MFD MEE6039 Rahul Kumbhare

Digital Assignment-01 (19MCD0034)

Machine Fault Diagnostic DA-01

A. Explain representation of bathtub curve and Criticality Index in

condition monitoring.

The Bathtub Curve is basically used to identify the failure rate with respect to
operating life of components. The typical machine failure rate versus time plot is given in
Fig. (1.5).The plot has three distinct zones:
 The Infant Mortality Zone
 The Useful Period
 The Wear-Out Zone.

Fig.1: Bathtub Curve

M.Tech CAD/CAM School of Mechanical Engineering

MFD MEE6039 Rahul Kumbhare
Digital Assignment-01 (19MCD0034)

The infant mortality zone with high failure rates occurs in the early stages of the
machine. There could be several reasons for such high failure rates; some of them are faulty
installation at the site, ignorance and unfamiliarity of the machine operator, improper
electrical power supply, no availability of a user or training manual, improper specifications,
and choice of the machine.
Once the above reasons are sorted out, the machine’s failure rate reduces
significantly; this state of the machine continues for a considerable time, which is known as
the useful life of the machine.
Finally, toward the end of the useful period, the failure rate of the machine again
increases, which can be due to excessive wear and tear on the machine and fatigue failure of
the machine component. Though by maintenance the failure rates can be controlled and
reduced, a time comes when the cost of maintenance or upkeep is so high that it is better to
completely replace the machine with a new one. The shape of the curve in Fig. (1.3), is in the
form of a bath tub, hence the name.

Fig.2 Bathtub Curve

M.Tech CAD/CAM School of Mechanical Engineering

MFD MEE6039 Rahul Kumbhare
Digital Assignment-01 (19MCD0034)

The availability of the machine is defined as the ratio of the useful period (also known
as uptime) to the total lifespan of the machine. Maintenance engineers strive to increase the
availability of a machine by decreasing the machine’s downtime. The total lifespan of a
machine is the summation of the uptime and downtime of the machine

Criticality Index provides a comparative measure of the relationship between the

probability of failure (PoF) and the consequence of failure (CoF) of an asset at a particular
point in time.
The Criticality Index is often used to determine the degree on condition monitoring on
a given machine taking into account the purpose of the machine, redundancy (i.e. if the
machine fails, is there a standby machine which can take over), cost of repair, downtime
impacts, health, safety and environment issues and several other key factors.

Fig (2). Risk Zones as per the Criticality Factor

M.Tech CAD/CAM School of Mechanical Engineering

MFD MEE6039 Rahul Kumbhare
Digital Assignment-01 (19MCD0034)

The criticality index puts all machines into one of three categories:

1. Critical Machinery:
 Machines that are vital to the plant or process and without which the plant or
process cannot function. Machines in this category include the steam or gas
turbines in a power plant, crude oil export pumps on an oilrig or the cracker in an
oil refinery.
 With critical machinery being at the heart of the process it is seen to require full
on-line condition monitoring to continually record as much data from the
machine as possible regardless of cost and is often specified by the plant
insurance.
 Measurements such as loads, pressures, temperatures, casing vibration and
displacement, shaft axial and radial displacement, speed and differential
expansion are taken where possible.
 These values are often fed back into a machinery management software package,
which is capable of trending the historical data and providing the operators with
information such as performance data, and even predict faults and provide a
diagnosis of failures before they happen.

2. Essential machinery:
 Units that are a key part of the process, but if there is a failure, the process
continues. Redundant units (if available) fall into this realm.
 Testing and control of these units are also essential to maintain alternative plans
should critical machinery fail.

3. General-purpose or balance of plant machines:

 These are the machines that make up the remainder of the plant and normally
monitored using a handheld data collector as mentioned previously to periodically
create a picture of the health of the machine

M.Tech CAD/CAM School of Mechanical Engineering

MFD MEE6039 Rahul Kumbhare
Digital Assignment-01 (19MCD0034)

B. By citing an application, explain how the dynamic wear debris image

processing system is used in non-destructive evaluation.

 Mechanical debris is an important product of friction wear, which is also a crucial

approach to know the running status of a machine. Many studies have been conducted
on mechanical debris in related fields such as tribology, instrument, and diagnosis.
 To identify a machine health condition, the failure mechanism should be known.
Among failure modes, wear fault is the most common type which is unavoidable.
Although different friction pairs exist in a machine, they are essentially composed of
two friction surfaces which move for each other.
 Their functions are transferring and transforming power so that the machine could
achieve a specified movement. During the movement, power is inevitably lost in the
movement, which is dissipated as heat and vibration and damages friction surfaces.
 By ignoring the running-in period, the wear rate of a friction pair is almost
continuously increasing. In the early stage of this wear process, the friction surface
gradually becomes rough caused by debris generation that will increase the mechanical
vibration.
 The friction surface is also heated by the energy released from asperity deformation so
the metal performance of the wear surface would be further degraded. These two
effects lead to that friction wear becomes more and more severe and finally causes
component damage and system failure.

In general, a four-ball test rig produces sliding wear debris. However, fatigue and
pitting wear often occur when the machine runs in the high load and speed conditions.
When the steel balls are in metal-to-metal contact, a large amount of heat is generated and
oxidation wear occurs. To reveal the wear mechanisms, the shape and colour of individual
wear debris were extracted to recognise particle types.

