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CONDITION MONITORING LEARNING OBJECTIVES

TABLE OF CONTENT

7701: Maintenance Management

7702: On-Line Condition Monitoring

7703: Vibration Monitoring & Analysis

7704: Non-Destructive Examination Techniques

7705: Electrical Testing

7706: Liquid Analysis

7707: Applications of Condition Monitoring

7701: Maintenance Management

The objective of this module, first in the series on Condition Monitoring, is to focus attention on the overall maintenance task, the different levels of maintenance required, and the development of Predictive Maintenance with its attendant need for "condition monitoring". After completion of this video and associated workbook, the participant should be able to understand the following concepts and apply them in day-to-day activities:

  • Machine (equipment) life span.
  • Reasons for degradation.
  • Functional failure.
  • Component failure.
  • Boiler -- mechanisms of degradation.
  • Turbine -- mechanism of degradation.
  • Electrical plant insulation.
  • Consequences of degradation.
  • Effect on safety, availability, performance.
  • Loss of capacity and efficiency.
  • Features of scheduled preventive maintenance (P.M.).
  • Negative aspects of P.M.
  • Need for continuous review and modification of P.M. schedule.
  • Corrective maintenance.
  • Running plant inspection.
  • Reliability Centered Maintenance (RCM)
  • Predictive Maintenance.
  • Trend analysis.
  • Condition monitoring on-line.
  • Introduction to condition monitoring techniques.
  • Off-line NDE testing.
  • Maintenance control documentation.
  • Features of a computerized maintenance control program.
  • Retention and access to P.M. schedule
  • Issue and control of work orders.
  • Retention and access to equipment history files.
  • Access to warehouse information, i.e. spare parts and inventory.
  • Ready access to maintenance data by other parties.

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7702: On-Line Condition Monitoring

The objective of this videotape is to present major features of an on-line condition monitoring program. The videotape also indicates various techniques used to monitor equipment and also demonstrates how one should analyze the data after it has been collected. In the final segment, plant performance testing is discussed, as part of the condition monitoring program. Upon completion of this videotape and workbook exercises, the participants should be able to understand the following concepts, and apply them in work activities:

  • What a Mollier Diagram is composed of and how the steam expansion through a turbine can be
  • On-line and off-line measurement of degradation.
  • How often selected systems and components should be monitored for an on-line condition monitoring program.
  • Failure analysis of systems and components.
  • Major consequences of failure of critical equipment.
  • Definitions of failure rate.
  • Analysis methods used to examine data that has been collected and entered into the condition monitoring program.
  • The significance of the rate of change (Trend Analysis).
  • Predicting degradation.
  • The definitions of the four limits used in the Test Against Limits method.
  • The principle of thermography.
  • The importance of preventing interference when using an infrared camera for Thermography.
  • Interpretation of the thermogram.
  • Limitations of thermography.
  • Why a lubricating oil analysis is conducted.
  • Acoustic leak detection.
  • The significance of turbulent flow.
  • Why an ultrasonic leak detector is used.
  • The function of a thermocouple.
  • How thermocouples differ.
  • The function of an RTD (Resistance temperature detector).
  • Application of temperature sensors in the power plant.
  • Flow measurement devices.
  • The kind of instruments that are used to measure pressure.
  • Spotting degradation from performance testing.
  • Elementary testing of pumps, compressors, heat exchangers, boilers and turbines.
  • Definition of heat rate and efficiency.

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7703: Vibration Monitoring & Analysis

The objective of this module is to provide an understanding of vibration in machinery, including modes of vibration measurement. Typical examples of vibration analysis are presented, plus an introduction to the technique of balancing. After completion of this video and associated workbook, the participant should be able to understand the following concepts, and apply them in day-to-day work activities.

  • The causes and consequences of vibration in machines and structures.
  • Physical displacement due to vibration.
  • Plotting displacement against time.
  • The effect of frequency on determining the severity of vibration.
  • The objectives of a vibration monitoring scheme.
  • The application of portable vibration measuring equipment for routine collection of data from major items of equipment.
  • Trending and analysis of vibration data.
  • The installation of continuous vibration monitoring equipment on major items of plant such as turbine generators.
  • Relationship between the three modes of vibration measurement: displacement, velocity, and acceleration.
  • Units of measurement for displacement, velocity of vibration, and acceleration.
  • Vibration measuring devices.
  • Frequency range of different types of vibration transducer.
  • The meaning of "natural frequency" and resonance.
  • The significance of rotation at "critical speed".
  • The complex waveform due to multiple components of vibration at harmonic frequencies.
  • Separating out vibration components according to their individual frequencies.
  • Analyzing the frequency spectrum.
  • Examples of vibration signature and its causes.
  • Measuring and correcting for static imbalance.
  • Measuring the phase angle of imbalance.
  • Dynamic balancing.

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7704: Non-Destructive Examination Techniques

The objective of this module is to present an overview of different types of NDE testing techniques which are performed on mechanical equipment. Various techniques are demonstrated, noting their suitability for identifying particular types of material defects and degradation. After completion of this module, the participant should be able to understand the following concepts and recognize their application in condition monitoring practice.

