Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 19

Condition Monitoring Related Publications

19 Fault Detection and Diagnosis of Broken Bar Problem in Induction Motors Base Wavelet Analysis and EMD Method: Case Study of Mobarakeh Steel Company in Iran

Authors: M. Ahmadi, M. Kafil, H. Ebrahimi

Abstract:

Nowadays, induction motors have a significant role in industries. Condition monitoring (CM) of this equipment has gained a remarkable importance during recent years due to huge production losses, substantial imposed costs and increases in vulnerability, risk, and uncertainty levels. Motor current signature analysis (MCSA) is one of the most important techniques in CM. This method can be used for rotor broken bars detection. Signal processing methods such as Fast Fourier transformation (FFT), Wavelet transformation and Empirical Mode Decomposition (EMD) are used for analyzing MCSA output data. In this study, these signal processing methods are used for broken bar problem detection of Mobarakeh steel company induction motors. Based on wavelet transformation method, an index for fault detection, CF, is introduced which is the variation of maximum to the mean of wavelet transformation coefficients. We find that, in the broken bar condition, the amount of CF factor is greater than the healthy condition. Based on EMD method, the energy of intrinsic mode functions (IMF) is calculated and finds that when motor bars become broken the energy of IMFs increases.

Keywords: Diagnostics, Condition Monitoring, Fourier transform, Wavelet Transform, empirical mode decomposition, broken bar

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 275
18 Condition Monitoring for Twin-Fluid Nozzles with Internal Mixing

Authors: C. Lanzerstorfer

Abstract:

Liquid sprays of water are frequently used in air pollution control for gas cooling purposes and for gas cleaning. Twin-fluid nozzles with internal mixing are often used for these purposes because of the small size of the drops produced. In these nozzles the liquid is dispersed by compressed air or another pressurized gas. In high efficiency scrubbers for particle separation, several nozzles are operated in parallel because of the size of the cross section. In such scrubbers, the scrubbing water has to be re-circulated. Precipitation of some solid material can occur in the liquid circuit, caused by chemical reactions. When such precipitations are detached from the place of formation, they can partly or totally block the liquid flow to a nozzle. Due to the resulting unbalanced supply of the nozzles with water and gas, the efficiency of separation decreases. Thus, the nozzles have to be cleaned if a certain fraction of blockages is reached. The aim of this study was to provide a tool for continuously monitoring the status of the nozzles of a scrubber based on the available operation data (water flow, air flow, water pressure and air pressure). The difference between the air pressure and the water pressure is not well suited for this purpose, because the difference is quite small and therefore very exact calibration of the pressure measurement would be required. Therefore, an equation for the reference air flow of a nozzle at the actual water flow and operation pressure was derived. This flow can be compared with the actual air flow for assessment of the status of the nozzles.

Keywords: Condition Monitoring, Flow Equation, operation data, Twin-fluid nozzles

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 550
17 Experimental and Finite Element Study of Bending Fatigue Failure: A Case Study on Main Shaft of a Gyrator Crusher

Authors: Rahim Sotoudeh Bahreini, Alireza Foroughi Nematollahi, Akbar Jafari

Abstract:

This study investigates the mechanism of a Gyratory crusher-located in Golgohar mining and industrial Co. specifically with a focus on stresses distribution and fatigue failure of its main shaft. At first step, the cross section of the fractured shaft is studied, and the crack growth is analyzed. Then, the rotational motion of the shaft and the oil temperature of oil circuit of equipment are monitored. Condition monitoring is used to help finding a better modification. Based on the results of this study, the main causes of shaft failure are identified, and corrective solution is offered to increase crusher performance, especially its main shaft life. To predict the efficiency of the proposed modification, finite element simulation is performed, and its results are compared with the similar modified cases. The comparison and interpretation of simulation results confirm the efficiency of proposed corrective method.

Keywords: Condition Monitoring, Finite Element Method, fatigue failure, gyratory crusher

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 946
16 Condition Monitoring System of Mine Air Compressors Based on Wireless Sensor Network

Authors: Sheng Fu, Yinbo Gao, Hao Lin

Abstract:

In the current mine air compressors monitoring system, there are some difficulties in the installation and maintenance because of the wired connection. To solve the problem, this paper introduces a new air compressors monitoring system based on ZigBee in which the monitoring parameters are transmitted wirelessly. The collecting devices are designed to form a cluster network to collect vibration, temperature, and pressure of air cylinders and other parameters. All these devices are battery-powered. Besides, the monitoring software in PC is developed using MFC. Experiments show that the designed wireless sensor network works well in the site environmental condition and the system is very convenient to be installed since the wireless connection. This monitoring system will have a wide application prospect in the upgrade of the old monitoring system of the air compressors.

