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MODULE 1: CONDITION MONITORING

CONDITION MONITORING

What is Condition Monitoring?

Simply stated, Condition Monitoring CM, also known as Predictive Maintenance, is the
continuous or periodic monitoring and diagnosis of equipment and components in order to
forecast failures (failure is defined as a loss of ability to function normally). Condition
Monitoring has been emerging within the last few years as more people have become aware of
its benefits and as the costs associated with monitoring the condition of systems and equipment
have decreased.

Typical Condition Monitoring technologies and approaches include

Infrared thermography,
Oil analysis,
Ultrasonic noise detection
Vibration analysis,
Flow and process analysis, and
Electrical circuit analysis.

Benefits of CM
Allow the early detection of potentially catastrophic faults, which could be extremely
expensive to repair.
Increase equipment availability.
Reduce costs.
More effective utilization of maintenance resources
Increase reliability, without sacrificing safety.
Avoid premature overhaul or replacement.
Extending service life.

System / Equipment Failure

The system/equipment failure is the inability of a system or system component to perform a

required function within specified limits.

A fan may still be turning, but if it is not performing within the system specification, it has
failed. Often times, especially on the component level, functional failures must be sought out.
This is because the system or machine appears to be operating satisfactorily even though some
components have functionally failed. In other cases, the function is only performed at
intermittent times and failure will have to be uncovered through testing. This is often the case for
safety devices, such as electric power circuit breakers.
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CONDITION MONITORING TECHNOLOGIES

Key to any effective maintenance program is economics. At what cost will you maintain
function? Areas that must be considered are effects on safety, operation (reason for being), and
capital costs. When all items are considered, Condition Monitoring often offers a cost effective
means of forecasting, and therefore preventing, failure.

The other maintenance approaches are Run-To-Failure and Interval Based Maintenance (the
traditional Preventive Maintenance). Both of these are appropriate choices in some
circumstances.

The Condition Monitoring technologies are only some of the approaches used in various
industries. You must ask yourself if you could improve the reliability of a system through the use
of Condition Monitoring, and then determine if there is a means to performing the monitoring.

1. Infrared Thermography (IRT)

Infrared Thermography (IRT) is the application of infrared detection instruments to

identify pictures of temperature differences (thermogram). As shown in figure 1 and
figure 2 the test instruments used are non-contact, line-of-sight, thermal measurement and
imaging systems.
Because IRT is a non-contact technique, it is especially attractive for identifying hot/cold
spots in energized electrical equipment, large surface areas such as roofs and building
walls, and other areas where "stand off" temperature measurement is necessary.

IRT inspections are identified as:

Qualitative or quantitative

The quantitative inspection is interested in the accurate measurement of the temperature

of the item of interest.
The qualitative inspection identifies relative differences, hot and cold spots, and
deviations from normal or expected temperature ranges.

Qualitative inspections are significantly less time-consuming than quantitative because the
thermographer is not concerned with highly accurate temperature measurement.

Any uneven heating (perhaps due to dirty or loose connections) would quickly be identified with
the IRT imaging system.
In mechanical systems, IRT can identify blocked flow conditions in heat exchanges, condensers,
transformer cooling radiators, and pipes.
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It can also be used to verify fluid level in large containers, such as fuel storage tanks, and
identify degraded refractory in boilers and furnaces. Inspections are performed on an annual or
biannual basis.

Figure 1 IRT Camera Figure 2 Non contact temperature measurement

Applications of IRT
Diagnose hot spots
Survey electrical panels
Perform energy efficiency surveys

Figure 3

As shown in figure 3. This image is a clear indication of overheating of a drive end motor bearing.
The temperature delta was over 40C. The root cause of the fault was insufficient lubrication.

Figure 4
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The image above highlights the importance of clean equipment. The temperature of this
motor was recorded at 110C. The cause of the high temperature was pinpointed to a blocked
cooling fan as shown in figure 4.

2. Oil Analysis (OA)

Lubricating oil analysis is performed for three reasons:

1. To determine the machine mechanical wear condition,
2. To determine the lubricant condition, and
3. To determine if the lubricant has become contaminated.

Benefits of OA
Informs you when your oil needs to be changed, often extending the intervals
between oil changes
Extend the life of your equipment
Spectral wear analysis
Test for viscosity breakdown
Determine what internal components are wearing
Check for contaminates

The test used depends on the test results sensitivity and accuracy, the cost, and the machine
construction and application. Note that the three areas are not unrelated, as changes in lubricant
condition and contamination, if not corrected, will lead to machine wear.
Oil should be analyzed on a quarterly to semiannual basis.