  • The meaning of NDE - Non-Destructive Examination.
  • The contribution of NDE to the maintenance program.
  • Types of defects found in metallic materials.
  • The effect of material wastage due to corrosion and erosion.
  • Crack formation and consequent effects.
  • The long-term effects of creep on high temperature components.
  • Visual inspection of disassembled equipment.
  • Use of the borescope and fiberscope for viewing machine internals.
  • NDE techniques commonly used to detect surface irregularities such as cracks.
  • Procedures for performing the liquid penetrant test, magnetic particle test, and the eddy / current test.
  • Features, advantages, and limitations of the above tests.
  • Tests on machine surfaces, castings, plates, tubes, rotating elements, and heat exchangers.
  • Comparison of test methods. The effect of test piece material (i.e. copper, iron, alloy, etc.) on selection of test method.
  • Techniques for detecting subsurface defects.
  • Ultrasonic testing ¾ features, advantages, and limitations.
  • Interpretation of ultrasonic test results.
  • The application of radiography for detecting flaws, particularly in high pressure welding.
  • Features, advantages, and limitations of radiography.
  • The need for observance of safety procedures when handling radioactive sources such as X-rays, and gamma rays.
  • The application of replication techniques for testing degradation of high temperature components.
  • On-line NDE techniques for continuous monitoring.
  • The use of sample coupons to measure the rate of corrosion and erosion in pipelines.
  • Application of the electrical resistance probe for continuous measurement of corrosion and erosion in pipe-work.
  • The application of acoustic emission techniques for measuring strain in material.
  • The application of radioactive isotopes as tracers to measure flow or leakage in. pipe work
  • Summary and comparison of the major techniques of NDE inspection.
  • Examples of NDE techniques used to measure degradation in boilers, heat exchangers, turbines, and pipe-work.

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7705: Electrical Testing

The objective of this module is to present and discuss the types of electrical tests being performed today for condition monitoring of large high voltage equipment such as generators and transformers. This includes "off-line" and "on-line" testing. After completion of this module and associated workbook, the participant should be able to understand the following concepts, and employ these in work activities.

  • The nature of conductor insulation, its function, common defects and deterioration.
  • Characteristics of the insulation resistance test (IR) and polarization index.
  • The effect of insulation conditions (moisture, dirt) on insulation resistance.
  • Temperature correction of IR readings for comparison purposes and trending.
  • Measurement of leakage current by the DC highpot test.
  • Calculation of maximum highpot test voltage allowed.
  • Generator construction and areas of concern.
  • The insulation of conductor strands, conductor bars, and slot insulation.
  • The function of slot wedges and the effect of loose wedges.
  • Means of testing wedge tightness.
  • Stator winding tests.
  • Iron core tests for inter-lamina imperfections.
  • Generator rotor tests.
  • On-line tests of stator winding - Partial Discharge Analysis (PDA).
  • The effect of partial discharges within insulation.
  • Methods of measuring partial discharges.
  • Types of PDA couplers.
  • Interpretation of PDA results.
  • The effect of loading on PDA discharge activity.
  • Required loading conditions for performing PDA tests.
  • Electrical testing of transformers.
  • The insulation dissipation factor (Power factor Test).
  • Electrical testing of motors, switchgear, and cables.

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7706: Liquid Analysis

The objective of this module is to present and discuss techniques of liquid analysis in order to collect data for condition monitoring of equipment. In particular insulating oils, lube oils, and water analysis are dealt with. After completion of this module, the participant should be able to understand and apply the following concepts in day-to-day activities:

  • Liquid analysis can provide indications of:
      1.Deterioration of the liquid itself.
      2.Change in the make-up of the liquid due to degradation of the equipment.
  • The application of dissolved gas analysis (DGA) to transformer insulating oils.
  • Trending of DGA analysis data.
  • Typical guideline limits of DGA values.
  • Physical properties of insulating oil for transformers and switchgear.
  • The effects of oxidation of insulating oil.
  • The significance and interpretation of tests for acidity, surface tension, color, and oil power factor.
  • Typical limits allowed on test results of oil physical properties.
  • The testing of lubricating oils.
  • Degradation of lube oil in closed cycle operation.
  • The significance of viscosity, acidity, pour point, flash point.
  • Test for lube oil contamination.
  • Analysis of particulate matter in lube oil.
  • Sources of wear products that may be present in lube oil particulates.
  • Power plant water systems.
  • Water analysis for condition monitoring data.
  • Corrosion and its causes.
  • The effect of corrosion products.
  • The formation of scale and deposits.
  • Conductivity measurement.

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7707: Applications of Condition Monitoring

The objective of this module is to demonstrate the application of condition monitoring techniques in different types of power plant, including hydro-electric, gas turbine combined cycle, reciprocating engine, and steam turbine generation. After completion of this module, the participant should be able to understand the following concepts and apply them in day-to-day work practice.

  • The three methods of collecting data from machinery and equipment.
      On-line continuous monitoring.
      On-line intermittent monitoring.
      Off-line physical measurements and NDE.
  • Typical temperature and pressure measurements in hydro-electric units.
  • Continuous vibration measurement by permanently installed equipment.
  • Intermittent vibration measurement of major auxiliaries by hand held equipment.
  • Interpretation of trends.
  • The significance of lube oil analysis to indicate its condition, and level of contamination.
  • The importance of insulating oil analysis, including dissolved gas content.
  • The application of partial discharge analysis tests to generator stator winding insulation. This is an on-line test.
  • Measurement of air gap between rotor and stator.
  • Typical off-line electrical tests on hydro generators.
  • Standard maintenance inspection procedures as part of off-line measurement to assess machine condition. For example:
      Generator wedge tightness.
      Turbine runner clearances.
      Degree and location of runner cavitation.
      NDE testing for cracks in the runner crown and other critical locations.
  • The need for review and assessment of condition monitoring data, and subsequent remedial action.
  • Who should be involved in condition monitoring within the power plant.
  • Typical monitoring points in a hydropower plant.
  • Typical monitoring points in a gas-turbine plant
  • Typical monitoring points and inspection frequency in a reciprocating engine generation plant.
  • Typical monitoring points and inspection frequency in a steam turbine power plant.
  • Coordination and integration of condition monitoring activities with scheduled maintenance.