Keywords: Condition Monitoring, Wireless Sensor Network, ZigBee, air compressor, data collecting

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 790
15 Assessment of Solid Insulating Material Using Partial Discharge Characteristics

Authors: Faiz Ahmad, Qasim Khan, Furkan Ahmad, Asfar A. Khan, M. Saad Alam

Abstract:

In this paper, partial discharge analysis is performed in cavities artificially created in insulation. The setup is according with Cigre-II Method. Circular Samples created from Perspex Sheet with different configuration with changing number of cavities. Assessment of insulation health can be performed by Partial Discharge measurement as this has been found to be important means of condition monitoring. The experiments are done using MPD 540, which is a modern partial discharge measurement system. By analyzing the PD activity obtained for various voids/cavities, it is observed that the PD voltages show variation for cavity’s diameter, depth even for its ratios. This can be employed for scrutiny of insulation system.

Keywords: Condition Monitoring, Partial discharges, PMMA, degradation and corrosion, MPD 540, cavities/defects

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1592
14 Application of Artificial Neural Network in the Investigation of Bearing Defects

Authors: S. Sendhil Kumar, M. Senthil Kumar

Abstract:

Maintenance and design engineers have great concern for the functioning of rotating machineries due to the vibration phenomenon. Improper functioning in rotating machinery originates from the damage to rolling element bearings. The status of rolling element bearings require advanced technologies to monitor their health status efficiently and effectively. Avoiding vibration during machine running conditions is a complicated process. Vibration simulation should be carried out using suitable sensors/ transducers to recognize the level of damage on bearing during machine operating conditions. Various issues arising in rotating systems are interlinked with bearing faults. This paper presents an approach for fault diagnosis of bearings using neural networks and time/frequencydomain vibration analysis.

Keywords: Condition Monitoring, frequency domain, Bearing vibration, Fault diagnosis

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1981
13 Dynamic Simulation of IC Engine Bearings for Fault Detection and Wear Prediction

Authors: M. D. Haneef, R. B. Randall, Z. Peng

Abstract:

Journal bearings used in IC engines are prone to premature failures and are likely to fail earlier than the rated life due to highly impulsive and unstable operating conditions and frequent starts/stops. Vibration signature extraction and wear debris analysis techniques are prevalent in industry for condition monitoring of rotary machinery. However, both techniques involve a great deal of technical expertise, time, and cost. Limited literature is available on the application of these techniques for fault detection in reciprocating machinery, due to the complex nature of impact forces that confounds the extraction of fault signals for vibration-based analysis and wear prediction. In present study, a simulation model was developed to investigate the bearing wear behaviour, resulting because of different operating conditions, to complement the vibration analysis. In current simulation, the dynamics of the engine was established first, based on which the hydrodynamic journal bearing forces were evaluated by numerical solution of the Reynold’s equation. In addition, the essential outputs of interest in this study, critical to determine wear rates are the tangential velocity and oil film thickness between the journals and bearing sleeve, which if not maintained appropriately, have a detrimental effect on the bearing performance. Archard’s wear prediction model was used in the simulation to calculate the wear rate of bearings with specific location information as all determinative parameters were obtained with reference to crank rotation. Oil film thickness obtained from the model was used as a criterion to determine if the lubrication is sufficient to prevent contact between the journal and bearing thus causing accelerated wear. A limiting value of 1 μm was used as the minimum oil film thickness needed to prevent contact. The increased wear rate with growing severity of operating conditions is analogous and comparable to the rise in amplitude of the squared envelope of the referenced vibration signals. Thus on one hand, the developed model demonstrated its capability to explain wear behaviour and on the other hand it also helps to establish a co-relation between wear based and vibration based analysis. Therefore, the model provides a cost effective and quick approach to predict the impending wear in IC engine bearings under various operating conditions.

