M T R O FIFTH UNIT

M T R O
FIFTH UNIT

CONDITIONAL BASED MAINTENANCE

1. What is conditional based maintenance? What are the different types of condition based maintenance?

Maintenance carried out in response to a significant deterioration in a condition or performance is called condition based maintenance. Condition based maintenance differs from both failure

maintenance and fixed time replacement is that it requires monitoring of some condition indicating parameter of the unit being maintained. This contacts with failure maintenance which impulses that no successful condition monitoring is undertaken and with fixed time replacement, which is based on statistical failure data for a type of unit in general therefore, condition monitoring undertaken and with fixed time replacement which is based on statistical failure date for a type of unit in general therefore condition based maintenance will the more efficient and adaptable than either of other maintenance actions on indication of

deterioration the unit can be scheduled for shut down at a time chase in advance of failure let if the production policy details the unit can be lift

run to failure alternatively the amount of unnecessary preventive replacement can be reduced while if the consequences of failure sufficiently dire the condition monitoring can be employed to indicate possible Impending failure well before it becomes a significant probability the advantages to be obtained from the use of condition monitoring are shown in figure. 2. List out the different types of condition based maintenance? Condition monitoring fills into two distinct classes (a) Monitoring which can be carried out without interruptions to the operation of the unit and (b) monitoring which requires the shut down the unit or at least the release of the unit from its prime duty clearly the former category has significant advantages over the latter since no interruption to plant out put is involved. However there are many situations where the monitored unit I shut down regard of frequently as part of the normal plant operating policy for example two shift power stations in such circumstances of load monitoring used to interrupt normal plant operation.

3.

How does condition based maintenance differ from the other

maintenance actions?

Condition based maintenance differ from both failure maintenance and fixed time replacement in that it requires monitoring of some condition indicating parameter of the Unit being maintained this contrasts with failure maintenance which implies that no successful condition monitoring is undertaken and with fixed time rep-placement which is based on statistical failure data for a type of unit.

In general therefore condition-based maintenance will be more efficient and adaptable than either of the other maintenance actions. On indication of deterioration the unit can be scheduled for shutdown at a time chosen in advance of failure yet if the production policy dictates, thee unit can be left to run to failure. Alternatively the amount of unnecessary preventive replacement can be reduced, while if the consequent of failure sufficiently dire, the condition of monitoring can be employed to indicate possible impending failure well before it becomes a significant probability

The advantages to be obtained from the use of condition monitoring. 4. What are the various on load condition monitoring techniques?

Temperature monitoring
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 Lubrication monitoring Leak detection Vibration monitoring Noise monitoring Corrosion monitoring

5. What are the various off load condition monitoring techniques?

Crack detection Leak detection Corrosion monitoring Vibration monitoring

Lubrication monitoring

Thermal monitoring

6. Describe on load thermal monitoring?

The temperature sensitive aspect of a unit can reading is monitored.

The

temperature

sensors

include

contact

thermometers,

thermocouples, thermostats and temperature chalks and paints and infrared detectors. Two examples where temperature monitoring can give warning of mechanical trouble are lubricant Temperature of bearing outlets and engine cooling water maintenance. This is a general purpose technique. 7. Describe on load leak detection monitoring? A number of leave detecting techniques are available including the soap and water method. The use of properties preparation can make this method leaks a lower 1ml./s. one Powerful technique is ultrasonic detection. When a fluid is forced through a leak under internal or external pressure sound is generated in the frequencies range 40-80 kHz. The ultrasonic leak detector identifies this very high frequency which easily separated from the lower frequencies of ordinances machine noise a typical detector can sense the pressure of 50mm dia hole in a unit containing a pressure of 0.1 bar at say 10m distance, or expressed ina flow rate, 10m halogen testing where a search gas e.g. Action 12,18 inserted into the system under the presence of the search gas outside the system indicates a leak can be used to detect leakage test as low a 1 pl/m. unfortunately, it is common to find sufficient halogens free around a plant to mask the effect of the leak. 8. Describe on load vibration monitoring?
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This can be used to detect a wide range of faults in machinery. This method has wider application than any other monitoring technique. For example vibration measurements made near the bearings of a machine can detect and distinguish between in balance shaft misalignment, damaged bearings, damaged gears and other transmissions components, mechanical looseness cavitations or stall and a number of either faults. Although the basic methods of monitoring are straight forward of any case very much more information can be extracted from the measurements if modern signal processing techniques area plied. This is field which is currently receiving much attention and Consequently understanding and practical experience are improving rapidly vibration monitoring is examined in detail. 9. Describe on load corrosion monitoring? Corrosion rate can be determined more accurately placing coupons. Ultrasonic measurement will detect the change in dimensions due to corrosion a new technique for remote measurement of corrosion thickness employees a pulsed laser to drill. A fixed depth per pulse and a light detector to indicate when the hole has reached the bright metal

10. Explain off-load vibration monitoring?

The response of a unit to vibration forcing can reveal much information. One of th4 most common vibration tests for rotating machines is the run-down test, which takes advantages of system resonances to magnify vibrations.