Oil analysis is performed on in-service machines to monitor and trend:

1. Emerging conditions,
2. Confirm problems identified through other means such as vibration, and
3. To troubleshoot known problems.

Lube condition trending, such as depletion of additives, can identify when the oil should be
changed.

Material, such as metal or seal particles, can identify machine damage before catastrophic
failure, allowing for less costly repair.

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In new buildings, oil analysis will confirm that the specified lubricants are being used and that
the system is free of construction contamination.

Wear particle analysis and Ferrography

Wear particle analysis and Ferrography in particular is an effective means to

identify and respond to maintenance needs
Wear is the inevitable consequence of surface contact between machine parts
such as shafts, bearings, gears, and bushing...even in properly lubricated
systems.
Equipment life expectancies, safety factors, performance ratings and
maintenance recommendations are predicated on normally occurring wear.

Technology of OA

Ferrography is a technique that provides microscopic examination and analysis of wear particles
separated from all type of fluids.

Two of the major types of equipment used in wear particle analysis are:

1. Direct-Reading (DR) Ferrograph,

2. Ferrogram Scanner (microscope).
a) Direct Reading (DR) Ferrograph

The DR Ferrograph Monitor is a trending tool that permits condition monitoring through
examination of fluid samples on a scheduled, periodic basis. (Concentration of ferrous wear
particles in lubricating or hydraulic oil)
An example is shown in figure 6 two sets of readings are obtained: one for Direct Large
>5 microns (DL) and one for Direct Small <5 microns (DS) particles. Wear Particle
Concentration is derived by adding DL + DS divided by the volume of sample,
establishing a machine wear trend baseline.

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Figure 5 Particle Counter

Figure 6 Example of trend analysis for additives 1&2

b) The Microscope

Ferrograms are typically examined under a microscope that combines the features of a biological
and metallurgical microscope. Such equipment utilizes both reflected and transmitted light
sources, which may be used simultaneously. Green, red, and polarized filters are also used to
distinguish the size, composition, shape and texture of both metallic and non-metallic particles
by the machine as shown in figure 5.

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LaserNet Fines Technology

Figure 7

Types of Wear Particles

There is six basics wear particle types generated through the wear process. These include ferrous
and non-ferrous particles comprises:

o Normal Rubbing Wear:

Normal-rubbing wear particles are generated as the result of normal sliding wear.
o Abrasive Wear
As shown in figure 8 the result of hard particles coming in contact with internal
components. Such particles include dirt and a variety of wear metals. Introducing a
filtration process can reduce abrasive wear. It is also important to ensure vents,
breathers, and seals are working properly.
o Adhesive Wear
Adhesive wear is when two metal surfaces come in contact allowing particles to break
away from the components. Insufficient lubrication or lubricant contamination normally
causes this. Ensuring the proper viscosity grade lubricant is used can reduce adhesive
wear. Reducing contamination in the oil will also help eliminate adhesive wear. As
shown in figure 8
o Cavitation
Cavitation occurs when entrained air or gas bubbles collapse. When the collapse occurs
against the surface of internal components, cracks and pits can be formed. Controlling
foaming characteristics of oil with an anti-foam additive can help reduce cavitation.
o Corrosive Wear
Corrosive Wear is caused by a chemical reaction that actually removes material from a
component surface. Corrosion can be a direct result of acidic oxidation. A random
electrical current can also cause corrosion. Electrical current corrosion results in welding
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and pitting of the wear surface. The presence of water or combustion products can
promote corrosive wear.
o Cutting Wear
Cutting Wear can be caused when an abrasive particle has imbedded itself in a soft
surface. Equipment imbalance or misalignment can contribute to cutting wear. Proper
filtration and equipment maintenance is imperative to reducing cutting wear. Many other
particle types are also present and generally describe particle morphology or origin.

Adhesive wear Abrasive wear

Erosive wear Corrosive wear

Figure 8

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3. Ultrasonic Noise Testing (UST)

A relatively inexpensive device called an ultrasonic noise detector can be used to locate
liquid and gas (pressure and vacuum) leaks.
When a fluid moves from a high-pressure region to a low-pressure region it
produce ultrasonic noise due to turbulent flow.
The detector translates the ultrasonic noise to the audible range, allowing an
inspector to identify the source of the leak. In-service fluid systems, such as
compressed air and steam, are usually inspected semiannually or annually.
The period of time between inspections is usually adjusted depending on the fluid
system and the number of leaks routinely found.