Keywords: Condition Monitoring, Vibration analysis, IC Engine, wear prediction, journal bearings

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1667
12 Bearing Condition Monitoring with Acoustic Emission Techniques

Authors: Faisal AlShammari, Abdulmajid Addali

Abstract:

Monitoring the conditions of rotating machinery, such as bearings, is important in order to improve the stability of work. Acoustic Emission (AE) and vibration analysis are some of the most accomplished techniques used for this purpose. Acoustic emission has the ability to detect the initial phase of component degradation. Moreover, it has been observed that vibration analysis is not as successful at low rotational speeds (below 100 rpm). This because the energy generated within this speed region is not detectable using conventional vibration. From this perspective, this paper has presented a brief review of using acoustic emission techniques for monitoring bearing conditions.

Keywords: Condition Monitoring, stress wave analysis, bearing defect diagnosis, low-speed bearings

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3052
11 Vibration Analysis of Gas Turbine SIEMENS 162MW - V94.2 Related to Iran Power Plant Industry in Fars Province

Authors: Omid A. Zargar

Abstract:

Vibration analysis of most critical equipment is considered as one of the most challenging activities in preventive maintenance. Utilities are heart of the process in big industrial plants like petrochemical zones. Vibration analysis methods and condition monitoring systems of these kinds of equipments are developed too much in recent years. On the other hand, there are too much operation factors like inlet and outlet pressures and temperatures that should be monitored. In this paper, some of the most effective concepts and techniques related to gas turbine vibration analysis are discussed. In addition, a gas turbine SIEMENS 162MW - V94.2 vibration case history related to Iran power industry in Fars province is explained. Vibration monitoring system and machinery technical specification are introduced. Besides, absolute and relative vibration trends, turbine and compressor orbits, Fast Fourier transform (FFT) in absolute vibrations, vibration modal analysis, turbine and compressor start up and shut down conditions, bode diagrams for relative vibrations, Nyquist diagrams and waterfall or three-dimensional FFT diagrams in startup and trip conditions are discussed with relative graphs. Furthermore, Split Resonance in gas turbines is discussed in details. Moreover, some updated vibration monitoring system, blade manufacturing technique and modern damping mechanism are discussed in this paper.

Keywords: Condition Monitoring, utility, Gas Turbine, fast Fourier transform (FFT), time wave form (TWF), non-contact probe, turbine compressor, vibration data collector, Relative Vibration, Absolute Vibration, Split Resonance

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3099
10 Turbine Compressor Vibration Analysis and Rotor Movement Evaluation by Shaft Center Line Method (The Case History Related to Main Turbine Compressor of an Olefin Plant in Iran Oil Industries)

Authors: Omid A. Zargar

Abstract:

Vibration monitoring methods of most critical equipment like main turbine and compressors always plays important role in preventive maintenance and management consideration in big industrial plants. There are a number of traditional methods like monitoring the overall vibration data from Bently Nevada panel and the time wave form (TWF) or fast Fourier transform (FFT) monitoring. Besides, Shaft centerline monitoring method developed too much in recent years. There are a number of arguments both in favor of and against this method between people who work in preventive maintenance and condition monitoring systems (vibration analysts). In this paper basic principal of Turbine compressor vibration analysis and rotor movement evaluation by shaft centerline method discussed in details through a case history. This case history is related to main turbine compressor of an olefin plant in Iran oil industry. In addition, some common mistakes that may occur by vibration analyst during the process discussed in details. It is worthy to know that, these mistakes may one of the reasons that sometimes this method seems to be not effective. Furthermore, recent patent and innovation in shaft position and movement evaluation are discussed in this paper.

Keywords: Condition Monitoring, Steam Turbine, journal bearing, Shaft centerline position, attitude angle, sleeve bearing, tilting pad, main compressor, multistage compressor, non-contact probe

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 6663
9 Vibration, Lubrication and Machinery Consideration for a Mixer Gearbox Related to Iran Oil Industries

Authors: Omid A. Zargar

Abstract:

In this paper, some common gearboxes vibration analysis methods and condition monitoring systems are explained. In addition, an experimental gearbox vibration analysis is discussed through a critical case history for a mixer gearbox related to Iran oil industry. The case history also consists of gear manufacturing (machining) recommendations, lubrication condition of gearbox and machinery maintenance activities that caused reduction in noise and vibration of the gearbox. Besides some of the recent patents and innovations in gearboxes, lubrication and vibration monitoring systems explained. Finally micro pitting and surface fatigue in pinion and bevel of mentioned horizontal to vertical gearbox discussed in details.

