COMADEM 89 International: Proceedings of the First International Congress on Condition Monitoring and Diagnostic Engineering Management (COMADEM)

557 Pages·1989·16.432 MB·English

by  Raj B. K. N. Rao (auth.), Raj B. K. N. Rao, A. D. Hope (eds.)

COMADEM89
International
II II
COMADEM89
International
II II
Proceedings of the First International
Congress on Condition Monitoring and
Diagnostic Engineering Management
(COMADEM)
Organised by Birmingham Polytechnic, 4 to 6 September 1989
Co-sponsoring Organisations
The British Institute of NDT
The Institute of Measurement & Control
The Institution of Electrical Engineers
The Institute of Acoustics
The British Society for Strain Management
The Safety & Reliability Society
The Institution of Diagnostic Engineers
Shells Thornton's Research Centre
Lucas Engineering & Systems Ltd
The Society of Environmental Engineers
Conference Director
RajBKN Rao
Proceedings Editors
RajBKN Rao
ADHope
&
KOGAN
PAGE
B K N Rao, A D Hope and contributors, 1989
All rights reserved. No reproduction, copy or
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WCIE7AE.
Softcover reprint of the hardcover 1s t edition 1956
Any person who does any unauthorised act in relation
to this publication may be liable to criminal prosecution
and civil claims for damages.
First published in 1989 by Kogan Page Ltd,
120 Penton ville Road, London N 1 9JN
British Library Cataloguing in Publication Data
COMADEM International 89. Conference
COMADEM International 89: proceedings ofthe First
International Seminar on Condition Management and
Diagnostic Engineering Management.
1. Manufacturing industries. Management
I. Title II. Y. A. D. III. Rao, Raj B K N
658.5
ISBN 978-1-4684-8907-1 ISBN 978-1-4684-8905-7 (eBook)
DOI 10.1007/978-1-4684-8905-7
Dedicated to Eng, Laxmi, Aruna
Acknowledgements
This international proceedings couldn't have been produced at such
short notice without the total support, dedication, sacrifice and true
professionalism that are displayed by all the authors representing
various organisations from many parts of the world. We are indeed
very grateful for their invaluble contributions. We are also grateful to
Mr Piers Burnett and his efficient staff at Kogan Page for putting up
with our excuses and for producing such high-quality workmanship in
such a short time.
Raj B K N Rao
A D Hope
Contents
Introduction ................................................................................................... 13
RajBKNRao
Key Note Lecture I
Total Quality in NDTand Condition Monitoring ..................................................... 15
JMFarJey
Key Note Lecture 2
Condition-based Maintenance - Where to Next? ..................................................... 20
D S T Rllubenheimer
Key Note Lecture 3
Condition Monitoring in Manufacturing ................................................................ 25
DA L West
Machinery/Systems Health Monitoring
Assessment of Symptom Limit Value in Vibration Condition Monitoring ....................... 29
CCempe/
Turbomachinery Failure Detection - Combination of Transfer Matrix and
Finite Element Method ...................................................................................... 34
Hengjun Zhu and R Firoozian
Diagnostic for Mechanical Systems through Analysing Variations in
Vibration Signatures ......................................................................................... 40
WJWang
Identification and Digital Control of a Turbo-charged Marine Diesel Engine ................... 45
JDForrest
Condition Monitoring and Diagnostic of a Diesel Engine through
Detecting Changes in Estimated Dynamic Models ...................................... ............. 50
Z Ding llnd J M Edmunds
The Fulmer Method of Monitoring Fluid Abrasivity as an Indication of
Fluid Condition and Machine Health ............................................ ............ 55
R Santilli
Practical Gear Fault Diagnosis Using Vibration-based Methods ................................... 68
A Penter
COMPASS: A Generalized Ground-based Monitoring System ................................... 74
MJProvost
Computer-Aided Machine Health Monitoring .................................. . . .............. 88
BZoltowski
A Revolution in Rotating Machinery Monitoring ..................................................... 93
TC/ark
Quality, Reliability, Health and Safety
