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 cross-checked
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 quality-checked with thermal
images.