PRESENTATION ON CONDITION MONITORING BY ER.

BIKRAM SINGH SM(E)

INTRODUCTION

CONDITION MONITORING HAS BEEN IN USE FOR OVER A DECADE NOW. IT HAS IMERGED AS A POWERFUL TECHNIQUE IN MODERN MAINTENANCE MANAGEMENT

CONDITION MONITORING

CONDITION MONITORING IS A TECHNIQUE FOR ACCURATELY AND QUANTITAVELY CHECKING THE CONDITION OF MACHINE AND PREDICTING ITS FUTURE

TOOLS

IR THERMOGRAPHY HV TESTING -PARTIAL DISCHARGE MEASUREMENT, ELCID TEST, TAN DELTA, CAPACITANCE VIBRATION ANALYSIS

Non-contact Temperature Measurement

Using Infrared Technology

Thermography

Human body Human body temperature is a complex phenomenon. Man is homeo-thermic, and produces heat, which must be lost to the environment. The interface between that heat production and the environment is the skin. By measuring skin temperature it is possible to see if there is any abnormality in the body

Hands Right hand has lower temperature than the left which Heart Surgery indicates serious blood Evaluation of cardiac circulation problem. perfusion during Coronary Artery Bypass Surgery

Non-Contact Thermometers

For fast and accurate measurement For moving and very hot objects For objects which are difficult to reach For application where contact would tear, contaminate or alter temperature

Benefits of Non-contact Thermometers

Improve Quality Increase Productivity Reduce energy wastage,Maintenance and scrap material cost Eliminate Down time

Infrared Thermography An Integral part of CM Programme

Non-contact inspection method with no need to shut down production and operation at a safe operating condition Portable equipment for surveying large areas quickly Accurate and repeatable temperature measurements

Infrared Thermography An Integral part of CM Programme

Thermal image analysis enables accurate fault diagnosis and trending Rugged camera design for operation in harsh industrial environment

The Advantage of Condition Monitoring

Scheduled maintenance programme improve plant safety and save money Early fault diagnosis prevents unscheduled and costly production stoppages Analysis of results enables failure trends to be predicted

IR Application Electrical System Defects

Loose Joint / Cable termination Oxidized / Rusted Joint Poor Cable Crimp Insulation Failure Overloading

IR Application Electrical System Defects

Phase Imbalance Dust / Carbon Accumulation on Slip ring Brush Improper tension of Slip rings Poor Cooling of Commutator / Armature Thyristor Bank failure

Infrared Thermography An Integral part of the R&D program

Non-contact inspection method for nondestructive testing of materials and components Real time image analysis and recording of both static and dynamic thermal patterns

Infrared Thermography An Integral part of the R&D program

Accurate and repeatable temperature measurements Thermal image analysis enables accurate fault diagnosis and Trending Rugged Camera design for operation in harsh environments as well as the laboratory

Research and Development Typical Applications

Materials evaluation Quality assurance Production Control Target thermal signature analysis Environmental / Thermal mapping Non-destructive testing Medical Thermography

Emissivity & Blackbodies

Ideal Blackbody
I=E I R

Real Body
I<E T

Perfect Absorber and emitter ,Emissivity=1

Some energy is transmitted and reflected, Emissivity< 1

Infrared Technique:

Spot Temperature Measurement

Thermal Scanning / Imaging

Important object Parameters

Temperature range Shape Material type Surface Characteristics Size and Distance Movement

Image Specification

Size: 150KB without voice comments *.img extension Naming as per date e.g. A0512-13.img i.e. 13th image of a directory stored on 12.05.2000 Cannot be opened without IRWIN Report 5.21 software package

IR Thermal Imaging System

Scans the Temperature profile of the area being focused Generates a coloured thermal image of the area being focused on the viewfinder Color profile indicates the temperature profile of the area

IR Thermal Imaging System

The temperature at any spot of the area can be measured in the camera view finder ( Field measurement) Also the thermal image can be stored in inbuilt PCMCIA Hard Disc Drive The image can subsequently be analyzed in the computer

IR Thermal Imaging System

The Software Package : IRWIN Report 5.21allows image processing Customized report can be generated The report shows coloured thermal image, hot spots, temperature profile along any line on thermo gram

Thermo vision 800 Key features

Choice of hand held infrared condition monitoring systems High resolution image quality for rapid fault detection Easy to use Rugged design for operation in harsh environment High accuracy and reliability