Chapter 4

Determination of State of Damage

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 Content:
❖Introduction

❖Measuring value for the state of damage

❖Method of condition monitoring

❖Condition Monitoring Techniques

❖Potential failure and condition Maintenance

❖Categories of Condition Monitoring Techniques

❖General purpose monitoring techniques

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 Introduction
❖ The state of damage of machinery refers to the condition or state in
which a machine or equipment exists after experiencing some form of
harm or damage.
❖ The state of damage of a machinery or one of its elements is the undesired
deviation from the required state fixed in the design procedures.
❖ This damage can manifest in various ways, such as physical
deformations, mechanical failures, or functional impairments.
❖ The state of damage is typically assessed by
❖evaluating the visible signs of deterioration,
❖examining the extent of mechanical impairments, and
❖assessing the impact on the machinery's operational capability and
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performance.
 Introduction

❖Understanding the state of damage is crucial for

determining the necessary repairs, replacements, or

maintenance actions needed to restore the machinery to its
optimal working condition.
❖ Knowledge of the state of damage provides a collection of

data or information about the state of machinery, which in

turn can be used for setting meaningful maintenance
routines.
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 Introduction cont.….
❖ The state of damage of an equipment depends on:

✓ kind and Conditions of damage, and

✓ Duration of Operation of Equipment

❖ Determination of the state of damage is part of Technical

Diagnostics and Maintenance Technique.

❖Technical diagnostics is the determination of the

technical state or state of damage of an equipment, evaluation
of the state and collection of information for deciding the date
and kind of maintenance
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 Introduction cont.….

❖Technical diagnostics is done without disassembling

while the equipment is in operation.

❖Conclusions arrived at about the state of damage of

an equipment are probabilistic

❖ the accuracy of results obtained depends on the

accuracy of the method of investigation used,

sampling techniques and measuring techniques.

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 Schematic representation of technical diagnostics

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Measuring Values for the State of Damage
❖ Direct measured quantities

✓ The direct measuring technique determines the difference between

the initial state and the state after wear process.

✓ The measurements taken can be direct linear, volumetric or mass

quantities.
❖ These measured quantities can be absolute or related to
duration of operation.
✓ Absolute measurement gives the amount of wear as an average

worn out thickness.

✓ Related measurement gives amount of wear per unit time of

8 operation.
 Cont…
✓ Direct measurement gives dimensions of parts. If the

wear is not constant over a surface, the measurement

should be done in different planes with different
orientations.

✓ Direct measurement is usually done after disassembly.

But it can also be made without disassembling provided

there is easy access to the measured quantities.

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 Indirect measuring quantities

✓ During the operation of a machine or parts

of it, certain signals are produced which are

related to the state of operation of the machine.

✓ These signals, which are known as the diagnostic

parameters, if properly analyzed provide some

information regarding the state of the machine.

✓ It should be noted that influence from the environment

introduces errors in the measured results

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 Condition monitoring techniques
 Condition monitoring refers to the practice of continuously or

periodically assessing the health and performance of machinery,

equipment, or systems to detect any signs of potential faults,
degradation, or anomalies.

 The primary goal of condition monitoring is to identify any early signs

of deterioration, wear, or impending failure in order to take proactive

measures such as maintenance, repairs, or replacements.

 By monitoring the condition of machinery, engineers and technicians

can optimize maintenance strategies, minimize downtime, and improve

overall equipment reliability and performance.
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 Condition monitoring techniques…cont’d
 It involves the use of various techniques and tools to monitor key
parameters and indicators that can provide insights into the
condition of the monitored assets.
 Depending on how the monitoring is done, the techniques can be

classified as:

A. On-load monitoring techniques: mostly carried out

without interruption of operation

✓ visual, aural, tactile inspection of accessible components

✓ temperature monitoring

✓ lubricant monitoring

12 ✓ leak detection
 B. Off-load monitoring Techniques:

Off-load monitoring techniques require shutdown of the

unit. These include:
✓ visual, aural and tactile inspection of normally inaccessible

or moving parts;
✓ crack detection;

✓ leak detection;

✓ corrosion monitoring.

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 Potential Failures and On-condition Maintenance:
✓ Potential failure is defined as an identifiable physical condition
which indicates that a functional failure is either about to occur
or it is in the process of occurring.