Figure 9

Ultrasound instruments, often referred to as "ultrasonic translators", provide information two

ways:
Qualitatively, due to the ability to "hear" ultrasounds through a noise isolating
headphone, and
Quantitatively, via incremental readings on a meter. This is accomplished in most
ultrasonic translators by an electronic process called "heterodyning", which accurately
converts the ultrasounds sensed by the instrument into the audible range where users can
hear and recognize them through headphones.

Applications of UST:
Detect steam leaks
Analyze steam traps
Locate gas leaks
Determine electrical faults

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a) Leak Detection
This category covers a wide area of plant operations. It can be viewed as a way of keeping a
system running more efficiently. Some plants include it as part of an energy conservation
program, while others refer to it as fugitive emissions. Regardless, leaks cost money; affect
product quality and can wreak havoc with the environment.

Figure 10 Sources of US noise

b) Mechanical inspection

Ultrasonic inspection and monitoring of bearings is a reliable method for detecting incipient
bearing failure. The ultrasonic warning appears prior to a rise in temperature or an increase
in driving torque. Ultrasonic inspection of bearings is useful in recognizing the beginning of
fatigue failure, brinelling of bearing surfaces, flooding of or lack or lubricant.

In ball bearings; as the metal in the raceway, roller, or bearing balls begins to fatigue, a subtle
deformation begins to occur. This deforming of the metal will produce an increase in the
emission of ultrasonic sound waves.

Figure 11 Ultrasonic inspection of mechanical components

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c) Steam Traps
Steam traps are also inspected easily with ultrasonic translators. It is important to determine
exactly how a particular trap is supposed to operate. This can be accomplished by consulting
with steam trap suppliers. In some instances, manufacturers of ultrasonic translators supply
video cassette training tapes that show exactly how each type of trap can be inspected

ANALYSIS TECHNIQUES

Trend Analysis (TA): This technique typically uses two-dimensional graphs in order to visually
display trends. The graph may have alert or alarm levels to aid in the analysis.
Pattern Recognition (PR): Often times machines exhibit recognizable operation patterns.
Deviations from the pattern or norm are indications of changes that may identify the onset of
failure. For example, the infrared thermography inspections discussed earlier are looking for
unexpected thermal patterns.

Test Against Limits or Ranges (LR): For parameters or conditions that do not follow
continuous trends or repeatable patterns. Useful in instrument calibration.

Relative Comparison of Data (RC): Look for change as related to earlier data or from another
baseline (such as similar equipment). Need stable building/system conditions.

Statistical Process Analysis (Also called Parameter Control monitoring): Generally uses
process or maintenance data that already exists or is collected. Applies statistical techniques to
process or maintenance data looking for deviation from the norms.

Correlation Analysis: The most powerful technique is the one that uses data from multiple
sources, related technologies, or different analysts.

TEST MEASUREMENTS FOR PERFORMANCE ANALYSIS

Performance analysis requires repeatable measurements of process parameters such as

temperature, pressure, flow, displacement, speed, power and time.

Experience will show whether sufficient repeatability is obtained by use of permanent

instrumentation. Readings can be made manually and processed manually or by computer.
Improved productivity and accuracy result from use of a hand-held data collector for subsequent

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downloading into a computer for processing. Permanent plant computer systems can often be set
up and used to calculate and display condition monitoring parameters - once repeatability and
readability of the available indications has been assured. Recent developments look promising in
transducers used for permanent installation.

Even if the stringent conditions required by Standards such as for flow measurement do not exist,
useful data can be gained by adapting these methods. Some brief points follow.

1. Temperature
Calibration of primary elements does require special facilities, such as stirred liquid salt bath
furnaces, or dry-well types. Thermocouples of the steel-sheathed mineral insulated type are
reliable, if calibrated. Digital temperature indicators with thermocouples are useful, and pipe
surface temperatures can be read repeatably with non-contact infra-red thermometers.

For the highest accuracy up to about 600 C, resistance elements (ie RTD) are more stable. For
lower temperatures, calibrated mercury-in-glass thermometers are often applicable.

