SPM- Condition Monitoring Methodology _ Lanco

Condition Monitoring the intelligent Way

0

Condition Monitoring the Intelligent Way

Condition Monitoring Services

– Methodology For

Offer for Consultancy Services Contract

for Implementing Integrated Condition Monitoring

SPM INSTRUMENT INDIA PVT.LTD Fortune Chambers, 4th Floor, Silicon Valley, Madhapur, HYDERABAD-500 081

Phone: +91 40 444 555 55 Fax: +91 40 444 555 55

E-mail: [email protected]; [email protected]


1

CONTENTS

SL. NO. DESCRIPTION PAGE NO.

1. GOAL 3

2. ABOUT US 3

3.

INTRODUCTION

A) Importance of Condition Monitoring

B) Benefits of Condition Monitoring

4

4. METHODOLOGY 7

4.1

MACHINE DATA

a. Introduction

b. Applications

c. Flow Chart

d. Procedure

8

8

8

8

4.2

SPM Measurement, SPM Spectrum & Analysis

a. Introduction

b. Applications

c. Flow Chart

d. Procedure

e. Sample report

10

10

11

12

13

4.3

Vibration Measurement, Vibration Spectrum & Analysis

a. Introduction

b. Applications

c. Flow Chart

d. Procedure

e. Sample report

14

14

15

16

17

Condition monitoring the intelligent Way

Lanco Date: 08.03.2011


2

4.4

Machine Alignment – Correction Activity

a. Introduction

b. Applications

c. Flow Chart

d. Procedure

e. Sample report

18

18

19

20

21

4.5

Dynamic Balancing – Correction Activity

a. Introduction

b. Applications

c. Flow Chart

d. Procedure

e. Sample report

22

22

23

24

25

4.6

Thermal Image

a. Introduction

b. Applications

c. Flow Chart

d. Procedure

e. Sample report

26

26

27

27

28

4.7

Ferrography

a. Introduction

b. Applications

c. Flow Chart

d. Procedure

e. Sample report

29

29

29

30

31-32

4.8

Oil Analysis

a. Introduction

b. Applications

c. Flow Chart

d. Procedure

e. Sample report

29

29

29

30

31-32


3

2. ABOUT US

CONSULTANCY SERVICES DIVISION, SPM INDIA

We wish to introduce ourselves as pioneers in offering Condition Monitoring and Corrective

Maintenance Services.

SPM INDIA is a Swedish Joint Venture Company having full-fledged World-class production

facilities to manufacture the latest Instruments in the field of Condition Monitoring at

Hyderabad.

We are Head Quartered at Hyderabad, having Branch Offices at Chennai, Mumbai, Baroda,

Kolkata and Delhi.

In addition to our Sales Activities for more than three decades, we also provide “Professional

Consultancy Services” with more than 40 engineers engaged in various projects all over India

delivering Condition Monitoring Services.

We have a Support Team with 20 engineers who are handling only Technical Presentation,

Installation & Commissioning & Training program.

We have a dedicated Training Center at Hyderabad where we conduct Training Program with

theory & practical for 4 days at very nominal charges.

1. GOAL To provide full Time Services of Condition monitoring Experts to implement Predictive and Proactive condition based maintenance system in your plant. The aim is to achieve, increased Equipment / Plant Availability, Lesser Breakdowns, Decreased maintenance cost, and higher amount of reliability.


4

3. INTRODUCTION

Condition Monitoring is the process of monitoring one or more specific Condition Parameters

in Machinery at regular intervals, such that a significant change becomes indicative of a

developing failure to identify impeding damages. It is a major activity of Condition Based

Predictive Maintenance.

The use of Condition Monitoring allows Maintenance to measure the deterioration of the

Machine Condition well in advance so that appropriate Correction Activity may be scheduled

to avoid the consequences of failure, before the failure occurs

Importance of Condition Monitoring

� To recognize developing problems ahead of time.

� To avoid & limit Machine Damage.

� To increase Machine Availability.

� To extend Machine Service Life.

� To improve Personnel Safety.

� To reduce Spare Parts Inventory.

� To eradicate possible defects at their Infant Stage.

� To plan Corrective Measures during a Planned Shutdown.

