AEMA-2203 (Fall 2022)

Principles of Maintenance
[SECTION 4]

Lab Report 6:
CONDITION MONITORING

Student names and IDs:

Fouad Noorhossain – 60102591

Abdulla Abdulla – 60094408
Anees Khan – 60100461
Muhammad Usman Hussain – 60098397

Lab Experiment Date: 13th September, 2022

Instructor: Mr. Jamel Mezghani

Mechanical Engineering Technology

 INTRODUCTION AND THEORY

Condition monitoring is a type of predictive manitenance, that is performed by taking

action before the failure occur by using particular techniques to detect early signs of a failure.

There are three components involved in condition monitoring: they are measure, compare and

predict.

By performing condition monitoring, we can save more money over preventive

maintenance. There are common tasks can be performed, for example, vibration analysis,

thermal imaging, ultrasound techniques. We can get good results by collecting good data

Advantages of condition monitoring:

 Reduce parts

 Decrease labour costs

 Reduce downtime

Disadvantages:

 Require training for technicians

 High cost of tools required

 Analysis equipment is expensive

In this lab we have performed vibration analysis, Thermal imaging and Ultrasonic detection

on a centrifugal pump.
 OBJECTIVE

1. The objective of this lab is to perform predictive maintenance on a centrifugal pump

2. To learn and understand how to perform each type of maintenance tasks /checks on

different positions of the pump (horizontal, vertical, bearing area…)

3. Verify abnormal temperatures and vibrations.

PROCEDURE & INSPECTIONS TO PERFORM

Vibration Analysis:

1. It is done using a vibration analyzer. To begin, touch the probe on different positions of

the working pump and the rotating motor. Measure the vertical, horizontal and axial

vibrations of the pump and motor.

(MNDEV, MNDEH, MNDEA, PDEV, PDEH, PDEA…)

2. Note the readings and compare with the maximum allowed vibrations by the standards.

Thermal imaging:

1. It Is done by using the Thermal infrared imager, by pointing towards the crucial points of

the pump, where there is possibility of high temperatures.

2. Note the readings of the highest and the lowest temperatures.

Ultrasonic detection:

1. It is done by using the ultrasonic detector by hearing the abnormal sounds of the pump or

motor. Mainly the shaft side bearing area and the fan side bearing.
 MAINTENANCE CHECKS

Vibration Velocity Vibration acceleration

ips mm/s m/s2

MNDEV 0.03 0.7
MNDEH 0.02 0.5
MNDEA 0.10 2.7
MDEV 0.04 1.1
MDEH 0.60 1.5
MDEA 0.08 2.0
PDEV 0.60 1.5
PDEH 0.04 1.2 3.4
PDEA 0.04 1.1
PNDEV 0.01 0.7 12.5
PNDEH 0.02 0.6
PNDEA 0.08 2.4 8.5
The cause of the vibrations and the sounds may be due to the shaft
Discuss
misalignment or bearing wear. The vibration readings kept on
abnormalities
changing
 QUESTIONS

1) Q 1
a) what is the motor power in kW?
i) 15kW
b) What is the discharge pressure?
i) 24 psi

2) Q 2
a) How long the pump has been running continuously?
i) 25-30 mins
b) What is the discharge pressure
i) 24 psi
3) Ultrasonic detection
a) Was there any difference between the sound of the shaft end bearing and the sound of the
fan end bearing? Do you hear hissing, grinding, or crackling noises? Describe.
i) We heard minute hissing sound on both the ends. Though, the sound on the fan end
was less and the bearings were smoothly rotating compared to shaft end.

LEARNINGS

We learned many different areas of how to perform predictive maintenance using three

commonly used methods; infrared analysis (thermal imaging), ultrasonic detection (contact) and

vibration analysis. When we did the infrared analysis, we noticed higher surface temperature on

the rotating shaft end, as it generated more action and so more heat throughout the equipment.

An uneven or higher temperature can be the result of mechanical or electrical sources. We also

noticed that there were no abnormal sounds while performing the ultrasonic detection. This

means that the rotating motion was smooth with no interference.

Learning 1: The sources of heat generation throughout the mechanical device was learned such

as misalignment and inadequate lubrication.

Learning 2: We learned how to study the output image on the thermal imaging device, the

greater the intensity of the color produced, the hotter the spot.

Learning 3: We learned where to do the contacts when performing ultrasonic detection to get the

vertical, horizontal, and axial vibrations on the non-ends and ends of both pump and the motor.

CONCLUSION
This lab offered a variety of practical experience when we worked on finding vibrations at

different areas across the device by doing vibration analysis, heat spots on the pump while doing

thermal imaging and when we used ultrasonic detection to figure out the abnormal sounds. The

goal was to get a heat pattern on the thermal imaging device which can represent the parts that

need to either be repaired or be lubricated because of overheating. We first made sure that we

have the proper equipment to use for both the detections, then made sure we wear proper PPE

which included hard hats. Then moved to doing thermal imaging for finding hot spots where the

thermal imaging device showed uneven heating distribution across the electric motor. After we

tabulated the results (temperature) from the thermal imaging device, we moved on to do the

vibration analysis where we noted down the values of displacements (m) over time (s) at

different points and at different axis. Then we moved on towards ultrasonic detection which

showed no abnormal sounds. All this is a part of predictive maintenance which is essential in

order to keep the data in terms of readings that are collected for future references of the

machine/equipment.