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GETTING STARTED WITH CONDITION
MONITORING FOR ONLY $2,000? Ray Beebe
(Bitten by the CM bug in 1964!)
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CM IS POWERFUL
Can be costly to do properly with depth
Cost can deter smaller companies (or even big
over-thrifty ones!)
BUT, much can be done for low cost
All depends on the mode of degradation…..
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CASE 1: DEGRADATION OF “INVISIBLE”
DAMPER
Situation: duct, with hot gas
1000degC
CM – view damper around
bend and assess condition:
Will it last until next repair
opportunity?
Cost of viewing tool: $10?
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CASE 2: LINER EROSION
Coal mill casing liners erode in varying
pattern of grooves
Changeout is needed, but wear rate
varies, so routine change may mean
changeout is too early.
Simple CM – straightedge and rule to
get depth of deepest valley.
Plot vs service time
Cost nil
(Note: must carefully spell out in Job
Card how measurement is taken.
Previous method showed liners
apparently “growing”)
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CASE 3: FAN EXCESSIVE VIBRATION
Fan handling
hot damp dirty
gas.
High vibration
hot, also
high when cold!
Much
investigation
looking for
complex cause
– and then……
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LOOSENESS OF BEARING ASSEMBLY
Vibration
difference on
concrete
shows loose
bolts
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CASE 4: FAN UNBALANCE DUE TO DEPOSITION
Moist dust sticks unevenly on fan blades
Unbalance results
Overall vibration goes up!
Manual readings and trending cost little, BUT define and mark
test points……
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CASE 4: CONTINUED
Moist dust sticks unevenly on fan blades
Unbalance results
Overall vibration goes up!
Manual readings and trending cost little……
Solution: balancing the fan is expedient, or clean it
Re-design to eliminate cause: not practicable here
Overall vibes are OK if this is the only problem encountered
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CASE 5: PUMP NEAR RESONANCE High vibration – so high that outlet valve
wobbled shut!
Stiffening easy to try - and it worked!
(Worth a try. If NBG, then further
investigation needed)
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ISO GUIDELINES – EXPERIENCE HELPS
OK
NOT OK
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VIBRATION OVERALL
– MANY INSTRUMENTS
AVAILABLE
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TRY EBAY! E.G. $300 S/H
Ack: P Todd
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VIBRATION OVERALL- THE WEDGY
Make triangle of card, vertical side 2.5mm (i.e. 2500µm),
horizontal side 25mm.
Carefully mark 10 even graduations on base
0 1 2 3 4 5 6 7 8 9 10
Amplitude
Fix on machine with short side in direction of vibration.
Persistence of vision shows double image: cross-over point
shows vibration amplitude.
For high vibration of crude machines!
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TURBINE SUPERVISORY INSTRUMENTATION
On bearing in line
with the centreline?
Does that matter?
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CASE 6: CASING DISTORTION - 350MW TURBINE
GENERATOR
HP
P LP BGenerator
Journal bearings
Couplings
LP AHP-IP
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CASE 6: WHAT TSI RECORDS SHOWED
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CASING DISTORTED, PULLED ROTORS OUT OF
LINE Unit was below half
full load, but cooling
water flow was not
reduced, despite ops
instructions.
Pressure
too low-
casing
distorted
If ops
rules
had
been
kept…
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CASE 7: BUT, WHAT IS TSI
MEASURING?
Air gap
to actual
bearing
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TSI: NON-CONTACT DISPLACEMENT
BETTER THAN SHAFT RIDERS OR
BEARING CAP
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OVERALL + BEARING CONDITION
Velocity
Frequencies around rotation order:
Overall machine condition
Unbalance, temporary and permanent
Looseness
Misalignment
Acceleration and ultrasonics
Higher frequencies:
Rolling element bearing condition
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CASE 8: RE BRG
Acceleration level trend showed
bearing degrading
Acceleration spectrum
showing bearing
frequencies
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Selected Spot
Ack: P Todd
Ultrasonics
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TEMPERATURE INDICATION
Thermography, yes – use iPhone adpator?
Spot temperature indicator may be enough: cheap
Temperature sensitive paint
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CASE 9: GOT A DCS? STEAM TURBINE INTERNAL
DAMAGE:
INFO FOR “FREE”
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Main steam strainer blockage
Blockage in blading
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CASE 10: DCS FOR MAJOR PUMPS
Boiler Feed Pump 7000kW
3 × 50%: run all three
combinations: if two sets show
low, the most worn pump is the
one common to both
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OR, TAKE DATA FROM HISTORIAN
Head
…then follow
procedure for
optimisation (see
Ray’s book and
papers)
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WEAR PARTICLE ANALYSIS
Lube sampling pump: oil samples for both on-site
and lab CM
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CM & DEFECT ELIMINATION
Understand defect levels in CM parameters
Record experience- what was found vs what was predicted
Understand key defect causes when a CM parameter changes
Take immediate action to eliminate or slow
Use defect understanding to improve the quality of repair tasks
Use baseline measurements on equipment start-ups
Post overhaul CM checks
Understand defect and causes through equipment post mortems.
Design out where justified!
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IMPROVING CONDITION MONITORING
SYSTEMS
Better use of simple equipment inspections & simple
CM techniques
More use of Defect Elimination (Get proactive)
Greater involvement of non-CM specialists
Increase efficiency of CM data analysis
Better prognosis
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Simple methods often enough
VITAL: define clearly how measurements are taken, stored, action outcome.
More complex machines deserve more complex approach
Email me for papers on
case studies
Happy monitoring!