Unit Description and General Aims

The objective of this unit is to provide students with a thorough understanding of the concept of condition monitoring and its importance to machine’s general health or condition. The subject also involves the identification and use of sensing arrangements with data acquisition and analysis. 

The general aim is to enable students to learn and apply various condition monitoring techniques to quantify the health of a machine so that problems can be diagnosed early and corrected by a condition-based maintenance strategy to prevent unwanted equipment failure.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

1. Evaluate the concept of machine condition monitoring as an effective maintenance management tool. 
   Blooms Level 5

2. Examine the techniques of visual inspection and thermography. 
   Bloom's Level 4   
   
   
3. Analyse various surface and internal defect detection and visual monitoring techniques                                                                                                                  
   Bloom's Level 4 
   
   
4. Examine performance monitoring and system input/output monitoring as tools of condition monitoring 
   Bloom's Level 4 
   
   
5. Evaluate vibration monitoring and wear debris analysis techniques 
   Bloom’s Level 5  
   
   
6. Justify the need to adopt a condition-based maintenance strategy and engineering failure analysis techniques 
   Bloom's Level 5

Student assessment

Overall requirements: Students must achieve a result of 50% or above in the exam itself to pass the exam, and must pass the exam to be able to pass the unit. An overall final unit score of 50% or above must be achieved to pass the unit once all assessment, including the exam, has been completed.

Prescribed and Recommended Readings

Textbook

1. Randall, B 2021, Vibration-based Condition Monitoring: Industrial, Automotive and Aerospace Applications, Wiley-Blackwell.

2. Davies, A 2012, Handbook of Condition Monitoring: techniques and methodology, Chapman and Hall, London, U.K.

3. Mohanty, AR 2017, Machinery Condition Monitoring: Principles and Practices, CRC Press, ISBN-13: 978-1466593046

Reference

1. Rao, BKN 1996, Handbook of Condition Monitoring, 1st edition, Elsevier Science Ltd, ISBN-13: 978-1856172349

2. Randall, R.B. 2010 Vibration-based Condition Monitoring: Industrial, Automotive and Aerospace Applications. John Wiley & Sons, Incorporated, Hoboken, N.J.

Journal, website

http://www.plant-maintenance.com/maintenance_articles.shtml 
https://www.wbdg.org/resources/rcm.php 
www.scirp.org/journal/PaperDownload.aspx?paperID=3165

Notes and Reference Texts

Machinery Vibration Analysis and Predictive Maintenance, IDC Technologies, Perth 
Practical Lubrication Engineering for Engineers and Technicians, IDC Technologies, Perth 
Reliability Centred Maintenance, IDC Technologies, Perth

Other material advised during the lectures

Unit Content

Topic 1

Introduction to Machine Condition Monitoring  

1.1 Introduction 

1.2 Condition Monitoring and Diagnostic Engineering Management (COMADEM) 

1.3 Economic justification and benefits 

1.4 Market research 

1.5 COMADEM education

Topic 2

Conditioned Based Maintenance 

2.1 Introduction 

2.2 Vibration monitoring

2.3 Thermography 

2.4 Tribology

2.5 Other monitoring techniques

Topic 3

Techniques for Visual Inspection 

3.1 Introduction

3.2 Unsophisticated low-cost aides 

3.3 Portable information logs

3.4 More sophisticated systems

3.5 Automated visual inspection

Topic 4

Thermal monitoring using infrared thermography

4.1 Introduction 

4.2 Simple temperature measurementtechniques

4.3 Pyrometry and infrared line scanners 

4.4 Thermal imaging or thermographicsystems

4.5 Condition monitoring case studies 

4.6 The future of thermography,applications and conclusions

Topic 5

5.1 Introduction 

5.2 Eddy current testing 

5.3 Electrical resistance testing (AC or OCPD) 

5.4 Flux leakage testing and magnetictesting 

5.5 Penetrant testing 

5.6 Radiographic testing 

5.7 Resonant spectroscopic testing 

5.8 Ultrasonic testing 

5.9 Visual testing

Topic 6

Commercial applications of visual monitoring

6.1 Introduction 

6.2 Borescopes, fibre scopes and endoscopes 

6.3 Video imaging 

6.4 Thermal and ultrasonic imaging 

6.5 Laser systems 

6.6 Special applications

Topic 7

Techniques for Performance Monitoring

7.1 Introduction 

7.2 Energy conversion, flow monitoring  and efficiency 

7.3 Steady-state signals and instrumentcalibration 

7.4 Instrument installation - hydraulicpower 

7.5 Instrument installation - electricalpower 

7.6 Instrument installation - torque and speed 

7.7 Instrument installation - temperature 

7.8 Instrument installation – flow measurement

Topic 8

System input/output monitoring and use of models

8.1 Introduction 

8.2 System monitoring 

8.3 Machine health analysis 

8.4 Graphic pattern analysis 

8.5 Tracking rate analysis 

8.6 Neural network application

8.7 Statistical measures

8.8 Time-based analysis

8.9 Models

8.10 Spectrum analysis

Topic 9

Techniques of Vibration Monitoring 

9.1 Introduction 

9.2 Measuring vibration 

9.3 Frequency 

9.4 Phase 

9.5 Vibration analysis 

9.6 Complex vibration 

9.7 Vibration severity 

9.8 Velocity RMS 

9.9 High-frequency detection systems 

9..10 Vibration and predictive maintenance 

9.11 Monitoring machine vibration

Topic 10

Techniques for Wear Debris Analysis

10.1 Introduction

10.2 Wear in lubricated systems 

10.3 Wear debris - transport, monitoringefficiency and analysis 

10.4 Lubricant properties and oil analysismethods 

10.5 Wear debris analysis methods

10.6 Physical testing of lubricants 

10.7 Implementation of wear debris monitoring and oil analysis programmes

Topic 11

Adopting a Condition-Based Maintenance Strategy

11.1 Introduction 

11.2 Assessing the need for condition monitoring 

11.3 Cost justification

11.4 Justifying CM at present

11.5 Technique selection and implementation in condition monitoring

11.6 Pitfalls, benefits and collective wisdom

Topic 12

Engineering Failure Analysis (book: Mohanty)

12.1 Introduction 

12.2 Overview of failure analysis

12.3 Failure modes

12.4 Failure analysis

12.5 Failure analysis sampling guide

Software/Hardware Used

Software

• Software: N/A
• Version: N/A
• Instructions:  N/A
• Additional resources or files: N/A

Hardware

• N/A

Unit Changes Based on Student Feedback