Industrial Maintenance Techniques

Different Condition monitoring technologies for predictive maintenance in industry like vibration, Thermal
Imaging, temperature, oil analysis, current / voltage / power / process variable analysis, acoustic analysis etc.

Sustainable Growth & Solar Energy in India- Challenges

& Opportunities

Sustainable Growth & Solar Energy in India- Challenges &

Opportunities
INTRODUCTION:
The decade of1980s & 90s witnessed the start of IT/Software revolution & those who were the first movers
like Infosys, Satyam, Tata, Wipro, Airtel, Essar etc., got the first mover advantage & reaped the benefits of
the revolution. Similarly the present era is witnessing the start of sustainable technologies revolution &
those who are first movers will get the first mover advantage. The renewable sector is not only important
for the organizational growth per se but also to a greater good of the sustainable development of mankind.
The days are not far ahead when the development of a nation would not be judged by the conventional
GDP but by the Green GDP; the balance sheet of the companies would be evaluated as green balance
sheets.The last century witnessed the tremendous growth in world GDP due to rapid industrialization &
urbanization, particularly in western world but no one bothered about the environmental damage because
of uncontrolled GHG emissions, unsustainable resource utilization & production of excessive waste. The
nature has self-healing mechanism for the impact of pollution which is caused because of natural calamities
& optimum utilization of resources, but it has failed heal the damage inflicted by human on the
environment. The effects like global warming, erratic weather patterns and other harmful effects on flora
& fauna is cause of more concern now. The need of hour is to adopt sustainable technologies for the
development in order to survive on earth. International platforms like UN & IPCC and local government
bodies of different countries are awakening global community to stand in favour of sustainability by
adopting clean & renewable technologies. Ratification& implementation of Kyoto protocol has become
relevant for the world for the survival of mankind.

India is one the fastest growing economies in the world & fourth largest economy in the world. The
relevance of sustainable development & adoption of clean technologies is going to be the most sought of
policy in India. As a second most populous country in the world, there is tremendous pressure on available
non-renewable resources. To continue the present rate of growth & satisfy the ever growing demand of
energy, it needs to adopt clean, green & renewable technologies. India has a very good solar profile &
harnessing this energy alone can solve much of the energy related problems. Moreover the government
policies like preferential tariff, ADR, mandatory RPO (still to be implemented strictly by GOI- to make the
distribution companies & open access consumers to comply RPO regulations) will increase penetration of
renewable technologies in India.

India is also blessed with many rivers & harnessing this hydro power by building small & micro hydro dams
for electricity generation & irrigation can be a sustainable mode of generating electricity without inflicting
damage to environment.

Coastal areas & some parts of southern India/western India/Northern India have a very good wind profile
& a lot of wind sites have developed across the country. Still there is enough potential to develop wind
sector in India. Due to withdrawal of GBI & AD policy the investment has dropped considerably in this sector
over last two years, but in 2013-14 government has introduced GBI & AD policy to boost investment. But
there is a need for long term solution to promote investment without GBI & AD.

As far as biomass is concerned, India has a good potential, but it has been a disappointment on this front.
About 60 per cent of the countrys grid-connected power plants that run on biomass have either shut down
or are on the verge of shutting down.

Analysis of Solar Segment:

Strength:
Sustainable & environment friendly source of energy.
Vast solar potential due to excellent solar profile of the subcontinent.
Government initiatives and schemes for solar development: MNRE is first renewable energy dedicated ministry
in the world which aims to propagate renewable energy across country. Set up of NAPCC that envisages
renewable energy to constitute approximate 15% of the energy mix of India by 2020. Subsidy Scheme to
Promote Solar Energy through the Jawaharlal Nehru National Solar Mission.
Commitment to international treaties like Kyoto Protocol.
Govt schemes like GBI, promotion of solar technologies like water heating, solar home lighting through state
nodal agencies.
Promotion of Solar Thermal Systems for air heating/Steam generating applications, solar buildings and Akshay
Urja Shops.
Development of Solar Cities in 11th FYP.