M.Tech CAD/CAM School of Mechanical Engineering

MFD MEE6039 Rahul Kumbhare
Digital Assignment-01 (19MCD0034)

Fig: Experimental set-up includes (a) principle of particle imaging sensor and (b) schematic
sketch of oil cup

 Above analysis results demonstrate that the wear rate and wear mechanism are
independent indicators for the wear characterisations.
 The quantity, shape and colour characteristics of dynamic wear debris are used to
examine these two aspects to comprehensively identify the wear status.
 Compared to where particle information was used for wear rate assessment, it enables
that more wear information is extracted for wear mechanism examination.
 Although the capacity of this development is demonstrated by identifying fatigue and
sliding wear as well as oxidation, by extracting more particle features from multi-view
images, such as length-to-width ratio and sphericity more wear debris including
cutting and sphere particles can be recognised.

M.Tech CAD/CAM School of Mechanical Engineering

MFD MEE6039 Rahul Kumbhare
Digital Assignment-01 (19MCD0034)

Fig: Identification of the wear debris

 Wear particle characteristics, including quantity, size, shape, colour, are widely used to
reveal wear conditions. In particular, the amount or concentration of wear particles are
used to determine wear rate and wear severity.
 The size and shape features contain the information of wear severity and wear
mechanisms. The colour can indicate the wear sources, as well as oxidation wear.
 The particles are sampled in moving conditions to image individual particles, and they
are counted by utilizing video streaming for wear rate analysis. The particle quantity is
as input of a mean-shift algorithm.
 Different wear processes are thus identified based on the clustering results. By doing
this, a full-life evolution of wear states is obtained.

C. Discuss about importance for condition monitoring in industrial

applications.
Machine condition monitoring is the process of monitoring the condition of a machine
with the intent to predict mechanical wear and failure. Vibration, noise, and temperature
measurements are often used as key indicators of the state of the machine. Trends in the data
provide health information about the machine and help detect machine faults early, which
prevents unexpected failure and costly repair.

Machine condition monitoring is important because it provides information about the

health of a machine. You can use this information to detect warning signs early and help your

M.Tech CAD/CAM School of Mechanical Engineering

MFD MEE6039 Rahul Kumbhare
Digital Assignment-01 (19MCD0034)

organization stop unscheduled outages, optimize machine performance, and reduce repair
time and maintenance costs. Figure (3.1) shows a typical machine failure example and the
warning signs.

The following list includes the main condition monitoring techniques applied in the
industrial and transportation sectors:
 Condition Monitoring Overview
 Vibration analysis and diagnostics
 Lubricant analysis
 Acoustic emission
 Infrared thermography
 Ultrasound
 Oil Condition Sensors
 Motor condition monitoring and motor current signature analysis (MCSA)
 Model-based voltage and current systems (MBVI systems)

M.Tech CAD/CAM School of Mechanical Engineering

MFD MEE6039 Rahul Kumbhare
Digital Assignment-01 (19MCD0034)

Types Of Machine Condition Monitoring:

 Route-based monitoring involves a technician recording data intermittently with a

handheld instrument. This data is then used for trending to determine if more
advanced analysis is needed.
 Portable machine diagnostics is the process of using portable equipment to monitor
the health of machinery. Sensors are typically permanently attached to a machine and
portable data acquisition equipment is used to read the data.
 Factory assurance test is used to verify that a finished product meets its design
specifications and to determine possible failure modes of the device.
 Online machine monitoring is the process of monitoring equipment as it runs. Data
is acquired by an embedded device and transmitted to a main server for data analysis
and maintenance scheduling.
 Online machine protection is the process of actively monitoring equipment as it
runs. Data is acquired and analysed by an embedded device. Limit settings can then
be used to control turning on and off machinery.

Significance:
 Faults always develop in machinery and even the most thorough and comprehensive
routine maintenance programme cannot stop that. Therefore, it’s important to have
condition monitoring put in place as it puts you in the driving seat to actively prevent
breakdowns and optimise maintenance resources where and when they are needed.
 Making it part of your routine maintenance is critical as it allows you to get to know the
equipment better and allows for long-term productivity.
 The benefits of a prognostic maintenance tool are that it can be employed to not only
recognised developing faults within a machine but also to identify factors within a
machine that caused these faults to develop in the first place.
 Condition monitoring is an efficient, non-intrusive process with the potential to save
thousands of pounds in secondary damage, lost production and unnecessary
maintenance.
 The data collection not only helps to identify problems before a breakdown occurs
which can cut the average repair time by 60%, but it can also help companies
streamline their operations and cut costs.

M.Tech CAD/CAM School of Mechanical Engineering

MFD MEE6039 Rahul Kumbhare
Digital Assignment-01 (19MCD0034)

 All manufactured and processed goods are subjected to severe international competition
in today's marketplace. Accordingly, consumers' perceptions towards order winning
criteria such as total quality, reliability, health and safety, environmental issues, energy
conservation and the cost of ownership are changing day by day.
 To match the dynamics of the marketplace, and to provide the goods required,
industrial machinery and systems are therefore also changing.
 For example, the speed of rotating machinery, together with the capabilities of their
control and processing systems, are now improving at an ever-increasing rate.
 Many of these machines are currently being designed to operate almost super critically,
and this trend is likely to continue under the competitive demands of the marketplace.
 Thus, the monitoring and control of excessive vibration, noise, thermal variation, dust
and dangerous emissions from plant and machinery of various types are now required
by law in many countries.

M.Tech CAD/CAM School of Mechanical Engineering