Benefits of Condition Monitoring

� Improvement in Production Quality.

� Prevention of Machine Damage.

� Reduction in Production Downtime.

� Plan effective Maintenance Activities.

� Efficiency of Manpower Utilization.

� Reliability of Machine Operation.

Condition monitoring the intelligent Way

4. METHODOLOGY

The methodology is acronym for the step-by-step procedure for the Implementation of

different Condition Monitoring Techniques.

Condition Monitoring

Technique

Machine Data Creation

Measuring Data from the Machine

Analyzing the Measuring Results

Correction Activities Implemented

Final Report Document

Flow Chart

Created

Procedure

Described

Preliminary Report

Generated

Feed back from

the Customer

Customer

Domain Inputs

Check the condition After 3 Months


1

4.1. Machine Data:

a. Introduction: The data, which identify as the equipment Technical data of the complete

equipment – both drive and driven details,

b. Application:

Gearbox and generator set for windmill – testing purpose.

c. Flow chart:

Machine Data

Verify the data

� Check Name Plate Details

� Machine Log Book

Manufacturer/

Engineer In-charge

Data obtained / Analysis to Start

Insufficient Data


2

d. Procedure:

The manufacturer / engineer in-charge will provide the complete data like;

• Equipment type

• Generator or motor Capacity – ratings (MW / KW)

• Class classification of the equipment as per ISO std

• Various rpm like Input-Output and intermediate speeds

• Gear box type

• Input speed & output speed

• Number of stages

• Bearing details like type and bearing number etc.

• Type of lubrication systems

• Type of cooling systems

• Other relevant details, If any.

All the machine data are tabulated and schematic diagram of equipment system is framed as shown here under.

8


3

4.2. SPM Measurement, SPM Spectrum & Analysis:

a. Introduction:

The SPM Method – Basic Theory

In simple terms, the SPM method detects development of a mechanical shock wave

caused by the impact between two masses. At the instantaneous moment of impact,

molecular contact occurs and a compression

(shock) wave develops in each mass. The SPM

method is based on the events occurring in the

mass during the extremely short time period after

the first particles of the colliding bodies come in

contact.

Pressure variation translated into shock pulse pattern.

SPM Spectrum enables in identifying the Source of the Failure in the Bearings and

Gears by measuring the Individual Bearing Components / Gear Mesh Frequencies.

b. Application:

Bearing condition analysis.

Bearing Lubrication Condition identification.

Possible to identify Lubrication film thickness.

Identifying the bearing mounting problems etc.

10


4

c. Flow chart:

SPM

SPM

� Measure LR Values

� Measure HR Values

� Collect Spectrum

LR/HR

Values

Within

SPM Std Limits

Bearing

Condition

found to be Satisfactory

SPM

Spectrum

found Healthy

Recommendations � Check Lubrication

� Check Brg. Condition

� Check Mounting

� Change Brg

Recheck

Report Preparation

Cleared for Operation

YES

YES

NO

Correction

Activity Carried out

NO

11


5

d. Procedure:

Details of input like Shaft internal diameter and Bearing numbers are to be given as input before starting the SPM measurements. To measure the LR / HR Values.

To measure Cond values. To collect SPM time wave and spectrum.

The measured values are to be compared with the std values. View the colour codes like Green-Yellow-Red. When the vibration amplitudes are crossing more than the satisfactory level, the detailed analysis is conducted to identify the possible causes and root cause for generating the higher vibration amplitudes. Reports will be submitted for possible correction activities at site, are suggested to the

manufacturer / shop floor personnel.

Minor variations in the readings are normal. They can be caused by temperature and load variations, time since re-greasing or other variations in the operating condition of machine and bearing. On damaged bearing, the sharp edges of fresh spallings will cause high readings which drop when the damage is partly rolled out. Important for the planning of bearing replacements in the trend of the readings and

the rate of change. Bearings with high readings (yellow and red zone) are measured more frequently than bearings in good, stable condition.

After completing the correction activity, Vibration amplitude are re-checked. When found satisfactory the final report is submitted for clearance as well as for future references.

