1. WELCOME

2. CONDITION MONITORING THROUGH NON DESTRUCTIVE TESTINGS OF MACHINES AND PLANTS
PRESENTED BY :
ANOOP GOPAL
ROLL NO: 09
S7 MECHANICAL

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

5. CONDITION BASED MAINTENANCE

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

7. 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

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

9. VIBRATION METER (HAND HELD)
SPM VIB by SKF
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.

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

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

13. 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

14. 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.

15. 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)

16. CASE STUDY AE DURING HYDROTESTING OF A HORTON SPHERE
MAX: PRESSURE 22 Kg/cm2
Pressurization (Stage 1)
Random AE activity due to
Mechanical rubbing between support structure and vessel
2. Paint layer peel-off .
Re pressurization (Stage 2)
No significant AE activity
AE SIGANLS FROM NEWER AREA ( local plastic deformation )
NO SIGNAL DURING SUBSEQUENT PRESSURIZATION
Fig.2(f) AE monitoring during hydro testing of Horton sphere

17. 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

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

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

20. FERROGRAPHY 1.WEAR DEBRIS ANALYSIS 2.SPECTROMETRIC 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.

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

22. WEAR METAL ORIGIN TABLE
METAL WEAR
POSSIBLE 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.

23. 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

24. 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

25. FIELD PATTERN Graphical plots indicating the
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

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

27. CONCLUSION

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

29. THANK YOU