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In simple words, CBM is a preventive maintenance carried out

at irregular intervals based on actual condition of the
machine.

Carried out by monitoring the health and condition of
machines regularly by observing, checking, measuring certain
parameters and signals.

CBM a.k.a Equipment Health Monitoring(EHM).
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M/c produces 2 types of signals: Primary and Secondary.
Primary signals are used to assess the performance of the
m/c like production rate, product quality etc. Monitoring
of primary signal- Performance trend monitoring.
Signals like vibration, sound, thermal, chemical and
physical changes are called secondary signals.
The secondary signals are the main causes for loss of
output.
Therefore, monitoring of these secondary signals are
inevitable.
70% of the damages can be found out using sec. signal.
Secondary signals are classified into two:
Dynamic signal- Vibration, sound, leakage, heat etc.
Tribological signal- Friction and wear characteristics,
lubricant contamination and chemical changes.
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CM is not a life extending activity, it only provides information on failure before there is
a breakdown.
Done Off line or On line
Offline
Monitoring equipment is used in parallel to the equipment to be monitored.
Can be Periodic or continuous.
In offline periodic, the monitoring equipment can be made switch on and off
whenever needed (eg: for taking readings).
In offline continuous, the monitoring equipment monitors as long as the machine
to be monitored operates (eg: record readings)
Online
In series.
Generally continuous online systems are used,
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Performance monitoring
Visual, tactile and aural monitoring
Vibration Monitoring
Lubricant Monitoring
Temperature monitoring
Crack Monitoring
Corrosion Monitoring
Sound Monitoring etc..

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Performance monitoring is used to:
Measure variation in production rate

Measure variation in product quality

Efficiency

Power in and out.
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Direct methods
Eye, ear
Optical probes
Microscope, stroboscope
Indirect
Radiograph
X ray
Thermograph
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Most equipment operate in ambient temperature.

Wear, friction can cause heating of m/c parts.

Difference between ambient temperature and that of equipment
operating under load is the temperature rise, and this is monitored
to detect any fault.

Thermometers, Pyrometers, Thermocouples, Thermistors,
Thermography (Infrared radiation scanner), etc
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Thermography or Infrared Camera
Many application: medical fields, inspections, environmental
studies, etc
Thermographic camera or infrared camera is a device that
forms an image (temperature profile) using infrared radiation,
similar to a common camera that forms an image using visible
light.
All objects emit a certain amount of radiation as a function of
their temperatures. Higher the temperature, the more IR
emitted.
EM radiations having wavelength btw 0.75 to 1000 microns is
called IR radiation.

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Thermography or Infrared Camera





IR thermal imaging is a technique of producing 2D
images of temperature in a matter of seconds.

No contact has to be made .
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Factors affecting:
Obstruction b/w sensor and target
Background radiation from objects other than target
Low emissivity
Advantages
Non contact
Safe
Cost effective
Quick problem detection without interrupting service
Prevention of premature failure and extension of life
Can monitor target in motion
Temperature profiles can be recorded and displayed easily.
Wide temperature range can be measured
Application:
Detecting fault in electrical panels, insulators, wirings,
transformers etc.
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Vibration- Heartbeat of machines.

Includes vibration measurement / collection and analysis program

The response is measured by a transducer and is passed to the
analyzer.

The result is then downloaded to the software and further analysis
is made.

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Vibration is rotating/ oscillating of m/c parts, back and forth
from its position of rest.
M/c vibration is very complex consisting of numerous
frequencies due to the vibration of many components.
So it will be very difficult to pinpoint a fault.
Plot of amplitudes and frequencies of all individual vibrating
components of a machine is known as VIBRATION SIGNATURE.
Signature are characteristics of the machine.
Change in this is an indication of impending failure and its location.
Also known as VIBRATION SPECTRUM.




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Vibration transducers: converts vibration i/p to electrical o/p
Eg: Accelerometers, Velocity transducers , PZT actuators
Accelerometer
o/p is directly proportional to acceleration forces.
o/p created by applying force to piezoelectric crystal.
The electrical signal is amplified & displayed as a time waveform.
Velocity Transducer
o/p is directly proportional to velocity of measured unit.
Eg: velocity pickup used for monitoring velocity of rotating machinery.
Consist of magnet suspended on a coil surrounded by a conductive coil.
Movement of transducer induces movement in magnet and results in
generation of electric current
The electrical signal is amplified & displayed as a time waveform.