12


6

e. Sample Report:

13


7

4.3. Vibration Amplitude Measurement, spectrum & Analysis:

a. Introduction: Vibration Analysis is a Non-Destructive Technique, which helps early detection of

machine problems by measuring/evaluating vibration.

Vibrations are caused by movement of components within the Machine due to internal or

external excitation. Any small change in the Machine behavior shall change the

Vibration Pattern of the Machine. Hence Vibration Monitoring and Analysis provides

reliable information on Machine Operating Condition.

b. Application:

Knowing the Severity of the problem necessary Corrective Action can be taken at the

most appropriate time, for any rotating equipment and critical operating equipment. The

equipment like Turbo generator, Pumps, Fans, Mills, Crushers, Compressors. The

components like Motor and gear boxes, generator are to be critically need to be

analyzed using vibration measurement and spectrum analysis.

Most of the mechanical troubles in a machine cause Vibration. By analyzing Vibration

most of the problems of Rotating Machines can be identifies such as:

� Unbalance (Static, Couple, Quasi-Static).

� Misalignment (Angular, Parallel, Combination).

� Eccentric Rotor, Bend Shaft.

� Mechanical Looseness, Structural Weakness, Soft Foot.

� Resonance, Beat Vibration.

� Mechanical Rubbing

� Problems of Belt Driven Machines.

� Journal Bearing Defects.

� Antifriction Bearing Defects (Inner race, Outer race, Cage, Rolling elements).

� Hydrodynamic & Aerodynamic Forces (Blade or Vane, Flow turbulence, Cavitations).

� Gear Problems (Tooth wear, Tooth load, Gear eccentricity, Backlash, Gear

misalignment, Cracked or broken tooth).

� Electrical Problems of AC & DC Motor.

14


8

C. Flow Chart:

Vibration Analysis

(Vibration Measurement & Spectrum)

D-Displacement; V-Velocity

A-Acceleration; F-Frequency;

φ-Phase

Compare with ISO Stds

for given class of equipment

Found within the satisfactory limit

Equipment Cleared for

Operation

Corrective actions by

Customer/manufacturer Carried out

Operate the Equipment @

rated RPM and simulated Normal Operation

Report Preparation

Conduct detailed Analysis to Identify

� Possible causes for the vibration

� Root cause for the vibration

Submission of report

for correction Activities

Correction

Activities

by SPM

Team

Laser

Alignment

YES

NO

Dynamic

Balancing

15


9

d. Procedure:

The equipment is operated at rated rpm and normal operating conditions are to be met. Using the sophisticated vibration analyzer the basic and advanced vibration data to be collected.

Key measurements in the Vibration analysis are: Vibration Displacement, Velocity, Acceleration, Frequency and Phase angle. Colour codes like Green-Yellow-Red to be noted. The measured values are compared with ISO 10816 standard requirements as per the given class, for example Class-4. When the vibration limits are crossing than the satisfactory level the detailed analysis is

conducted to identify the possible causes and root cause for generating the higher vibration amplitudes.

Reports will be submitted for possible correction activities at site are suggested to the manufacturer / shop floor personnel. Note: During analysis the root causes are like Misalignment and dynamically imbalanced, the desired correction activities like Laser alignment and dynamic balancing using the sophisticated analyzer like Leonova Infinity will be done SPM team.

After completing the correction activity, Vibration amplitude are re-checked. When found satisfactory the final report is submitted for clearance as well as for future references.

16


10

e. Sample Report:

17


11

4.4. Machine Alignment:

a. Introduction: Misalignment is the deviation of the relative shaft position from collinear axis of rotation when the equipment is running at normal operating condition. Alignment is a vital part in the daily maintenance work. . Nearly 50% of all machine breakdowns are caused by misalignment. The types of misalignment can be Parallel or offset, Angular and Skew (combination of both).

b. Applications:

All equipment need to be aligned across the shaft & coupling, few types of coupling are; Flexible : Tyre, Pin bush, ESBI Valkan tyre, Lovejoy

Semi Flexible : Fluid

Rigid : Greard, Resilient, Hydraulic, Magnetic A flexible coupling can handle some misalignment but it will generate heat and it will increase forces on the shafts. This will crease vibrations and coupling elements, seals, bearing will fail prematurely. Causes of misalignment may be due the following reasons;

• Poor workmanship during alignment.