Inspection of Re-manufactured Gearboxes Using Noise Analysis ................................. 98
DE Johnson and G J Trmal
Reliability of Aircraft High Lift Devices ................................................................. 104
K W Chan, G J Trmal, A PH May and G Southcombe
A Design Study of a Production Centrifuge with Respect to Maintainability
and Condition Monitoring .................................................................................. 111
Xu Yuankai and G Thompson
A Personal Computer Based Burn-in System ........................................................... 117
T H Ooi, K Kumar and R Lim
Development of a Micro-computer Based System for On-line Monitoring
of the Reliability Characteristics of a Recycle Gas Compressor .................................... 122
M J Harris, R S Mann and T R Moss
A Fiscal and Process Controller for a Hardboard Mill ................................................ 127
D F Pearce and A W Self
The Assessment of Availability through Simulation .................................................. 134
TTWongandSL Tang
Automatic Environmental Monitoring .................................................................. 139
A TDadd
A Supervisory Officer's Guide to Effective Interviewing/Counselling of
Personnel Suspected of Having an Alcohol Dependency Problem ................................. 144
GHVPaviour
Plant and Process Health Monitoring
System for Real Time Process Monitoring and Adaptive Control
during CNC Hole Drilling ........................................................................ 148
Y Kavaratzis and J D Maiden
Plant Health Monitoring Using a Turbine Flowmeter ..... 154
J E Amadi-Echendu, E H Higham and P J Hurren
Real Time Monitoring of Roll Cooling Water Flow Rate ................ 159
H Kaghazchi and R Hilliard
Health Monitoring of Motorised Valve Actuators and Similar Devices ................... 165
J J S Derry and R C Waterfall
Blanking Process Characterization Using Acoustic Emission ...... 170
A S Mardapittas and Y H J A u
A Monitor for the Cooling System of a Large Electrical Generator .... ...... 175
M P Jenkins and S G C Hadden ct al
Pump Performance - Its Application to Condition Monitoring. ..... 182
BGMurray
The Monitoring of the Alignment of Continuous Casting Machines ...................... 187
W D N Pritchard and G Hyde
Application of Expert Systems in COMADEM
The Adaptive Acoustic Monitoring of Aircraft Engines .................................. 194
R C Witcomb. P J C Skitt and P D Hewitt
Power System Network Loadflow Management Using Fuzzy Knowledge-based
Expert System .......................................................... .. .............................. 199
TChui.1 Esat. DChui and B Parsons
Towards Unmanned Manufacture: Applications of an Expert System ............................ 206
S Sadeque. R Benhadj. M M A Safa and B Dawson
Expert Systems Applied to Gas Turbine Condition Monitoring. ............................ 212
R M DunlopandJ Davis
Post Flight Analysis of EH 10l Helicopter Maintenance Data ........ 219
1M ReasonandJ Davis
A Strategy of Knowledge Elicitation for the Monitoring and Control of
Industrial Processes ....... 226
BE Sanders. B A Lewis. SAC Sanders and J E Cherrington
Computerised Technical Documentation ........ 231
S Toole and M Winfield
A Diagnostic Expert System which Generates Explanations. ......... 238
S Ghallab and J Efstathiou
The Application of Expert Systems and Computer Simulation Technologies
to Process Monitoring and Control ............................ . .......... 242
K Maughan and W Walker
Computer-assisted Analysis of Evoked Transients .............................. 247
A S Sehmi. N B Jones and N L Robinson
Information/Data Management
Development of Computer-aided Data Acquisition, Control and Analysis System
(CADACAS) for Remote Condition Monitoring ....................................... 254
CONwagboso. TL WhomesandPBDavies
Data Acquisition System for High Strain Fatigue Testing ............................................ 260
P Adkin. R J Rider and SJ Harvey
On Maintaining and Reasoning with Incomplete Information ...................... 266
NObeid
Decision Support Systems for Manufacturing Management ............................... 271
E J Fletcher and P Smith
Concurrent System Behaviour ............................................................................. 276