Weakness:
High cost of solar energy infrastructure.
Solar energy can have difficulty competing with traditional forms of energy on the basis of price.
Poor implementation track record of solar policies.
States not obliging their RPO commitments.
Low investment in solar segment by private players due to lack of clarity of GOI on solar sector.
O&M issues due to poor quality of Chinese products.

OPPORTUNITIES:
Most of the perceived strengths are opportunities if there GOI brings clarity on its solar/renewable policies &
demonstrate will to implement.
Oil, coal and other fossil fuels are a finite resource they will eventually be depleted and there will be rise in its
costs. Over a period of time it presents an opportunity for theSolar industry to compete on the basis of
price, eventually becoming cheaper than fossil fuels in market as well as environmental cost.
India is a power starved state & its most of the rural/hilly areas dont have even 8 hrs/day power. This is an
opportunity for the solar/renewable technologies. We can provide renewable energy to the deprived mass
& help the country to develop by providing cost effective& clean power to this segment. Solar irrigation,
power generation, solar heating, solar lighting, development of mini grids in these areas are real
opportunities of growth.
India has huge renewable energy resources, especially solar energy. It can be a major source of income to
generate renewable energy& earn REC / CC (Carbon Credits which can be traded in domestic / international
markets.

Threats:
Availability of efficient & latest technology for power generation is causing percolation of relatively less
efficient / high maintenance technologies, making to look the investment unviable.
High initial installation cost, lack of proper financing mechanism, lack of private investment & financial risks.
Lack of appropriate laws & policies, lack of will to implement the available policies, bureaucratic & procedural
delays in clearing projects.
Supply chain issues.

Some potential areas in solar segment to explore:

Grid connected solution: As per Jawaharlal Nehru National Solar Mission, grid connected
solar power has been planned to be 1100 MW by 2010-13 in phase-I, 4000-10000 MW by 2013-17 in phaseII & 20,000 MW by 2017-22 in phase-II. PV & Solar Thermal are two proven technologies in this area.

DC Pump Irrigation Solution: At present Ac solar water pumps are being used widely, but
DC solar water pumping is technology of future as its more efficient & maintainable. There are only few
players in DC segment& is a good opportunity for growth. Along with DC pump, there is scope for
popularizing Sprinkler irrigation technology (a booster pump with additional solar panel to boost pressure)
could be used to reduce the water wastage.

O&M of Solar Installations: The solar PV installations in India are not very old now but in
few years they will be out of warranty & would require O&M contractors to maintain these assets. The user
would get following benefits:
Optimization of plant production for increased asset revenue
Reduction of risks for asset owners and investors
Protection of asset value and longevity
Compliance with applicable regulations
Transparency on plant production, performance, issues, risks and O&M activities

Hydro Power:

Mini & Micro Hydyl power promises a clean energy without degrading the

environment. India has a big network of rivers & canal system. The commercially viable & technically
suitable locations can be used for generation of clean electricity.

Energy/REC Trading: RECs are interstate tradable certificates issued for every unit of renewable
energy produced. Mechanisms such as these are essential to achieve NAPCCs goal of increasing the
mandatory RE usage for states from 5% today to approximately 15% in the next 10 years. Instead of
producing RE by their own, states can purchase RECs from each other to increase their RE content in total
energy. This mechanism will enable low RE potential states to purchase RECs from high potential states,
enabling them to meet NAPCCs increased demands. Moreover, these purchases will incentivize high RE
potential states to produce more RE than required currently, enabling overall increase in RE production.

Innovation in Present Offerings:

R&D on renewable portfolio solutions to make them affordable & reliable.

DC
irrigation
pumps
with
pressure
booster
pump&
Online / offline condition monitoring system for O&M of solar solutions.

sprinkler

system.