• Improper grouting or shrinkage after grouting. • Improper foundation or larger holes for holding down bolts. • Thermal expansion due to a process heating. Most machines are aligned cold, and then as they operate and heat up thermal growth causes misalignment.

• Vibration due to unbalance, resonance and bearing problems etc. • Forces transmitted due to the machine by piping and support members. • Machines directly coupled not properly aligned. • Soft foot.

Shaft alignment can be performed with a lot of tools. The easiest way is to use a ruler or a straight edge over the two coupling halves and align by eyesight. The result is not very accurate and it is operator dependent. To achieve a better result is to use dial indicators. A skilled and experienced user can achieve good and reliable result, but it takes time. The easiest way and most accurate is to use laser based alignment systems. They do not require special skill and delivers very accurate and repetitive results.

18


12

c. Flow chart:

Laser Alignment

� Fixing of TDs

� Dimensional measurement I/P

Alignment found

satisfactory (within

the Tolerance Limit)

in both Horizontal &

Vertical

Alignment

checking/correction

completed and cleared for operation

� Horizontal correction

� Vertical correction

Laser Alignment

Report

Preparation

YES

NO

Soft Foot Found

Correct the Soft

foot Before

Alignment

� Alignment process � Calculate shims and foot � Select suitable shims

YES

NO

19


13

d. Procedure:

1. The Transmitter–Detector (TD) Units are connected/tied firmly to the

shaft.

2. Dimensional in-put are fed in to the laser alignment system.

3. Check for the soft foot and do the needful correction.

4. Check amount of misalignment.

5. Correction shims and locations to be noted.

6. Carry out horizontal corrections.

7. Carry out vertical corrections.

8. Re-check for the alignment, and check with the tolerances given by ISO

stds / manufacturer limits etc.

9. If still alignment is still scope for the improvement, the process will

repeated for the improvement.

10. When the required alignment is achieved, within the tolerances given,

the report will be prepared and the equipment will be released for further

operation or further works if any.


14

e. Sample report:

21


15

4.5. Dynamic Balancing:

a. Introduction: There are several types of unbalance conditions; the most important of which are called static

and dynamic. Static unbalance is a condition where the center of rotation of a rotor does not

correspond to its center of mass, or in other words, its center of gravity does not lie on its

axis of rotation. This result in a centrifugal force applied to the bearing at the 1X frequency.

This 1X force is proportional to the square of the speed of the rotor, meaning that high-speed

machines require much more accurate balancing than low speed ones.

Unbalance forces in machines will always produce vibration at the bearings where the radial

and tangential 1X components are 900 out of phase. This is a sure test of unbalance and can

be used to help distinguish unbalance from misalignment.

b. Applications: Rotors which can be treated as having a single large mass along their length and that have

access to the main mass. Examples are Fans, Single Stage Centrifugal Pumps, Single Sage

Centrifugal Compressors, Flywheels, etc… The Main requirement is that there is access to the

plane that requires balancing, if there is no access to this plane then the rotor will need to be

removed to be balanced. Occasionally, when it is known that the balance problem is mainly

due to a coupling hub as opposed to the main impeller or wheel, then balancing can be

carried out on the coupling along with acceptable results.


16

c. Flow chart:

Dynamic Balancing

� Check for Vibration Amplitudes

� Phase Angle Horizontal & Vertical

Check static Unbalance &

found

Vibration FFT

YES

NO

General imbalance

conditions & Phase Shift ≅

900 found

Carryout Dynamic Balancing

NO Check for other

sources of vibration problems

YES

Carryout Static

Balancing

Vibration Amplitudes &

Balancing Tolerances Found within Limit

Equipment Cleared for Operation

Report Preparation

YES

NO

Trim Balancing

Vibration Amplitudes & Balancing Tolerances Found within Limit

YES

NO

23


17

d. Procedure:

There are two ways of giving phase information, as ‘Phase Lagging’ or ‘Phase

Leading’. In ‘Phase Lagging’ the keyphasor point is 00 and the phase angle increases

in the opposite direction to the direction of rotation i.e. if the rotation is clockwise

then the phase angle increases in an anticlockwise direction. In ‘Phase Leading’ the

keyphasor point is again 00 but the phase angle increases in the direction of rotation

i.e. if the rotation is clockwise the phase angle increases in a clockwise direction. The

instruments in use at JTPCL Refinery are all ‘Phase Lagging’ so this is the method we

will concentrate on.