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PZT (Lead Zirconate Titanate) Actuators:
Is a type of piezoelectric material that changes
dimension when an electric field is applied.
The change in dimension is directly proportional to the
applied electric field.
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a. Fluid Properties Analysis- viscocity, additivies etc
b. Fluid contamination analysis-dirt, soot, water etc
c. Fluid wear debris analysis (Wear particle analysis or Wear Debris
analysis)- worn out metals in lubricants
Types of contaminants:
Rubbing wear particles: Normal wear, small flakes of metals.
Fatigue chunks: Large chunk of metal due to fatigue damage
Sliding wear particles
Cutting wear
Laminar wear
Oxides , rusts etc.
Sources of contaminants:
Built- in contaminants: occur during running of machines
Internally generated contaminants: Wear debris from gears, bearings.
Ingressed contaminants: include moisture, acids etc.
Contamination added during maintenance
Biological contamination
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FERROGRAPHY
Quantifies and examines wear particles suspended in lubricants.
Wear debris present in the lubricant sample are taken on a glass substrate
which is viewed through microscope.
Findings: wear mode, rate, severity and location.
Two types: Direct reading and Analytical
Direct Read Ferrography: quantitative analysis of ferrous particles present in
oil.
Wear particle concentration (WPC)= DL + DS (DL = Density of large particle (>5microns) )
Percentage of large particle = (DL DS) / WPC
Analytical Ferrography: qualitative analysis. Microscopic analysis to identify
the composition of material present.
Powerful magnet is used to trap ferrous particles and analyzed based on metallic and non
metallic.

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SPECTROSCOPIC OIL ANALYSIS PROGRAM (SOAP)
Most widely applied technique for lubricant debris monitoring.
Procedure of extracting fluid samples from operating systems and analyzing
them spectroscopically to determine the concentration of key elements of
contaminants.
Multi elemental analysis of wear debris in lubricating oil.
Iron, Aluminum, chromium, copper, tin, lead, silver etc.. are detectable.
4 independent basic operations:
Sampling - Sampling methods, frequencies.
Spectrometric analysis - Emission spectroscopy and atomic absorption spectroscopy
Diagnosis data interpretation
Validation of the diagnosis
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1. Sampling
Sample should be hot and well mixed with possible
contaminants after a running period.
There are three methods of obtaining sample- sampling
valve, vacuum sampling and drain stream.
Sampling valve- valve is fitted in oil line. No need to shut
down the m/c and wastage of oil is less.
Vacuum sampling- involves a manually operated suction
gun to take oil.
Drain stream- sample is taken when the oil is changed.
Sampling frequency
Importance of m/c, time since overhaul, operating
schedule, safety consideration, etc.
Sampling precaution
Clean, no contaminant, sampling should be done during
operation, sample should indicate the date, hours since
change, etc.
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2. Spectrometric analysis

Two methods of spectrometric analysis:
Emission spectrometry (electric spark) (ESS)

Atomic absorption spectrometry (flame) (AAS)

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Emission spectrometry:
A HV(15000v) causes excitation of metallic particles in
the oil and emits radiations which is then spectrally
analysed.
Spectrometer consists of a narrow slit , prism, exit slit,
photodetector and data processors.

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Atomic absorption spectrometry:
An energy source which emits light- a hollow cathode
discharge lamp.
An energy source to transport and atomize metallic
elements- eg: an air-acetylene gas
Slit, prism and exit slit.
Photodetector
Data processing
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Fluorescent Penetrant Inspection (Zyglo Process)
Used to detect small surface cracks and pores.
Can be used for testing of both ferrous and non-ferrous parts.
Surface of the part to be inspected is cleaned.
Fluorescent is applied on the surface so that cracks are filled
with the applied fluorescent due to capillary action.
The rate and extent of this penetration depends on surface
tension, viscosity etc..
Surface is then washed with water to remove the penetrant
from surface not from the cracks.
Developer is applied so as to enlarge the size of the area of
penetrant indication.
Then the surface is viewed under Black Light (having
frequency between visible and U.V Light). Black Light causes
the penetrant to glow in dark.

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Device which measures the size of any grains or particles found in a given
sample. It checks for size, shape, concentration and distribution of a
specific particle in an item.
A common type is the "laser diffraction particle size analyzer".
Application: Spray paint, so the paint spray nozzle will not clog.
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When this is passed through lens, a
series of light rings emerge on the
focal plane, radius of which are
related to the size of the particles.
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Laser particle size analyzer works according to the optic properties.
Laser beam illuminates the particles distributed in the liquid, the diffraction
and scattering phenomenon take place.
By using photodetectors on focal plane, diffraction and scattering signals
from the particles in different diameters are received.
Signals are transferred to the computer through A/D conversion.