Consultancy on Sustainability:

Over a period of time each country will have to comply the

international rules on emission reduction & sustainability. Here lies the scope for consultancy to
government/organization on sustainability.

Carbon Trading as a Source of Revenue: Solar power generation emits lesser amount of
CO2 compared to conventional sources of energy such as coal. Trading this reduction in the emissions
trading market can be another source of income. We estimate that on an average considering the current
rate of emissions trading - savings of anywhere between Rs 0.9-1.5 can be achieved per unit of electricity
produced. This will partially help in offsetting the high cost of solar production.

Consultancy & establishment of renewable Mini Grids: In India power availability is

still an issue with its rural / hill area population & the current national grid is not delivering the same value
to them as compared to urban population. Development of mini-grids would be major step to solve the
power availability problem of the large strata of the population.

VIBRATION- SYNCHRONOUS ASYNCHRONOUS &

SUB-SYNCHRONOUS SPECTRUM ANALYSIS
SYNCHRONOUS, ASYNCHRONOUS & SUB-SYNCHRONOUS SPECTRUM ANALYSIS

The raw vibration data consists of a wide range of frequencies & its analysis in raw form
is very complex job. To analyse the data, we have to take the help of technology. FFT
Analysis is a very good tool for analysing rotating assets. Raw vibration signal can be
analysed in three ways-

Synchronous Vibration Analysis

Asynchronous Vibration Analysis
Sub-Synchronous Vibration Analysis
Synchronous: The synchronous time averaging technique is used to detect the source of
vibration at the 1X frequency. 1X frequency is the running speed of the machine. The
vibration probe collects the data & the speed probe give the speed information mounted
on the reference shaft. This running speed is tracked& the time averaged 1X data is
monitored & analysed. This is very useful in the machine trains with variable speeds or if
many other machines are running at close proximity to machine under measurement.
Rotor related problems like imbalance, misalignment; rotor related looseness & rotor rub
can be identified by using this technology. Other peaks are discarded.

Asynchronous Vibration Analysis: Asynchronous time averaging technique is used to

detect the vibration components that are not related to rotating speed & are above 1X
speed i.e. above the running speed. These faults are bearing fault, electrical noise,
cavitation, etc. Resonance also produces asynchronous frequencies.

Sub-Synchronous Vibration Analysis: Sub-synchronous time averaging technique is used

to detect problems like severe bearing looseness, rotor rub, vibration from nearby
machines, belt vibrations & other low frequency components. These are below 1X running
frequency.

THERMOGRAPHY (THERMAL IMAGING) AN

INTRODUCTION
In this section we will discuss about thermal imaging, another powerful tool in machine diagnostics
& predictive maintenance arena. Thermography is an art & science to detect & measure radiation
using electro-optical device & correlating to surface temperature of the subject. The history of
thermal imaging can be understood by looking at the certain chronological developments in past.
In 1672 Newton passed a beam of light though a prism & observed a coloured strip of light
containing the colours purple, blue, green, yellow, orange and red. Later on Sir Frederick William
Herschel in 1800 made an important discovery by moving Newtons experiment one step ahead.
He placed glass thermometers on different spectral colour patterns & observed a rising trend in
temperature from blue to red colour spectrum. He also observed that the temperature beyond the
visible colour spectrum was even higher. He concluded from this experiment that an invisible form
of energy must be at work in that range, and that the sun emits invisible radiation beyond the visible
light range. He called this radiation as ultra-red, now known as infrared radiation.