To get the phase information we require a ‘tacho’ signal. This can either be from a

permanently mounted system such as a ‘Bently Nevada KeyPhasor’ or from a

temporary system such as an optical or electro-magnetic tacho.

The set-up of the instruments varies so each will need to be set-up according to the

relevant instruction manual.

Most modern instruments will normally include a balancing program as an option or

as standard. The balancing program will work out the required balance weight after

the required information is inputted and the readings have been taken. This means

that the manual method of working out the correction weight and position is not

required, however, it is always useful to carry out the manual calculation, as

described, as a double check.


18

e. Sample report:

25


19

4.6. Thermal Image:

a. Introduction:

Thermal Imaging or Thermography is a type of Infrared imaging. Infrared Radiation is

emitted by all objects based on their temperatures, Thermography makes it possible to capture images (or “see”) without visible illumination. Amount of Radiation emitted by an object increases with temperature. Thus, Thermography allows one to see variations in temperature, and hence the name. A Typical Thermography camera detects radiant energy or heat in the infrared range of the electromagnetic spectrum, generally between 800 to 20000 nanometers of wavelength. By a non-contact mode the infrared energy (heat) is detected and after converting the same into an electronic signal, it is processed to produce a Thermal Image or Heat Picture (Thermo gram), with indication of Temperatures.

b. Applications:

1. Hot spot/ Cold Spot Detection for Maintenance Intervention (Electrical, Mechanical & Process Equipments).

2. Condition Monitoring of Refractory Lining of Blast Furnace, Petrochemical Process Heaters and others type of Furnaces, Ladles, Chimney.

3. Condition Monitoring of Insulation Lining of Boiler, Steam Pipeline, Hot air duct & other Process Equipments.

4. Detection of Cold spots in Rotary Kilns to assess Deposition. 5. Calculation of Heat Loss. 6. Identification of anomalies in Cooling Systems. 7. Detection of Thermal abnormalities (due to loose contact/ joint) in Outdoor Switch Yards & Transformers, in Switch Gears and Electrical Panels.

Different applications like:

Electro thermo graphic applications – Thermography generally used in varieties of applications like: 1. Control Panels

2. Switch gears

3. Transformers

4. Motor body, bearing and coupling temperatures etc

5. Furnaces

6. Industrial thermal imaging applications

7. Building Thermography applications

8. Application in Leakage Location

9. Appliance in Research and Development

26


20

c. Flow Chart:

Thermography

d. Procedure:

The relative motion / vibration or motion of atoms and molecules in the object causes Infrared.

The thermal images are captured and analysis is done based on the temperature

levels and hot spots etc.

Thermal Imaging

captured

Hot Spots identified &

Digital Image Captured

Report Preparation

27


21

e. Sample report:

28


22

4.7. Ferrography:

a. Introduction:

Ferrographic Wear Particle Analysis is a Non-Intrusive examination of the Oil wetted parts to determine the source, size and severity of the Wear Mechanism. Particles generated by specific types of wear have distinctive characteristics that

reveal the wear mechanisms at work.

Trained and experienced Predict Ferrography Analysts with knowledge of equipment and the metallurgy of its components identify these microscopic wear

particles and relate them to Equipment Condition. In this manner Analysts “look”

inside your equipment to identify Abnormal Wear Conditions and pinpoint wearing components. Being a microscopic study Ferrography identifies the earliest possible

indication of abnormal wear, providing sufficient lead time to take maintenance action and correct the problem before any major breakdown. b. Application

Any application where oil lubricant / oil coolant are involved.

c. Flow chart

Ferrography

Quantitative Analysis

WPC found within acceptable Limits

Report Preparation

Qualitative Analysis:

1. Ferrogram Prepared

2. Image Captured & Compared

3. Analysis Done

YES

NO

29


23

c. Procedure

The Ferrography tests are conducted in two steps:

Step-1 – Quantitative Analysis to monitor the qualification of the wear rate.

