From Practical Machinery Vibration Analysis and Predictive Maintenance

7.1 Introduction

In the earlier topics, we covered the technique of vibration analysis in detail. It is undoubtedly the most important predictive maintenance technique. Oil analysis is another predictive maintenance technique that evolved through the years and is currently maturing into a reliable source of predictive machinery information.

Oil analysis is not merely a tool to analyze the condition of a lubricant. With modern diagnostic tools, it is used to monitor the condition of equipment as well. By utilising these advanced techniques, equipment reliability can increase, and unexpected failures and downtime are minimized. There are many wear mechanisms that lead to the deterioration of machine components. Though there are different types of wear, there are only a few primary sources of wear.

The mechanisms that contribute to wear of a component include misalignment, unbalance and improper use of the equipment (such as overload or accelerated heating conditions). One of the sources for wear can be the lubricant itself, e.g. in cases where the lubricant has degraded or has become contaminated.

The different types of wear that can occur are:

  • Abrasive wear

  • Adhesive wear

  • Cavitation

  • Corrosive wear

  • Cutting wear

  • Fatigue wear

  • Sliding wear.

In an operating machine, there is a continuous attrition of its components due to the generation of wear debris. Lubricants normally carry the debris away. Identification and analysis of this wear debris can pinpoint the type of wear and also identify the source, which could be any component under distress. Oil analysis can highlight the necessity...

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Predictive Maintenance and Condition Monitoring Systems
Predictive maintenance (PdM) systems and condition monitoring systems are used to predict equipment maintenance, and to monitor corrosion, oil condition, bearing wear, overheating and other parameters than can lead to the breakdown of capital equipment.
Condition Monitoring and Predictive Maintenance (PdM) Software
Condition monitoring and predictive maintenance (PdM) software is used to predict equipment maintenance, and to monitor corrosion, oil condition, bearing wear, overheating and other parameters than can lead to the breakdown of capital equipment.
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Product and component testing services is the evaluation of a finished product or component through performance in electrical, life, environmental exposure, dynamic, ergonomic or other specialized tests.  Also testing to standards such as UL 489, CE or MIL-STD 810.
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Condition monitoring and machine maintenance services monitor the condition of critical machines, battery banks, power supplies, processes and rotary equipment. They also perform predictive maintenance (PdM) and/or preventive maintenance.
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Topics of Interest

7.2 Oil Fundamentals A lubricant usually has a base fluid. The base fluid is generally of petroleum origin, combined with additive chemicals that enhance the various desirable properties for a base...

Overview Predictive maintenance is the monitoring of equipment operating conditions to detect any signs of wear that is leading to a failure of a component. The goal of the predictive maintenance...

Machine Wear Analysis The wearing parts of a machine such as the gears, hydraulic pistons, bearings, and wear rings generate fine metal particles during normal operation. At the onset of a severe...

7.10 Conclusion In the past, companies considered, the vibration analysis program as the mainstay of the predictive maintenance philosophy. However, with technical improvements, sophisticated...

In order to quickly and accurately determine the "cause and effect" of oil and wear related problems, proper tests and procedures based on the equipment sampled and its application must be performed.