CBM Condition-Based Monitoring CBM is the use of advance techniques and technologies to determine and predict faults/failure in a specific

c system. It extracts information from an equipment/system and analyse data to predict health of a machine. This consists of technologies such as: 1. 2. 3. 4. 5. 6. Vibration and noise analysis Oil analysis and tribology Ultrasonic Leakage Corrosion Infrared thermograph

CBM is carried out in response to deterioration in a unit as pointed out by the monitored parameter. Reports arise from human observations, test and checks or from a fixed instrumentation. Benefits from a CBM In terms of safety, it helps to reduce injuries and fatal accidents to personnel. Enables plant to be stopped safely. It helps to increase machine availability more running time, less maintenance cost. Machine condition is indicated by an alarm Output increase rate of output, improved quality of product/service Levels of Condition Monitoring L1 Normal preventive schedule daily weekly activities Sight, hearing, touch and smell sensory impression of the assets. It holds great values on skilled human observation at this level L2 This is an extension of human senses and provides a wide range of instruments, and magnify undetectable physical characteristics, so that incoming quality problem, equipment failure, leading to major machine damage can be prevented. L3 Lubricated items. At this level, check is made on components for wear and checks on contamination of the lubricants. This is indicated by metal particles/debris floating in lubricant. This is collected by magnetic devices. L4 Monitoring fixed systems. Range from simple remote system to comprehensive data collection. Use of microprocessors to transmit data.

On-load monitoring Techniques On-load monitoring strategy involves monitoring some conditions/variable associated to the equipment and then repairing/replacing when the condition shows that failure is imminent. The simplest method of monitoring is the use of human senses: sight, sound, touch, smell. Results will be only qualitative depending on skills and judgment. (Conditioning variable is decreasing as failure approaches over time) Visual, aural and tactile inspection of accessible components Looseness can be detected instantly in non-rotating part. Wear debris is a clear indication of looseness. Relative motion as small as 1m at the interface, can be sensed by touch. Temperature monitoring 1. To enable the temperature of a process to be monitored manually and properly 2. To detect an increase in heat generation due to mal function e.g. damaged bearing 3. To detect a change in heat transmitted through and out of the machine. Surface measurement can provide an idea of the heat generated within a machine and on heat transmission paths. There are actually sharp discontinuities of temperature profile which occur at the surface and this can be easily modified using sensors. Therefore it is more difficult to take temperature on surface than immersion techniques. Surface temperature measurements are restricted to small devices such as: thermocouple, noncontact methods. Thermal monitoring: There is a range of general faults that can be detected by thermal monitoring: bearing damage, failure of coolant, incorrect heat generation. Vibration and Noise monitoring Analysis of vibration signals produced during operation of machine provides important information about its health. The most serious fault will lead to an increase in vibration level before complete failure. Vibration provides a warning for future trouble. Cause. This results from unbalanced rotating parts. Components which moves, rub, roll on adjacent components create vibration due to roughness of mating part. Looseness results in impacts. Noise levels are often convenient to measure since no equipment is attached. But there is the problem of noise masking due to extraneous noise. Vibration monitoring techniques 1. Periodic field measurements with portable instruments long-term changes in the condition of the plant 2. Continuous monitoring with permanently installed instruments - Continuous monitoring employed when machine failures are known to occur, e.g. turbine 3. Signature analysis is a scientific collection of data, diagnosis, signals, signatures and detection of faults, if any, present by a thorough analysis of these signatures and

based on the knowledge acquired in the field, and judging on the severity of the faults for decision making. Lubricant Monitoring It is not possible to examine a machine when it is in its operational state nor it is not convenient to strip down any complex machine. The oil that circulates into the machine provides an indication for the health. Techniques: Wear debris analysis, debris suspension, condition of oil Wear debris collection: The larger particles carried along the lubricant can be collected on-load in filters by magnetic debris collectors. There are 3 phase in machine life: Running, normal and failure. Phase 1, any surface roughness is worn out producing particles which are small and large in quantities. Phase 2 ,the rate of chip generation is expected to be low and also low in quantity. Phase 3, break-up of the surface may occur and inducing more stress and thus producing larger particles. (electric chip detectors - alarm) Debris in suspension: The smaller particles collected by the lubricant will remain in suspension. This gives the earliest warning of damage. The particles can be examined using SOAP techniques Condition of used oil: Indication Foaming Emulsion Colour Cause Detergent Contamination Water ingested water Oxidation of oil Action Check system Drain-off water Change oil Change oil

Leak detection Pressure containing components Ultrasonic detection Off-load Monitoring Techniques Crack detection 1. Dye penetration Causes of crack as small as 0.025 micrometer revealed to naked eyes. Use of developer and dye 2. Flux testing of magnetic materials A crack or detects which passes through the path of the magnetic field, causes the magnetic flux to spread around the crack. This is done by the use of magnetic powder.

3. Electrical resistance testing. The presence of crack at the surface will increase the resistive path measured between two probes in contact on the surface. 4. Eddy current testing A coil carrying current placed closed to the surface will increase will induce eddy current in the material. Detection of eddy currents are detected by a change in inductance of the generator 5. Ultrasonic testing Suitable orientation of the transmitter enables detection of cracks. (anywhere) 6. Radiographic examinations Imperfections can be detected using x-rays or gamma rays from a radioactive source. e.g. imperfections in welding of seamless pipes.