Direct Reading Ferrography (DR Ferrography) determines the wear particle

concentration (WPC) as preliminary check to understand the waering conditions of the

internals.

Step-2 – Qualitative Analysis to identify the type of wear & sources of wear.

Microscopic evaluations of wear particles separated from used lubricants to determine

the type of wear, sources of wear and the wearing mechanisms.

Result:

Machine health condition will be indicated in 0 – 10 severity scale by analytical method

by an experienced analyst in the following manner.

Range: 0 – 4 ------ considered as Normal

5 – 7 ------ considered as Marginal

8 – 10 ----- considered as Critical

30


24

d. Sample report

31


25


26

4.8. Oil Analysis:

a. Introduction:

Oil Analysis involves Sampling and Analyzing Used Oil to identify the presence of Metals, Non-Metals and Contaminants. Sampling and Analyzing on a Regular Basis establishes a Baseline of Normal Level and helps to identify Onset of Abnormality.

Oil Chemical Condition Monitoring and Particle Measurement in Oil Samples are

important Monitoring Elements for Predictive Maintenance Program.

b. Application

Any application where oil lubricant / oil coolant are involved.

c. Flow chart

29

Oil Analysis

Test

YES

NO

Check Oil

Characteristics

like Viscosity, TAN/TBN,

Moisture etc

found within the Limit

Check the condition

After 3 Months

Continue to use

Change Oil


27

c. Procedure

The Oil analysis tests are conducted for following characteristics as per ASTM

standard:

1. Viscosity

2. Water by Karl Fischer (Moisture)

3. Oxidation stability

4. TAN / TAB Titration

5. FTIR Spectrography

6. Flash Point

7. Fire point

8. Foaming Characteristics

9. Emulsion Characteristic

The results are compared with standard values given by OEMs.

Result:

The health condition of the used oil will be tested for the above characteristics and will

be declared whether the oil be continue to be useful or to be changed / replaced.

30


28

d. Sample report

EQUIPMENT SPECIFIC ANALYSIS

Predict Technologies India (P) Ltd.

Opp.Allahabad Bank

Yellareddyguda, Hyderabad 500 073

Tele Fax: 040-23741790

SAMPLE ID: TPL-S/30 MAV M L OIL/14462. SAMPLE DATE: 15.03.10

SAMPLE DESC: 30 MAV MAIN LUBE OIL (GT,ST&GENERATOR PLANT). RECD'DATE: 26.03.10

COMPONENT: TURBINE REPORT DATE: 31.03.10

MANUFACTURER: SIEMENS.

LUBRICANT: TURBO 46T

RESERVOIR CAP: 4000 L

S.NO. TEST PARAMETERSampl Date

26.11.2009

Sampl Date

15.03.10LIMITS

TEST

METHOD

1Kinematic Viscosity @ 40

deg.C,cst41.5 42.6 41.4-50.6 ASTM D 445

2Kinematic Viscosity @ 100

deg.C,cst6.8 6.6 6.9 ASTM D 445

3 Viscosity Index 120 109 104 ASTM D 2270

4 Moisture Content ppm 79.75 234.9 500 PPM MAX ASTM D 1744

5TAN (Total Acid Number)

mg of KOH/gm0.13 0.15 1.0 max ASTM D 664

6TBN (Total Base Number)

mg of KOH/gm12.85 11.42

1/2 of the

original valueASTM D 4739

7

Partical Counting

ISO-

18/16/13,

NAS-08

ISO-

15/13/9,

NAS-05

NAS 6-8

ISO

4406/NAS

1638.

9 Pour PointºC 12ºC -9ºC <-12 ASTM D 97

10 Flash Point ºC 226ºc 229ºc 220 ASTM D 92

Sample tested as received

Recommendations:

Used oil test results shows normal condition of oil.

TEST-1

TEST-2

TEST-4

OIL ANALYSIS TEST RESULTS

Lubricant Condition Report

Normal

XYZ Manufacturing-Sample report

Documents

SPM- Condition Monitoring Methodology _ Lanco