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WELCOME

WELCOME. CONDITION MONITORING THROUGH NON DESTRUCTIVE TESTINGS OF MACHINES AND PLANTS. INTRODUCTION. CONDITION MONITORING SIGNATURE ANALYSIS NON-DESTRUCTIVE EVALUATIONS(NDE) IN-SERVICE INSPECTIONS (ISI) SAFTEY. CONDITION BASED MAINTENANCE. NDE TECHNIQUES. 1.VIBRATION MONITORING.

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WELCOME

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  1. WELCOME

  2. CONDITION MONITORING THROUGH NON DESTRUCTIVE TESTINGS OF MACHINES AND PLANTS

  3. INTRODUCTION • CONDITION MONITORING • SIGNATURE ANALYSIS • NON-DESTRUCTIVE EVALUATIONS(NDE) • IN-SERVICE INSPECTIONS (ISI) • SAFTEY

  4. CONDITION BASED MAINTENANCE

  5. NDE TECHNIQUES 1.VIBRATION MONITORING 2.ACOUSTIC EMISSION (AE) 3.INFRARED THERMOGRAPHY (IRT) 4.FERROGRAPHY 5.FIELD SIGNATURE MAPPING (FSM)

  6. MACHINE CHANNEL SELECTOR FREQUENCY ANALYSER RECORDER VIBROMETER fig,(1.a) SIGNAL FLOW DIAGRAM VIBRATION MONITORING INSTRUMENTATION • VIBRATION MEASURING AND ANALYSIS SYSTEM • MINI COMPUTERS • PROBABILITY DENSITY FUNCTION ANALYSIS (PDF) • BY INSPECTION

  7. ANALYSIS OF RESULTS 1. VIBRATION CAUSE IDENTIFICATION

  8. VIBRATION METER (HAND HELD) SPM VIB-11 by SKF Vibration Meter: for imbalance, structural weakness, loose parts etc INDUSTRIAL MACINERY CLASSIFICATION Class 2: Medium size machines without special foundation Class 3: Large machines on rigid foundations Class 4: Large machines on soft foundations.

  9. APPLICATIONOF VIBRATION MONITORING IN PLANTS • MONITORING AT ‘ROURKELA STEEL PLANT’ • maintenance cost 10-15% of prod: cost

  10. year GROWTH THROUGH CBM ACTIVITIES AT RSP BREAK DOWNS PREVENTED-10-102 EQUIPMENTS INCLUDED - 40-140 No: of machines

  11. ACOUSTIC EMISSION MONITORING AE sensors respond with amazing sensitivity to motion in the low ultrasonic frequency range (10 kHz - 2000 kHz).  Motions as small as 10-12 inches and less can be detected

  12. ACOUSTIC-EMISSION METHOD This method is based on the registration of the elastic compression waves that are emitted by the defects developing in the stressed constructions.

  13. ACOUSTIC EMISSION SYSTEMS • AE data collection systems • Laptop based AE system • DiSP Systems (any number of channels can be used) •  Portable AE test system (lunch box)

  14. CASE STUDY AE DURING HYDROTESTING OF A HORTON SPHERE MAX: PRESSURE 22 Kg/cm2 • Pressurization (Stage 1) • Random AE activity due to • Mechanical rubbing between support structure and vessel • 2. Paint layer peel-off . • Re pressurization (Stage 2) • No significant AE activity • AE SIGANLS FROM NEWER AREA ( local plastic deformation ) • NO SIGNAL DURING SUBSEQUENT PRESSURIZATION Fig.2(f) AE monitoring during hydro testing of Horton sphere

  15. IR THERMOGRAPHY • Infrared thermography is based on the principle of detection and measurement of infrared radiations QR) arising from the natural or stimulated thermal radiation of an object21

  16. I R MEASURING SYSTEMS ThermaCAM S60 : Real-Time Thermal • highly sensitive thermal imaging, • precision temperature measurement, • enhanced connectivity options including • high speed data transfer • extensive thermal analysis capabilities

  17. CASE STUDY raw thermo graphic data. data after removing the noise and vertical gradient. correspond to low strength welds. high strength welds data processed for the local gradient in surface temperature. Fig setup for infrared testing of lap joints

  18. FERROGRAPHY 1.WEAR DEBRIS ANALYSIS MODE: ABRASION, IMPACT, FATIGUE, EROSION, CORROSION RATE : CONCENTRATION OF WEAR DEBRIS SEVERITY : SIZE OF DEBRIS INDICATES LOCATION : COLOUR OF THE PARTICLES 2.SPECTROMETRIC ANALYSIS • OIL ELECTRICALLY EXCITED TO THE POINT WHERE LIGHT IS EMITTED. • ELEMENT EMITS A LIGHT OF ITS OWN PARTICULAR COLOR AND FREQUENCY. • SPECTROMETERS TRANSLATES THE INTENSITY OF THIS RAINBOW OF COLORS INTO A COMPUTERIZED READOUT.

  19. HOW IS THE TEST PERFORMED

  20. WEAR METAL ORIGIN TABLE

  21. MEASURING INSTRUMENT ModelT2FMAnalyticalFerrograph. Bi chromatic microscope. Video camera. Video capture card. Image capture software. industrial standard personal computer. This measure the effects of Contamination and electro-chemical changes that occur in synthetic and petroleum based oils

  22. FIELD SIGNATURE MAPPING • The FSM Inspection Tool (FSM) is a new technology for monitoring and inspection of metallic pipes and structures, pipelines and storage vessels • Reduce life cycle inspection costs • Reduce inspection time

  23. FIELD PATTERN Sensing pins (electrodes) in an array over the monitored area to detect changes in the electrical field pattern. The voltage = the signature. Graphical plots indicating the severity and location of corrosion, and calculates actual corrosion and metal loss

  24. INDUSTRIAL ARRANGEMENT A typical refinery monitors high temperature areas such as heater bends in the distillation unit.

  25. CONCLUSION

  26. SUMMARY OF APPLICABILITY AND CAPABILITY OF VARIOUS NDT TECHNIQUES

  27. THANK YOU

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