The laws of radiation that revolutionized the field of thermal imaging-

Kirchhoffs Radiation Law: This states that every type of matter continuously radiates energy. The
radiant energy is visible or invisible, depends on the temperature. Later on Kirchhoff coined the
term Black Body which means that a body always emits precisely as much heat as it absorbs.
Hertz oscillator & Stefan-Boltzmann-law: In 1865 James C. Maxwell first predicted the assumption
that light consists of electromagnetic waves which was later confirmed experimentally by Heinrich
Rudolf Hertz. Josef Stefan and Ludwig Boltzmann refined Gustav Kirchhoff's theory in 1884 and
established the findings of their research in the Stefan-Boltzmann law which states that the total
thermal energy emitted by a black body depends on that body's intrinsic temperature.
Plancks radiation law: In 1900 Max Planck did a breakthrough discovery which laid foundation of the
present day understanding of electromagnetic radiation & gave birth to quantum physics, & still
regarded as physical basis for thermography. It defines the intensity distribution of the
electromagnetic energy emitted by a black body as a function of temperature, wavelength and
frequency.
In principle thermograph is device to detect temperature pattern in the infrared wavelength of the
subject. It started with the Herchels experiment & later on after discovery of seeback effect, which
led to invention of the thermomultiplier, an early version of a thermocouple by Leopoldo Nobili.
Samuel Langley used bolometer to detect body heat from a cow from a distance of 304 m. Sir
William Herschels son Sir John Herschel, used a device called an evaporograph and produced
the first infrared image in 1840. From photo-conducting detectors in early phase, the thermal
imaging technology has advanced a lot till date. Unlike earlier cumbersome cooled detectors, now
a days much sophisticated, uncooled simple detector technology is available at a reasonable price
in the market. Till 1960s the thermography technology was basically used in military applications
but after that, non-military applications like medical, industrial & building maintenance stated taking
prominance. Today thermography has emerged as a proven predictive maintenance technology in
the industrial domain.

VIBRATION ANALYSIS TECHNOLOGIES:

VIBRATION ANALYSIS TECHNOLOGIES:
Amplitude Monitoring: We all know that all machines vibrate. But the question is what the
acceptable limit of this vibration is? Basically it all depends on the machine type & its design. OEM
gives a different vibration limit of alarm & trip for different machines. The different vibration
technologies that can be employed for root cause analysis depends on the vibration transducer
involved in picking up the data.
With contact type transducers following analysis can be performed1. Amplitude monitoring & analysis of asset deterioration over a period.
2. Frequency (FFT technology) - Raw time domain signal is broken into frequency domain signal by
FFT technique (Fast Fourier Transform). As different frequencies are associated with a peculiar
machine characteristic, by comparing the amplitudes of a good machine spectra & test machine
spectra, it is possible to pinpoint troubles very accurately. For example 1X (one times the running
frequency) frequency is responsible for unbalance, 2X for misalignment etc.
With proximity (non-contact) type transducers following analysis can be performed1. Amplitude monitoring & analysis.
2. Frequency (FFT technology)
3. Phase: Phase is the position of a rotating part at any instant with respect to a fixed point. Phase tells
about the vibration direction. Phase becomes very useful when the source of the vibration is not
clear. Various useful insights regarding problems like Machine Soft Foot, Cocked Bearings and
Bent Shafts, Imbalance confirmation, Looseness, Bending or Twisting, Shaft misalignment etc. can
be identified by phase analysis.
4. Form Analysis (Orbit Analysis): X-Y plane time domain signal plot: For performing orbit analysis, the
input signals from the two proximity sensor placed at 90 with each other on the bearing & a key
phase (tacho) probe is viewed by the software & the resulting lissajous pattern is analysed. Orbit
plot gives visual graph of actual shaft central line movement in bearing housing. With
accelerometers & velometers also orbits can be achieved and as the sensors are mounted outside
the casing of the machine, these orbits are called case orbits and provide absolute shaft motion
with respect to space. But the orbits taken from proximity sensors are more common & useful. The
shape of the orbit tells about the nature of the machine fault.
5. Position: Position monitoring is done with the help of non-contact type of probes & various parameters
like shaft eccentricity, Axial shift, housing & rotor (shaft) expansion & valve position can be
monitored (A part of TG TSI system). With the help of X-Y probes the average shaft centreline can
be plotted & rotor lift can be seen. These parameters prove valuable information regarding present
condition of the machine.
6. Bode Plot: Bode plot contains two graphs- Amplitude vs machine speed & Phase vs machine speed.
It gives valuable information regarding amount of run out associated with a proximity probe, balance
condition & system damping.
7. Polar Plots: In polar plots also same variables are used as in bode plot. They also serve the same
purpose, only the methid of representation is different.