2. Pressure
Bourdon test quality pressure gauges, calibrated at around the range of use, are satisfactory, but
industrial quality types can be acceptable if carefully used. A wide range of electronic
transducers are also available, and are necessary if a computer-based data collection and
processing system is to be used. Where safety conditions allow, quick-connect couplings speed
connection. Gauges and transducers are calibrated using a dead-weight tester. If excessive
hysteresis is found in an instrument, it should not be used.

3. Flow
Orifice plates can be made cheaply and may be able to be inserted at existing flanged joints in
piping.
Ultrasonic flowmeters measure and display the mean velocity of flow.
For small flows, such as the crankcase return oil flow on hydraulic pumps, a smaller container
such as laboratory glassware is used.

4. Displacement
Linear transducers of several types and ranges provide outputs, which can be recorded by data
processing equipment or traced on a pen recorder.

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5. Speed
Electronic tachometers count a pulse from a reflective tape on the shaft. Mechanical tachometers
require contact with the shaft end or surface. Stroboscopes are often sufficient.

6. Power
Plant ammeters are usually too crude, and high-accuracy test instruments will usually be needed.

CENTRIFUGAL PUMPS
The graph as shown in figure 12, the centrifugal pumps are one of the most common industrial
machines and deteriorate in several ways: internal wear at sealing rings and joints, erosion of
impeller vanes, corrosion and physical damage of parts, blockage with deposit. The rate of wear
varies with the duty, pump design and construction, liquid pumped, etc

Figure 12 Pump deterioration: Head-Flow characteristics around the operating point (sketch
from actual data boiler feed pump)

HEAT EXCHANGERS
Shell-and-tube heat exchangers are common items of plant. An increase in the simple parameter
of the Terminal Temperature Difference (Temperature difference between Cooled Liquid outlet
and Coolant outlet) indicates tube fouling, providing the coolant flow is relatively constant. This
is so with any gate type control valve more than about 25% open.

The temperatures can usually be found with sufficient repeatability by measurements on the pipe
surfaces using a contact or non-contact thermometer.

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Case Study: Shell-and-tube heat exchanger

Figure 13 shows a TTD trend for a small heat exchanger where mud had gathered in the water
side over some years. The effect of the clean is evident

Figure 13 Fouling trend plot for small shell & tube heat exchanger

FINDING THE OPTIMUM TIME FOR MAINTENANCE TO RESTORE LOST

PERFORMANCE

If the rate of deterioration in performance of a plant item is found by test, and maintenance work
can restore the lost performance, then the time for performing this work for the minimum overall
cost can be calculated using the relevant costs.

As an example of how to apply this method, take a major pump which has worn internally and is
assumed to continue to wear at a constant rate. A test 24 months since overhaul shows that an
extra 50kW of power is required. Power can be measured, or estimated from performance data
when new and the worn state head-flow data (Beebe 1998).

The pump runs in a system where production costs are not affected - the only penalty is the
increased cost of operation. If production were affected, then the cost penalty would be included.

The pump operates for 90% of the time, or 648h per month on average. Electricity costs
10c/kWh, and overhaul would cost $50 000. The average cost per month of the overhaul and the
wasted power can be calculated and totalled to find the minimum:
Cost of overhaul per month = $50 000 no. of months to when overhaul is done (e.g. if
overhaul is done after 10 months, cost/month has reached $5000).
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The average cost of increased power usage per month is found using the rate of cost
increase. Using the test data at 24 months, the rate is 50 0.10 648 / 24 =
$135/month/month. The average cost per month is therefore $135 0.5 no. of months.
At 10 months, this is $675/month.
The total cost per month at 10 months is therefore $5000 + $675 = $5675.

These calculations are repeated for a range of months, preferably using a spreadsheet so that
alternatives can be examined quickly, to show the month when cost per month is a minimum, in
this case at 27.2 months. Also, the cost penalty of either deferring the work or of scheduling it
sooner can be seen. The example is plotted in Figure 14.

The results may of course show that overhaul is not justified purely on energy savings alone.

The above calculation is only correct if the deterioration is progressing at a constant rate, which
is often a reasonable assumption.

This approach has much potential for wider use, on both rotating and stationary plant, given the
ever increasing interest in minimizing greenhouse gas emissions by reducing energy
consumption and the large savings often achievable.

Figure 14 Plot of calculated data to show the optimum time for overhaul to restore lost
performance

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