✓ A functional failure is defined as the inability of an equipment in

meeting a specified performance standard.

✓ Techniques of detecting potential failures are known as

on-condition maintenance tasks. This is so because equipment is
left in service on the condition that they meet specified
performance standards
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 The P-F Diagram

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Potential Failures and On-condition …

❖The P-F curve is employed to show what happens in the final

stages of failures.

❖The P-F curve shows:

✓where failure in the equipment starts to occurs;

✓where equipment condition deteriorates to the point at which

the failure can be detected; and finally,

✓where the equipment has failed indicating functional failure.

❖P point at which it is possible to detect whether failure is or is

about to occur is known as potential failure. F point where failure
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has taken place – functional failure
 Cont…

✓ Tasks designed to detect potential failures are known as on-

condition tasks.

✓ On-condition tasks entail checking for potential failures so that

action can be taken to prevent functional failure or to avoid
the consequences of the functional failure. This is known as
predictive maintenance or condition-based maintenance.

✓ On-condition tasks are carried out at intervals less than the P-F
interval,

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 ✓ The P-F interval is the interval between the occurrence
of a potential failure and its deterioration into
functional failure

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Cont.…

✓ The P-F interval is the warning period, or the lead time to failure, or
the failure development period.

✓ The on-condition task is done at intervals which are less than the P-F

interval, usually at a frequency equal to half the P-F interval. This

ensures that the inspection will detect the potential failure before
functional failure takes place.

✓ In applying the P-F curve to condition monitoring, the sooner a

potential failure can be detected, the longer the P-F interval would be.

✓ Longer P-F interval would entail that the frequency interval for

inspection would be done less often. Hence there would be more time

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to take appropriate actions to avoid the consequence of failure.
 Categories of Condition Monitoring Techniques

Condition monitoring techniques are designed to detect

specific symptoms which are related to the state of
damage of the equipment.
➢ Dynamic Monitoring

➢ Particle Monitoring

➢ Chemical Monitoring

➢ Physical Effect Monitoring

➢ Temperature Monitoring

➢ Electrical Effect Monitoring

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 1. Dynamic Monitoring
✓ Dynamic monitoring detects potential failures which cause emission
of abnormal energy in the form of waves such as vibration and noise.
✓ Equipment which contain moving parts that vibrate are monitored
dynamically. This is done by measuring how much the system
vibrates.
✓ Techniques employed
 Broad band vibration analysis
(changes in vibration characteristics are monitored)
 Constant bandwidth analysis
(changes in vibration characteristics are monitored by
using accelerometers)
 Real time analysis
(measurement of vibrational signals; shock analysis)
 Ultrasonic analysis
(changes in sound pattern are monitored)
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 2. Particle Monitoring

✓ Particle monitoring detects potential failures which cause particles

of different sizes and shapes to be released into the environment in

which the component is operating.

✓ These include wear particles and corrosion particles. Examples of

Techniques employed in particle monitoring are:

❑ Ferrography

▪ (Wear and corrosion particles are monitored by taking a representative

sample of oil)

❑ Real time ferromagnetic sensors

❑ Graded filtration

22 ❑ Sedimentation
 3. Chemical Monitoring
❖ Chemical monitoring detects potential failures which cause traceable
quantities of chemical elements to be released in to the environment.

❖ This technique is used to detect elements in the lubricating oil which

indicate occurrence of potential failure elsewhere in the system.

❖ They are employed to detect wear, corrosion, leakage. Some of the

techniques are :
➢ Atomic emission spectroscopy

➢ X-ray fluorescence spectroscopy

➢ Infrared spectroscopy

➢ Electro-chemical corrosion monitoring

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➢ Exhaust emission analyzers
 4. Physical Effects Monitoring
❖ Physical effects monitoring includes changes in the physical
appearance or structure of equipment which can be detected
directly.
❖ The monitoring techniques involved detect potential failures in
the form of cracks, wear, corrosion, etc. Some of the techniques
employed are:
➢ Liquid dye penetrants
➢ Magnetic particle inspection
➢ Ultrasonic techniques
➢ X-ray radiography
➢ Light probes
➢ Deep-probe endoscope
➢ Oil odor
➢ Strain gauge
24 ➢ Viscosity monitoring
 5. Temperature Monitoring

➢ These techniques look for potential failures which cause

rise in temperature of an equipment itself.