Keywords: Condition Monitoring, fast Fourier transform (FFT), Gear box, time wave form (TWF), gear mesh frequency (GMF), Shock Pulse measurement (SPM), bearing condition unit (BCU), pinion, bevel gear, micro pitting, surface fatigue

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3905
8 A Study on the Condition Monitoring of Transmission Line by On-line Circuit Parameter Measurement

Authors: Il Dong Kim, Jin Rak Lee, Young Jun Ko, Young Taek Jin

Abstract:

An on-line condition monitoring method for transmission line is proposed using electrical circuit theory and IT technology in this paper. It is reasonable that the circuit parameters such as resistance (R), inductance (L), conductance (g) and capacitance (C) of a transmission line expose the electrical conditions and physical state of the line. Those parameters can be calculated from the linear equation composed of voltages and currents measured by synchro-phasor measurement technique at both end of the line. A set of linear voltage drop equations containing four terminal constants (A, B ,C ,D ) are mathematical models of the transmission line circuits. At least two sets of those linear equations are established from different operation condition of the line, they may mathematically yield those circuit parameters of the line. The conditions of line connectivity including state of connecting parts or contacting parts of the switching device may be monitored by resistance variations during operation. The insulation conditions of the line can be monitored by conductance (g) and capacitance(C) measurements. Together with other condition monitoring devices such as partial discharge, sensors and visual sensing device etc.,they may give useful information to monitor out any incipient symptoms of faults. The prototype of hardware system has been developed and tested through laboratory level simulated transmission lines. The test has shown enough evident to put the proposed method to practical uses.

Keywords: Condition Monitoring, transmission line, Circuit Parameters, Synchro- phasor Measurement

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2808
7 Monitoring Sand Transport Characteristics in Multiphase Flow in Horizontal Pipelines Using Acoustic Emission Technology

Authors: M. El-Alej, D. Mba, T. Yan, M. Elforgani

Abstract:

This paper presents an experimental investigation using Acoustic Emission (AE) technology to monitor sand transportation in multiphase flow. The investigations were undertaken on three-phase (air-water-sand) flow in a horizontal pipe where the superficial gas velocity (VSG) had a range of between 0.2msˉ¹ to 2.0msˉ¹ and superficial liquid velocity (VSL) had a range of between 0.2msˉ¹ to 1.0msˉ¹. The experimental findings clearly show a correlation exists between AE energy levels, sand concentration, superficial gas velocity (VSG), and superficial liquid velocity (VSL).

Keywords: Condition Monitoring, Multiphase Flow, Acoustic Emission (AE), sand monitoring, sand minimum transport condition (MTC)

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3098
6 Condition Monitoring in the Management of Maintenance in a Large Scale Precision CNC Machining Manufacturing Facility

Authors: N. Ahmed, A.J. Day, J.L. Victory L. Zeall, B. Young

Abstract:

The manufacture of large-scale precision aerospace components using CNC requires a highly effective maintenance strategy to ensure that the required accuracy can be achieved over many hours of production. This paper reviews a strategy for a maintenance management system based on Failure Mode Avoidance, which uses advanced techniques and technologies to underpin a predictive maintenance strategy. It is shown how condition monitoring (CM) is important to predict potential failures in high precision machining facilities and achieve intelligent and integrated maintenance management. There are two distinct ways in which CM can be applied. One is to monitor key process parameters and observe trends which may indicate a gradual deterioration of accuracy in the product. The other is the use of CM techniques to monitor high status machine parameters enables trends to be observed which can be corrected before machine failure and downtime occurs. It is concluded that the key to developing a flexible and intelligent maintenance framework in any precision manufacturing operation is the ability to evaluate reliably and routinely machine tool condition using condition monitoring techniques within a framework of Failure Mode Avoidance.

Keywords: Maintenance, Condition Monitoring, Machining, Accuracy, CNC, capability, Key Process Parameters, Critical Parameters

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1566
5 Performance Monitoring of the Refrigeration System with Minimum Set of Sensors

Authors: Radek Fisera, Petr Stluka

Abstract:

This paper describes a methodology for remote performance monitoring of retail refrigeration systems. The proposed framework starts with monitoring of the whole refrigeration circuit which allows detecting deviations from expected behavior caused by various faults and degradations. The subsequent diagnostics methods drill down deeper in the equipment hierarchy to more specifically determine root causes. An important feature of the proposed concept is that it does not require any additional sensors, and thus, the performance monitoring solution can be deployed at a low installation cost. Moreover only a minimum of contextual information is required, which also substantially reduces time and cost of the deployment process.

