(Ebook) Machinery Condition Monitoring Principles and Practices 1st Edition by Amiya Ranjan Mohanty ISBN 1138583219 9781138583214

(Ebook) Machinery Condition Monitoring Principles and Practices 1st Edition by Amiya Ranjan Mohanty ISBN 1138583219 9781138583214

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ISBN 10: 1138583219 
ISBN 13: 9781138583214
Author: Amiya Ranjan Mohanty

Find the Fault in the Machines- Drawing on the author’s more than two decades of experience with machinery condition monitoring and consulting for industries in India and abroad, Machinery Condition Monitoring: Principles and Practices introduces the practicing engineer to the techniques used to effectively detect and diagnose faults in machines. Providing the working principle behind the instruments, the important elements of machines as well as the technique to understand their conditions, this text presents every available method of machine fault detection occurring in machines in general, and rotating machines in particular. A Single-Source Solution for Practice Machinery Conditioning Monitoring- Since vibration is one of the most widely used fault detection techniques, the book offers an assessment of vibration analysis and rotor-dynamics. It also covers the techniques of wear and debris analysis, and motor current signature analysis to detect faults in rotating mechanical systems as well as thermography, the nondestructive test NDT techniques (ultrasonics and radiography), and additional methods. The author includes relevant case studies from his own experience spanning over the past 20 years, and detailing practical fault diagnosis exercises involving various industries ranging from steel and cement plants to gas turbine driven frigates. While mathematics is kept to a minimum, he also provides worked examples and MATLAB® codes. This book contains 15 chapters and provides topical information that includes: A brief overview of the maintenance techniques Fundamentals of machinery vibration and rotor dynamics Basics of signal processing and instrumentation, which are essential for monitoring the health of machines Requirements of vibration monitoring and noise monitoring Electrical machinery faults Thermography for condition monitoring Techniques of wear debris analysis and some of the nondestructive test (NDT) techniques for condition monitoring like ultrasonics and radiography Machine tool condition monitoring Engineering failure analysis Several case studies, mostly on failure analysis, from the author’s consulting experience Machinery Condition Monitoring: Principles and Practices presents the latest techniques in fault diagnosis and prognosis, provides many real-life practical examples, and empowers you to diagnose the faults in machines all on your own.

(Ebook) Machinery Condition Monitoring Principles and Practices 1st Table of contents:

1. Introduction
1.1 Machinery Condition Monitoring
1.2 Present Status
1.3 Fault Prognosis
1.4 Future Needs
2. Principles of Maintenance
2.1 Introduction
2.2 Reactive Maintenance
2.3 Preventive Maintenance
2.4 Predictive Maintenance
2.5 Enterprise Resource Planning
2.6 Bath Tub Curve
2.7 Failure Modes Effects and Criticality Analysis (FMECA)
2.7.1 Implementation of FMECA for Machinery Maintenance
2.7.2 Risk Priority Number for FMECA
3. Fundamentals of Machinery Vibration
3.1 Introduction
3.2 Single Degree-of-Freedom Motion
3.3 Forced Vibration Response
3.4 Base Excitation
3.5 Force Transmissibility and Vibration Isolation
3.6 Tuned Vibration Absorber
3.7 Unbalanced Response
3.8 Characteristics of Vibrating Systems
3.9 Vibration of Continuous Systems
3.10 Mode Shapes and Operational Deflection Shapes
3.11 Experimental Modal Analysis
4. Rotordynamics
4.1 Introduction
4.2 Simple Rigid Rotor-Disc System
4.3 Unbalance Response and Critical Speed
4.4 Journal Bearings
4.5 Oil Whirl and Oil Whip
4.6 Squeeze Film Dampers
4.7 Condition Monitoring in Large Rotor Systems
5. Digital Signal Processing
5.1 Introduction
5.2 Classification of Signals
5.3 Signal Analysis
5.4 Frequency Domain Signal Analysis
5.4.1 Fourier Series
5.4.2 Fourier Integral
5.4.3 Discrete Fourier Transform
5.5 Fundamentals of Fast Fourier Transform
5.5.1 Representation of Fourier Transform Data
5.5.2 Autopower Spectrum
5.5.3 Cross-Power Spectrum
5.5.4 Frequency Response Function
5.5.5 Coherence Function
5.6 Computer-Aided Data Acquisition
5.7 Signal Conditioning
5.7.1 Signal Filtering
5.8 Signal Demodulation
5.9 Cepstrum Analysis
5.10 Examples
5.10.1 Natural Frequency of a Cantilever Beam
5.10.2 Compressor Vibration
5.10.3 Engine Vibration
6. Instrumentation
6.1 Introduction
6.2 Measurement Standards
6.3 Measurement Errors
6.4 Calibration Principles
6.5 Static and Dynamic Measurements
6.6 Frequency Response
6.7 Dynamic Range
6.8 Basic Measuring Equipment
6.8.1 RMS/Peak Meters
6.8.2 Signal Amplifiers
6.8.3 Oscilloscope
6.8.4 Signal Generators
6.8.5 Signal Filters
6.8.6 Power Supply
6.8.7 Counters
6.9 Vibration
6.9.1 Displacement
6.9.2 Velocity
6.9.3 Acceleration
6.10 Force Measurements
6.11 Rotational Speed
6.11.1 Stroboscope
6.11.2 Inductive Probe
6.11.3 Optical Tachometer
6.11.4 Optical Encoder
6.12 Noise Measurements
6.12.1 Sound Intensity Measurements
6.13 Temperature Measurements
6.14 Laser-Based Measurements
6.14.1 Laser Vibrometer
6.14.2 Rotational Laser Vibrometer
6.15 Current Measurements
6.15.1 Inductive Current Sensor
6.15.2 Hall Effect Sensor
6.16 Chemical Composition Measurement
6.16.1 Atomic Emission Spectrophotometer
6.16.2 Atomic Absorption Spectrophotometer
6.17 Ultrasonic Thickness Measurement
6.18 Data Recorders
7. Vibration Monitoring
7.1 Principles of Vibration Monitoring
7.2 Misalignment Detection
7.3 Eccentricity Detection
7.4 Cracked Shaft
7.5 Bowed and Bent Shaft
7.6 Unbalanced Shaft
7.7 Looseness
7.8 Rub
7.9 Bearing Defects
7.10 Gear Fault
7.10.1 Gear Meshing Frequency for Planetary Gear
7.11 Faults in Fluid Machines
7.11.1 Cavitation-Induced Vibration
8. Noise Monitoring
8.1 Introduction
8.2 Acoustical Terminology
8.2.1 Sound Pressure Level
8.2.2 A-Weighting
8.2.3 Sound Power Level
8.2.4 Sound Intensity Level
8.2.5 Octave Frequency Bands
8.3 Noise Sources
8.4 Sound Fields
8.4.1 Near-Field Condition
8.4.2 Far-Field Condition
8.5 Anechoic Chamber
8.6 Reverberation Chamber
8.7 Noise Measurements
8.8 Noise Source Identification
9. Electrical Machinery Faults
9.1 Introduction
9.2 Construction of an Electric Motor
9.3 Faults in Electric Motor
9.4 Fault Detection in Electric Motors
9.5 MCSA for Fault Detection in Electrical Motors
9.5.1 Broken Rotor Bar