11. What are the various types of contact sensors used for thermal monitoring? Devices, which take up the temperature of the body which they are in contact and then transmit information on their own. Temperature are most commonly used they can provided temperature indicator locally and remotely or control some function from the temperature. Both accuracy and response time of contact sensors affected by attachment Method. Good thermal contact is important. This is used provided for surface measurement by embedding or welding the sensor to the body. Response times are related to the volume of the sensor so the smaller devices are more suitable if temperature very rapidly.

Liquid expansion sensors Bimetallic expansion sensors

Thermocouple sensors Resistance sensors

Liquid expansion sensors: Liquid expansion sensors are the most commonly used devices mercury or alcohol in gals thermometers is accurate but fragile device liquid in metal sensors. All these sensors are large (up to 9 *13 mm) and are therefore unreadable for surface measurement.

12. Describe off load corrosion monitoring? Corrosion can be determined m0ore accurately by placing coupons is the plant and removing them for weighing at intervals. Ultrasonic measurements will detect the change in dimensions due to corrosion. A new technique for remote measurement of Corrosion thickness employee a pulsed laser to drill. A fixed depth per pulse and a light detector to indicate when the hole has reached the bright metal. 13. What are the various types of non-contact sensors? Non-contact sensor energy radiation from body carries with the absolute temperature of the bodys and the emissive o the radiation surface, a according to the Stefan-bolt Mann law. This enables surface temperature to be detected from the energy radiated without any direct current. The various types of non contact sensors are Optical pyrometer
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 Radiation pyrometer The seaming infrared camera 14. Describe any one technique of vibration monitoring? This can be used to detect a wide range of faults in machinery. This method has wider application than any other monitoring technique. For example vibration measurements made near the bearings of a machine can detect and distinguish between in balance shaft misalignment, damaged bearings, damaged gears and other transmissions components, mechanical looseness cavitations or stall and a number of either faults. Although the basic methods of monitoring are straight forward of any case very much more information can be extracted from the measurements if modern signal processing techniques area plied. This is field which is currently receiving much attention and consequently understanding and practical experience are improving rapidly vibration monitoring is examined in detail. 15. Describe the total signal monitoring in vibration? This is the most string forward method resulting in only location. The total signal, product up by the transducer is employed time arranged and drop layer on a meter or recorded for use the schematic of a typical act of equipment is show to gauge such equipment is compact being

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typically contained in box of about 200mm cube and weighing only 2.5 kg. brook describes the application of typical portable equipment to signal monitoring. The vibration reading to obtain in potted on the machine record, whole should be dearly laid out in tabular form or alternately in graphical farm. A change is the Measurement between inspections indicates that some machines change may have occurred untilled experience with the machine change may have accrued. Until experience with the machine has been built up it is very difficult to provide whether a particular change is signing ward.

16. Describe peak signal monitoring in vibration?

Figure of merit some types of mauler migrated such as bearing failure cause impulses to be transmitted to the transducer and pitted have in a roller bearing. For example emits and impulse such time a ball comes in contact with pit. Though this caused an increase in the vibration control, which is a measure of the amount of impulse generating damage is called the figure of merit the normal vibration instruments. It is not possible to register peak values of vibrations contain transients of duration less than 10ms. However this presents no significant restriction for vibration monitoring. This measurement of peak vibration barrels is an additional means of detection damage.
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17. How does the used oil is reconditioned? Lubricant examination can cover the debris deposited the debris in suspension on the condition of the oil.

Debris deposited the larger articles carried along by the lubricant can be collected the load UN filters magnetic collectors. 1. Filters: The rate of build up of debris on a filter ion readily

monitored on load by measuring the pressure drop across the filter removal of the filter which can be carried out on-load if the machine is suitably designed, and subsequent examination of the debris under the scope to establish size and shape or with a spectrograph to determine the element of content provinces the more sophisticated method of detecting a significant change in any component visited by the lubricant. It is good practice to store the debris on an adhesive substrate the part of the routine condition records. 18. Describe shock pulse monitoring in vibration and noise? Impulses emanating from impacts between damaged surface described in the shock pulse monitoring method which was developed initially by S.P.M Instruments Ltd of Sweden.