Keywords: Condition Monitoring, energy baselining, fault detection and diagnostics, commercial refrigeration

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2235
4 Development of Condition Monitoring System with Control Functions for Wind Turbines

Authors: Jae-Kyung Lee, Joon-Young Park, Beom-Joo Kim

Abstract:

As an effort to promote wind power industry in Korea, Korea South-East Power Corporation has been developing 22MW YeungHeung wind farm consisting of nine 2 to 3MW wind turbines supplied by three manufacturers. To maximize its availability and reliability and to solve the difficulty of operating three kinds of SCADA systems, Korea Electric Power Corporation has been developing a condition monitoring system integrated with control functions. This paper presents the developed condition monitoring system and its application to YeungHeung wind test bed, and the design of its control functions.

Keywords: Reliability, Condition Monitoring, Wind turbine, control function

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1950
3 A Combined Practical Approach to Condition Monitoring of Reciprocating Compressors using IAS and Dynamic Pressure

Authors: M. Elhaj, M. Almrabet, M. Rgeai, I. Ehtiwesh

Abstract:

A Comparison and evaluation of the different condition monitoring (CM) techniques was applied experimentally on RC e.g. Dynamic cylinder pressure and crankshaft Instantaneous Angular Speed (IAS), for the detection and diagnosis of valve faults in a two - stage reciprocating compressor for a programme of condition monitoring which can successfully detect and diagnose a fault in machine. Leakage in the valve plate was introduced experimentally into a two-stage reciprocating compressor. The effect of the faults on compressor performance was monitored and the differences with the normal, healthy performance noted as a fault signature been used for the detection and diagnosis of faults. The paper concludes with what is considered to be a unique approach to condition monitoring. First, each of the two most useful techniques is used to produce a Truth Table which details the circumstances in which each method can be used to detect and diagnose a fault. The two Truth Tables are then combined into a single Decision Table to provide a unique and reliable method of detection and diagnosis of each of the individual faults introduced into the compressor. This gives accurate diagnosis of compressor faults.

Keywords: Condition Monitoring, dynamic pressure, reciprocating compressor, Instantaneous Angular Speed

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2912
2 A Model for Study of the Defects in Rolling Element Bearings at Higher Speed by Vibration Signature Analysis

Authors: Abhay Utpat, R. B. Ingle, M. R. Nandgaonkar

Abstract:

The vibrations produced by a single point defect on various parts of the bearing under constant radial load are predicted by using a theoretical model. The model includes variation in the response due to the effect of bearing dimensions, rotating frequency distribution of load. The excitation forces are generated when the defects on the races strike to rolling elements. In case of the outer ring defect, the pulses generated are with periodicity of outer ring defect frequency where as for inner ring defect, the pulses are with periodicity of inner ring defect frequency. The effort has been carried out in preparing the physical model of the system. Different defect frequencies are obtained and are used to find out the amplitudes of the vibration due to excitation of the bearing parts. Increase in the radial load or severity of the defect produces a significant change in bearing signature characteristics.

Keywords: Condition Monitoring, defect frequency, rolling element, vibration response

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2422
1 LabVIEW with Fuzzy Logic Controller Simulation Panel for Condition Monitoring of Oil and Dry Type Transformer

Authors: N. A. Muhamad, S.A.M. Ali

Abstract:

Condition monitoring of electrical power equipment has attracted considerable attention for many years. The aim of this paper is to use Labview with Fuzzy Logic controller to build a simulation system to diagnose transformer faults and monitor its condition. The front panel of the system was designed using LabVIEW to enable computer to act as customer-designed instrument. The dissolved gas-in-oil analysis (DGA) method was used as technique for oil type transformer diagnosis; meanwhile terminal voltages and currents analysis method was used for dry type transformer. Fuzzy Logic was used as expert system that assesses all information keyed in at the front panel to diagnose and predict the condition of the transformer. The outcome of the Fuzzy Logic interpretation will be displayed at front panel of LabVIEW to show the user the conditions of the transformer at any time.

Keywords: Condition Monitoring, Fuzzy Logic, labview, DGA, oiltransformer, dry transformer, terminal values

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2741