9.5.2 Eccentricity-Related Faults
9.5.3 Bearing Faults
9.6 Instrumentation for Motor Current Signature Analysis
9.7 Fault Detection in Mechanical Systems by MCSA
9.7.1 Relation between Vibration and Motor Current
9.7.2 Fault Detection in a Submersible Pump
9.8 MCSA for Fault Detection in Any Rotating Machine
9.9 Fault Detection in Power Supply Transformers
9.10 Fault Detection in Switchgear Devices
10. Thermography
10.1 Introduction
10.2 Thermal Imaging Devices
10.2.1 Optical Pyrometer
10.2.2 Infrared Cameras
10.3 Use of IR Camera
10.4 Industrial Applications of Thermography
10.4.1 Leakage Detection
10.4.2 Electrical and Electronic Component Heat Generation
10.4.3 Building Condition
10.4.4 Machineries
10.5 Applications of Thermography in Condition Monitoring
11. Wear Debris Analysis
11.1 Introduction
11.2 Mechanisms of Wear
11.2.1 Adhesive Wear
11.2.2 Abrasive Wear
11.2.3 Corrosion Wear
11.2.4 Fatigue Wear
11.3 Detection of Wear Particles
11.3.1 Spectroscopy
11.3.2 Ferrography
11.3.3 Particle Count
11.4 Common Wear Materials
11.5 Oil Sampling Technique
11.6 Oil Analysis
11.7 Limits of Oil Analysis
12. Other Methods in Condition Monitoring
12.1 Introduction
12.2 Eddy Current Testing
12.3 Ultrasonic Testing
12.4 Radiography
12.5 Acoustic Emission
13. Machine Tool Condition Monitoring
13.1 Introduction
13.2 Tool Wear
13.3 Sensor Fusion in TCM
13.4 Sensors for Tool Condition Monitoring
13.4.1 Direct Tool Wear Measurements
13.4.1.1 Dimensional Deviation
13.4.1.2 Tool-Work Electric Resistance and Radioactivity Analysis
13.4.1.3 Optical Sensors
13.4.2 Indirect Tool Wear Measurement
13.4.2.1 Force Sensor
13.4.2.2 Vibration Sensor
13.4.2.3 Surface Roughness
13.4.2.4 Cutting Temperature
13.4.2.5 Spindle Current, Voltage, and Power
13.4.2.6 Torque Sensor
13.4.2.7 Microphone
13.4.2.8 Acoustic Emission Sensor
13.5 A Tool Condition Monitoring System
13.5.1 Tool Wear Estimation in a Face Milling Operation
13.6 Other Manufacturing Operations
14. Engineering Failure Analysis
14.1 Introduction
14.2 Overview of Failure Analysis
14.3 Failure Modes
14.4 Failure Analysis
14.4.1 Manufacturing and Installation Defects
14.4.1.1 Metal Removal Processes
14.4.1.2 Metal-Working Processes
14.4.1.3 Heat Treatment
14.4.1.4 Welding
14.4.1.5 Cleaning/Finishing
14.4.2 Assembly at Factory/Installation at Site
14.4.2.1 Inspection Techniques
14.4.3 Laboratory Analysis
14.4.4 Material Selection
14.4.5 Failure Investigation Procedure
14.5 Failure Analysis Sampling Guide
14.5.1 Before Beginning Sample Removal
14.5.2 Selection of Samples for Laboratory Evaluation
14.5.3 Sample Removal
14.5.4 Packing and Shipping
14.5.5 Assembling Background Data
14.5.5.1 Information about the Failed Components
14.5.5.2 Information about the Failure
14.5.6 Analyzing the Data
14.5.7 Preparing the Failure Report
14.5.8 Preservation of Evidence
15. Case Studies
15.1 Introduction
15.2 Bend Pulley Failure Analysis
15.2.1 Design Audit
15.2.2 Resonance Conditions
15.2.3 Metallurgical Composition
15.2.4 Hardness
15.2.5 Visual Inspection of the Failed Shell
15.2.6 Microstructure Analysis
15.2.7 Summary of Observations
15.2.8 Recommendations
15.3 Root Cause Analysis of Torsion Shaft Failure in a Cement Plant
15.3.1 Vibration Measurement
15.3.2 Vibration Analysis
15.3.3 Recommendations
15.4 Failure Analysis of a Conveyor System Support Structure
15.4.1 Static Stress Analysis
15.4.2 Material Tests
15.4.3 Additional Load on Existing Design
15.4.4 New Design for Increased Load Capacity
15.4.5 Conclusions and Recommendations
15.5 Vibration Measurements on a Motor-Multistage Gearbox Drive Set
15.5.1 Summary of Observations Made
15.5.2 Conclusions and Recommendations

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