ONLINE & OFFLINE VIBRATION SOLUTIONS

ONLINE & OFFLINE VIBRATION SOLUTIONS
Vibration monitoring is just like checking the pulse of the patient. Now two methods can
be adopted based on the condition of the patient. One can be a periodic scanning of the
pulse & other can be continuous pulse monitoring in ICU. Similarly for the machines which
lie in less critical zone, periodic vibration scanning system is advisable. Machine which
are critical with respect of safety, environment & directly affect the production, online
vibration monitoring systems are advocated. Following is the broad criterion for
implementation of different technologies1. Online System: This system holds well for critical category of assets which have immediate
impact on safety, environment & production for example turbines, compressors, critical
pumps & blowers etc.
2. Offline System: Less critical or semi critical assets are good targets for portable/offline
technology. On these assets periodic scanning is good enough to judge the present
condition.
ONLINE VIBRATION MONITORING: These are continuous vibration monitoring systems
employed on critical rotating assets like turbines, critical compressors, blowers, pumps
etc. Sensor & system selection depends on many factors like machine type, type of
bearings, machine speed, machine components, machine elements etc. These types of
systems act as protection safeguard against excessive vibration & also do the condition
monitoring job if the analysis software & module has been included in the system. As far
as turbines are concerned where bearing of interest is fluid film (journal), Bently Nevada
System is one of the best systems that I have worked on. Bently system is really good in
rotor dynamics due to its long experience in this field. On rolling element bearings SKF
has deep understanding and does a really good diagnostic on them. CSI is also good
solution in this area.
PORTABLE VIBRATION MONITORING SOLUTION: As already discussed portable or
vibration scanning solution is good for less critical assets. These are the assets which can
be periodically scanned or can be scanned when there is some unusual indication
regarding performance of the machine. Normally amplitude monitoring & FFT analysis is
done on these kind of assets. Other techniques like phase analysis & orbit analysis may
also be employed where we have facility to tap the signal through BNC port. Again SKF &
CSI are very good in this area. Bently Nevada Snapshot & ADRE are also useful tools.
Recently some new players in the condition monitoring field like Fluke have also
introduced some exciting solution in the offline vibration segment. They have introduced
two models that I have used till now. One of them is FFT based vibration analyser with
auto fault diagnostic & auto advisory feature. This is a good tool for the shop floor
engineers / technicians who have limited knowledge of vibration. The system is easy to
use & interpret the faults.

Vibration Monitoring & Analysis- Sensor selection

Criterion
SENSOR SELECTION CRITERION:

