to low strength welds.

FERROGRAPHY 1.WEAR DEBRIS ANALYSIS MODE: ABRASION, IMPACT, FATIGUE, EROSION, CORROSION RATE : CONCENTRATION OF WEAR DEBRIS SEVERITY : SIZE OF DEBRIS INDICATES LOCATION : COLOUR OF THE PARTICLES 2.SPECTROMETRIC ANALYSIS OIL ELECTRICALLY EXCITED TO THE POINT WHERE LIGHT IS EMITTED. ELEMENT EMITS A LIGHT OF ITS OWN PARTICULAR COLOR AND FREQUENCY. SPECTROMETERS TRANSLATES THE INTENSITY OF THIS RAINBOW OF COLORS INTO A COMPUTERIZED READOUT.

HOW IS THE TEST PERFORMED Tests Conditions Detected # Abnormal Wear Fuel Dilution DirtWaterCoolant Incorrect Oil Oxidation Additive Depletion Glycol Test * Viscosity * * Appearance/Odor **** * Spectrometric Analysis * * ** Alkaline Reserve * * Blotter Spot Test ** * Water Content * Distillation * Flash Point *

WEAR METAL ORIGIN TABLE METAL WEARPOSSIBLE ORIGIN. ALUMINIUM BEARINGS,BLOCKS,BLOWERS,BUSHINGS, CLUTCHES,PISTONS. CHROMIUM BEARINGS,PUMPS,RINGS,RODS. COPPER BEARINGS,BUSHINGS,CLUTHES,WASHERS. IRON BLOCKS,CRANK SHAFTS, CYLINDERS,DISCS. SILVER SOLDERS. TIN PISTONS.

MEASURING INSTRUMENT ModelT2FMAnalytical Ferrograph. Bi chromatic microscope. Video camera. Video capture card. Image capture software. industrial standard personal computer. This measure the effects of Contamination and electro-chemical changes that occur in synthetic and petroleum based oils

FIELD SIGNATURE MAPPING The FSM Inspection Tool (FSM) is a new technology for monitoring and inspection of metallic pipes and structures, pipelines and storage vessels Reduce life cycle inspection costs Reduce inspection time

FIELD PATTERN Sensing pins (electrodes) in an array over the monitored area to detect changes in the electrical field pattern. The voltage = the signature. Graphical plots indicating the severity and location of corrosion, and calculates actual corrosion and metal loss

INDUSTRIAL ARRANGEMENT A typical refinery monitors high temperature areas such as heater bends in the distillation unit.

CONCLUSION

SUMMARY OF APPLICABILITY AND CAPABILITY OF VARIOUS NDT TECHNIQUES NDT TECHNIQUE DETECTION CAPABILITY NON CONTACT INSPECTION AUTOMATED INSPECTION DEFECT SIZING VIBRATION VOLUMETRICPOSSIBLE ACOUSTIC EMISSION VOLUMETRICPOSSIBLE NOT POSSIBLE I R THERMO- GRAPHY SURFACE, NEAR SURFACE POSSIBLE FERROGRAPHY VOLUMETRICPOSSIBLE F S M SURFACE, NEAR SURFACE POSSIBLE