Diagnostic Techniques

Objective:
Why do you utilize Diagnostic Techniques?
How we can apply Diagnostic Techniques in
the equipment or assets of the company.

Diagnostic Techniques.
We learned that an effective maintenance program
incorporates three types of inspections, operational
inspection, replacement inspections, and those
inspections that necessitate an equipment shutdown.
In all three of these inspections classes, there often is
the need to utilize diagnostic techniques in order to
predict maintenance by identifying a particular
disorder and its magnitude. The data needed in order
to diagnose the condition of equipment includes
overall vibration level, axial position indication,
bearing temperatures, speed, noise level, differential
expansion, and others.
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Diagnostic Techniques.
VIBRATION ANALYSIS.
The use of vibration analysis in order to learn
about a individual machine's condition is
becoming increasingly important in connection
with those inspections introduced in a PM
program.
Periodic checks of overall vibration and
velocity levels at selected bearings located in
equipment establish a point where action is to
take place.
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Diagnostic Techniques.
Setting Up the Vibration Measurement Program.
The following points should be adhered to in order
to have a viable vibration measurement effort:

Select the machines to be included in the program.

Select and mark check points.
Select the periodic check interval.
Establish vibration limits.
Conduct a vibration analysis of each select machine.
Begin a data bank and maintain records of the equipment.
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Diagnostic Techniques.
PROCESS PARAMETER MONITORING
Several of the parameters relating to the efficient
operation of a facility or system can be monitored.

Electrical Measurements.
Sound Intensity.
Hydraulic and Pneumatic testing.
Temperature Monitoring Including Thermograph.
Tribology.
Visual Inspection with Dimension and Motion Pattern
Monitoring.
Shock Pulse Measurement.
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Diagnostic Techniques.
NONDESTRUCTIVE TESTING.
There will be numerous occasions, especially in
connection with mechanical equipment, where the
PM inspector will need to check a component for
flaws, cracks, and so on, due to fatigue, misuse, or
wear. Usually it is essential that the component be
inspected with out destroying it. Several
nondestructive testing and inspection techniques are
available. The most important of these are:
Magnetic-Particle. Radiographic.
Sonic and Ultrasonic.
Fluorescent penetrant.
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Diagnostic Techniques.
INSTRUMENT AVAILABILITY.
Several of the instruments are costly and may be
difficult to acquire by the small or medium sized
maintenance department. This should not discourage
their use in connection with diagnostic procedures
used in conjunction with preventive maintenance.
Frequently, these instruments are already being used
in the inspection department. If so, it should be a
simple matter to have them periodically loaned to
maintenance.
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Diagnostic Techniques.
TRAINING FOR DIAGNOSTIC:
The diagnostic technician is a highly skilled
individual who has had extensive training and
experience. The availability of this type of
technician, especially in smaller plants, is limited.
Those technicians who perform diagnostic will
find that it is necessary to continually update
themselves in order to stay abreast of the ever
increasing new technologies characteristic of
modern facilities and equipment.
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Diagnostic Techniques.
Summary

The ability to diagnose the condition of key equipment is the heart of

predictive maintenance. As production equipment becomes more
sophisticated, so the instruments needed to diagnose it becomes more
complex. It is essential that technicians associated with predictive
maintenance receive regular training in the use of modern
instrumentation for sensing those parameters that facilitate the
diagnosis of critical production facilities used in a plant or business.
However the vast majority of mechanical, electrical, hydraulic, and
pneumatic equipment that may be classed as critical in the operation of
a plant should be subjected regularly to those diagnostic techniques
that can best identify their current condition and estimate when repair,
modification, or overhaul should take place to avoid crash down.
These inspections and evaluations are usually performed best by
internal technicians that have been trained properly.
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