The impacts generate shock pulse waves through the machine body and they are detected using a pies electric transducer similar to an
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accelerometer except that it is termed mechanically and electrically to have a resonant frequency at 32 KHz. The transducer resonant of this frequency in response in each pulse. The signal generated by the transducer is filtered to separate the resonant frequency from the ground of vibrations the magnitude of each resonance is held for an sufficient time for read on meter, by this method and the peak amplitude of the signal from a transducer to the magnitude. 19. What are the causes of vibration and noise in a machine tool? All machines vibrate. It is difficult to balance moving parts. So vibnrations originate in unbalanced rotating parts and in accelerations of components moving along linear parts components which make rap or roll on adjacent components generate vibrating because of the roughness in the mating surfaces. In the fit between making components results in impacts lead bearing components subject to load cycles detect under the loads and hence transmit vibrations. Machine vibrations cause noise, the level of which depends on the surface area of the vibrating parts and the efficiency of transmission of noise from the machine for health and environmental reasons much effort is being devoted to reducing the vibrations in machines and the efficiency of transmission of these vibrations.

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10 MARK QUESTIONS

1. What are the different types of on load conditions based maintenance explain anyone of the following? 2. Explain the on load vibration monitoring with example 3. Explain on load thermal heat monitoring with example 4. Explain on load lubricant monitoring with example 5. Explain on load leak detection monitoring with example 6. Explain on load vibration monitoring with example 7. Explain on load noise monitoring 8. Explain load corrosion monitoring with example 9. Explain the crack detection monitoring

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1.

Explain the following crack detection techniques? (i) Ultrasonic testing (ii) Radiographic examination (iii) Flux testing of magnetic materials.

Ultrasonic testing: Ultra sound generated the surface of the component will be reflected at any surfaces in the two path of the sound whether they are manufactured or faults the time delay between generation of the sound pulse and detection of the reflection is displayed to give a measure of the distance the surface from the force. The generation and propagation of ultra sound in the frequency range 0.25 10 MHz. is very directional of so suitable orientation of the transmitter enables imperfections such as crack as be displayed from out side of the surfaces of the component the technique has been developed to high degree of sophistication. Cracks can be detected by examination from one end and a suitable step the range of operation is 5 15 mm in steel. Radio Graphic Examination: Imperfections can be photographed using

either x-rays or gamma rays from radio active source not special photographic material a change in thickness of 2% can be detected member thickness normally limited to 50mm. The method usually requires dismantling of the unit being examined and raised problems associated with processes of personal. Flux detection of magnetic materials: A crack as small as crosses the path of magnetic field which is included locally into the surface of the
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material using U-type magnet causes the magnetic fields and hence the crack is revealed using magnetic powder. 2. Explain the various techniques of lubricant monitoring with examples? Lubricant Monitoring: It is not possible to examine the working

a part of the complexed machines on load not is converted to strip down the machine. However the oil which circulates through the machine carries with it evidence of the condition of parts encountered examination of the oil and any particles it has carried with it allow monitoring of the machine on load of it at shut down. Numbers of techniques are applied. Some are very simple others pain staking rests and expensive equipment. Lubricant monitoring techniques: Lubricant examination can over

the debris in suspension or the condition of the oil. Debris deposited: The larger particles carried along the lubricant can be collected on-load in filters or magnetic collectors. 1)Filters: The rate of build up of debris on a filter ion readily

monitored on load by measuring the pressure drop across the filter removal of the filter which can be carried out on-load if the machine is suitably designed, and subsequent examination of the debris under the scope to establish size and shape or with a spectrograph to determine the element of content provinces the more sophisticated method of detecting a significant change in any component visited by the lubricant. It is good
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practice to store the debris on an adhesive substrate the part of the routine condition records. 2)Magnetic debris collectors are a convention way of the capturing ferrous comforts Magnetic plugs can be designed to be readily removed on-load and one prosperity magnetic debris collector can be monitored without giving an indication of debris built-up. Debris in suspend: The smaller particle collected by the lubricant will remain in the suspension gives the earliest warning of component damage quantities loss of lubricant during the running and the dilute effect of tapping-up with demerits free fresh oil. 3. Explain the detection of various malfunctions by thermal monitoring? In addition to the prince function of monitoring a process or system temperature as a check the control are working correctly there is a range of general faults that can be detected by thermal monitoring. 1) Bearing damage 2) Failure of a coolant 3) Incorrect heat generation 4) Built-up of unwanted materials 5) Damaging to insulating materials 6) Faults in electrical components

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