Other predictive maintenance

techniques

Many condition-monitoring
techniques can be used to monitor
the same fault condition.
For example, a problem identified
by an oil sample can also be crosschecked with vibration analysis or
thermography.

Ultrasound
Ultrasound is defined as sound
waves that have frequency levels
above 20 kHz, higher than the
range of human hearing.

Properties
Small objects easily block air-borne
ultrasound.
It does not penetrate solid surfaces
(though it can go through cracks).
Air-borne ultrasound radiates in a
straight line.
Ultrasound does not travel a great
distance.

Ultrasonic translator

Applications
Leak detection in pressure and vacuum
systems
Bearing inspection
Steam trap inspection
Valve blow-by
Integrity of seals and gaskets in tanks,
pipe systems and large walk-in boxes
Pump cavitations
Detection of corona in switch gear
Compressor valve analysis.

Infrared thermography

Any object with a temperature

above absolute zero emits energy.
As its temperature rises, the energy
emission also increases.
Infrared thermography is a
technique that produces a visible
graph or a thermographic image of
thermal energy radiated by objects.

Advantages
It does not make contact with the surface.
The technique does not involve any
hazardous actions.
It can be used in hazardous zones.
It is not affected by electromagnetic waves.
Like other predictive techniques, it is used
while systems are operating.
It provides instant information.
Data can be collected and stored in digital
format.

Disadvantages
The cost of the hardware can be quite high.
Some systems have software limitations.
The emissivity of the object must be
calculated or should be known.
The ambience should be homogenous with
respect to the thermal energy.
Distance, atmospheric conditions and
temperature can affect the quality of
images.

Applications
Electrical equipment
Mechanical equipment
Energy systems
Electronic systems

Mechanical equipment
Cooling systems, earth faults, circulating
currents, laminations, cracking insulation.
Auxiliary equipment such as fuses, relay
contacts, switchgear, distribution boards
and transformers can suffer from loose
connections, imbalanced loads or
corrosion, which result in resistive heating.
In a three-phase system, unequal
temperatures can indicate imbalance in
the phases.

Mechanical equipment
Misalignment or bent shafts
Defective reciprocating
compressor valves
Insufficient lubrication
Damaged bearings, gears,
chains, clutches, belt slippage
and belt wear

Energy systems
Boiler and steam systems, flues,
heat exchangers and
regenerators.
In this case, integrity of the
insulation, brickwork and poor
joints of furnaces and kilns can
be assessed.

Electronic systems
Discrete components, printed
circuit boards (PCBs) and
electronic bonding can be qualitychecked with thermal images.