➢ Monitoring techniques included in here, among others,

are:
✓Infrared scanning

✓Temperature indicating painting

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 6. Electrical Effects Monitoring

➢ These techniques look for changes in resistance,

conductivity, etc. The techniques includes the

following.
✓ Electrical resistance monitoring

✓ Potential monitoring

✓ Power factor testing

✓ Breaker timing testing

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 General Purpose Monitoring Techniques

➢ Thermal, lubricant and vibration monitoring techniques

are considered to be general purpose monitoring

techniques.

➢ In each of these three techniques, the parameter being

monitored contains information that has been

transmitted through the machine.

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 1. Lubricant monitoring
❑ The oil which circulates through a machine carries with it evidence

of the condition of parts encountered.

❑ Examination of the oil and any particles it has carried with it

allows monitoring of the machine on-load or at shut-down.

❑Lubricant examination covers

✓debris deposited,

✓debris in suspension, and

✓condition of oil.

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 a. Examination of debris collected
❑ Debris deposited are the larger particles carried along by the

lubricant which can be collected by filters or magnetic collectors.

✓ Examination of the debris under the microscope to establish size
and shape provides a good information regarding the state of
damage of the machine.

❑ Debris in suspension are the smaller particles collected by the

lubricant which remain in suspension.

✓ Examination of the debris in suspension gives the earliest warning of

component damage.
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 Cont…
➢ A change in the rate of debris collection indicates the

change in the condition of the machine as related to

wearing out.

➢ Shape of debris collected carries information as to the

wear mechanism taking place.

➢ Normal shape of wear particles tends to be flat;

➢ cutting or abrasive wear results in spiral shaped
debris;
➢ surface fatigue failures produce larger angular
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particles.
 b. Condition of oil used
❑ Condition of used oil itself can be examined for indication of other

malfunctions.
➢ foaming of oil: cause is excessive churning or passage under

pressure through restrict

➢ darkened colour of oil: caused by oxidation of oil, excess

temperature, combustion or other chemical products reacting

with the oil used.

❑ Malfunctions that can be detected by lubrication monitoring

➢ damages of transmission components like gears, shafts,
bearings, etc.
➢ blockage of ducts, pipes, etc.
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 2. Thermal monitoring
➢ Monitoring the temperature of a component in a machine is

undertaken for one of three purposes:

I. To enable temperature control of a process
II. To detect increase in heat generation due to some
malfunction such as damage of bearings
III. To detect changes in the heat transmitted through and out
of the body of the machine caused by a change in some
component such as failed coolant circulation or ash build-
up in boilers, etc.

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 Cont…
❑ Temperature monitoring can be carried out

✓ at a point within the body of the plant (eg. measurement of

water temperature in a boiler),

✓ or at the surface of a component (eg. bearing housing).

❑ Temperature monitoring devices are diverse and can be

classified as:
✓ contact sensors, and

✓ non-contact sensors (pyrometers)

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 Malfunctions monitored thermally

❑ Possible areas where thermal monitoring can be applied.

✓ Bearing damages which result in heat generation and heating of the bearing

unit and other units that come in contact with the bearing unit.
✓ Failure of coolant or lubrication can be detected by a temperature rise of

appropriate bodies; such failures could result from pump failure, drive fault,
blockage in piping, valves or filter, or damaged heat exchanger.
✓ Incorrect heat generation like in internal combustion engines.

✓ Build-up of unwanted materials such as sediment is pipes, ash in boilers or

ducts, etc.

✓ Damage of insulating materials.

✓ Faults of electric components.

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 3. Vibration/noise monitoring

❑ Changes in vibration characteristics are indicative of trouble.

❑ The causes of vibration are

✓ unbalanced rotating and reciprocating parts,

✓ looseness in the fit between components,

✓ deflection of load carrying members,

✓ misalignment,

✓ damages in transmission components, etc.

❑ The equipment employed for vibration monitoring are

vibrometers and accelerometers of wide variety.

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 Cont…
❑Possible faults that can be detected by vibration

monitoring include:
✓ wear or failure of bearings;

✓ presence of unbalance in moving parts;

✓ changes in clearances;

✓ cracks in shafts and other moving components subjected to

cyclic loads.

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 Thank you!
Questions

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