Sensor selection is one of the most important things in vibration monitoring / Analysis system.
Basically its the quality of vibration data input that decides the accuracy & relevance of the
measurement. No matter how advanced electronics & complex analysis algorithm is used, the
sensor being the first element in the line of measurement, has high importance in determining the
quality of measurement. The mantra is gold in gold out, garbage in garbage out. Various factors
and operating conditions like ambient temperature, magnetic field interferences, g range, frequency
range, electromagnetic compatibility etc. decide the ruggedness of sensors in the field. Other
machine parameters like type of bearings (Rolling element or journal) & machine speed decide the
choice of measurement units & kind of sensor to be put in the field. Once the proper sensor
selection has been done, the proper installation & sensor orientation becomes very important.
DISPLACEMENT SENSORS: These are also known as proximity sensors or eddy current sensors
& are used to measure relative shaft vibration, shaft position and clearance. These probes are put
on sleeve or oil film bearings (Journal bearings). These sensors are best suitable to measure low
frequency and low amplitude displacements. If there is not any viability of mounting proximity
probes on the machine, the accelerometer with double integrator circuit is also used for the
displacement measurement. Normally in turbines & large compressors we find these probes.
VELOCITY SENSORS: Unlike proximity probes, velocity sensors are contact type sensors. Earlier
electromagnetic sensors were used but due to mounting constraints & change in sensitivity issue
with respect to time, now much rugged & sturdy piezoelectric sensors are used. These are
accelerometers which are integrated once to get the velocity output. These sensors are used for
low to medium frequency measurements (approx. up to 5000Hz). Majority of the machines lie in
this frequency range (low to medium RPM) for vibration monitoring & balancing operations.
ACCELEROMETERS:Accelerometer is made of piezoelectric wafers & produces emf when there
is force applied to it. These are the most preferred sensors for measuring vibration & have a very
wide frequency range (almost from DC to 20 KHz). They are very useful for high speed machines
& rolling element bearings. These are rugged devices & can sustain hash ambient conditions like
corrosive environment & extremely high temperature (e.g. gas turbines). The sensor & associated
electronics (charge amplifier) can be separated for high temperature applications. They have very
good signal to noise ratio.

One should ask the questions like application frequency, type of bearing, environmental conditions,
machine type, sensor size & mounting constraints before selecting suitable sensor.

Vibration Monotoring & Analysis- An important

condition monitoring tool
Different technologies can be applied for the maintenance of different category of asset.
We know that (Moubrays PF chart) vibration is one of the earliest indicators of start of
machine failure. In this section we will cover the vibration monitoring & analysis
technology. Again human analogy becomes relevant to the machine also. Machines are
like human body. The human body has complex balance system to maintain the internal
environment of the body to a predetermined level. This is known as homeostasis, for
example it maintains the body temperature around 98.6 Fahrenheit. Whenever there is
some problem or a breakdown in this regulatory system, this control mechanism is
disturbed. This is reflected in terms of rise in temperature, shivering etc. Similarly, if there
is some mechanical / electrical problem or a process disturbance, the machine also
expresses the problem in form of different variables like rise in temperature, vibration,
change in electrical parameters etc. Since we know that vibration is one of the earliest
indicators of the machine fault, it becomes important for us to use the available
technologies for early detection of machine faults.

Vibration: Everything in the nature, either static or dynamic vibrates. So, question is what
makes all these things to vibrate? The answer lies in the basic fundamentals of Physics.
Atoms are the basic building blocks of the matter and they have inherent property of
vibration. Vibration is the harmonic motion of a machine or machine part in either side of
its neutral or stationary position & the response of a system to some internal or external
excitation / force applied to it. So, the question is why different machines vibrate
differently? The answer lies in the machine design & fundamental conditions like
difference in mass, stiffness & damping. Even the same model & same design machine
behave differently under similar conditions. God has created human beings & all are
different from each other. Even two identical twins have some difference & they behave
differently. Similarly no two machines can be same, even if all the design parameters are
same & this follows law of nature. This distinction makes the machine diagnostic discipline
not only a pure science but also an art which can be developed by the detailed study of
the discipline & wealth of experience on different set of machines.

Units of Measurement: Vibration can be measured into three units-

1. Displacement: The total distance travelled by the vibrating part, from one extreme limit to
the other. This can be explained by simple spring mass balance where displacement is
equal to the peak & bottom position travelled by the mass. The unit of displacement is
microns (Pk-Pk).

2. Velocity: Velocity is the speed at which displacement occurs. Since the seed is changing
constantly, peak or RMS velocity are usually selected & the unit is mm/sec (Pk / RMS) &
ips (inches per second)

3. Acceleration: Acceleration is the rate of change of velocity. At the extreme limit of travel of
the vibrating part, acceleration is maximum or peak & most popular unit of acceleration is
- gs (peak).

Relation between Displacement, Velocity& Acceleration

Integration of Acceleration = Velocity, Integration of Velocity = Displacement