SSawyers
Condition-based Maintenance Management
Inspect or Monitor? - How to choose Maintenance Policy by Matrix Algebre .... 281
DJSherwin
Maintenance Management Technique for Small-sized Road Construction Companies ....... 290
MEl Shabrawy
Condition-based Maintenance System Engineering .................................................. 303
GAllenby
Effective Machinery Fault Diagnosis Avoids Unnecessary Gearbox
Maintenance (Case Study) .................................................................................. 308
AHEISherif
Automatic Condition Monitoring in the Hot Strip Mill of
Rautaruukki Oy Raahe Steel Works ..................................................................... 314
MPajukoski
On-line Surveillance for Predictive Maintenance in a Hazardous Environment ................ 325
PWHills
Cost-effective Condition Monitoring ..................................................................... 335
CNicholls
Debris Counting for Consistent Monitoring ............................................................ 348
TMHunt
Monitoring Liquid Levels ................................................................................... 353
TMHunt
Why Put Up with Bearing Failures? ...................................................................... 358
S N Harvey and A G Herraty
Computerised Maintenance Scheme for a Process Industry
Using Monte-Carlo Simulation Technique .............................................................. 364
M Ananda Rao. K R Divakar Roy and K Satyanarayana
The Fundamentals of, and the Application of Computers to, Condition
Monitoring and Predictive Maintenance ................................................................ 372
JTranter
The Use of Thermography in Industrial Predictive Maintenance ., ................................ 378
CNicholl.s
Set Vibration Alarm Levels without Guesswork ....................................................... 386
R GSmileyandT J Murphy
Advances in Instrumentation and Control Technology
Sampling Techniques for Monitoring Sinusoidal Waveforms ....................................... 397
GDBergman
Surface Temperature and Heat Flow Measurement .................................................. 402
TKimber
High Quality Non-contact Measurement Using Capacitance Gauges ............................. 409
J M Hale. H Walton and G McCarten
Analysis of Sigma Delta Modulators ..................................................................... 414
C P Lewis and C M Gordon
Dynamic Tip Clearance Measurements in Axial Flow Compressors .............................. 419
CJParrish
A Portable Scanning Laser Vibrometer for Surface Vibration Analysis .......................... 424
C J D Pickering. N R N Gant and N A Halliwell
Clean Window Design for Optical Access ..... 429
P 1 Foster lind P Panaka
Numerical Solution of the Matrix Riccati Equation for a
Time Variant Jet Engine System ..... 434
S M Mahmoud and I H Farhan
Non-linear Optimal Tracking Problem for Jet Engine Control ....... 439
S M Mahmoud and I H Farhan
Advances in Diagnostic Technology
Technical Diagnostics of Shafts and Bearings by Analysing Relative Speeds . .444
A Sturm and T Kid
Ferrogram Quantitive Analyser - Its Application in Industn .450
Huo Yuxiang and Xu Xiaodi
Methods and Experiences in the Application ofTechnieal Diagnosis for
Prevention and Early Detection of Damages to Components of the
Water-Stearn-Cycle of Thermal Power Stations ...................... . . .453
H Kalina and B Hahn
Energy Monitoring and Management
An Experimental Facility for Investigation into the Control and Monitoring of
Energy Consumption of V A V and CA V Air Conditioning Systems ... .458
A Soon and A Ameen
Advanced Control Techniques for Building Energy Management Systems (BEMS) .......... 463
GS Virk. K I H Alkadhimi. 1 MChcungandD Loveday
Energy Management and Optimisation Using Adaptive Control Techniques ..... .469
TT AI-Shcmmcri and C Bouchalis
Condition Monitoring of Offshore Structures and Installations
Monitoring and Control of Unmanned Machinery at Sea ... 477
DGRedpath
Condition Monitoring for Fatigue - Implications of Fatigue Crack Shape. .......... .483
RASmith
Biofouling on Offshore Installations - An Impact and Monitoring Assessment ..... 488
S Kapoor. K 1 Chauhan. A K Srivastava. R Saxena and K L Goyal
Advances in Non-destructive Testing (NDT)/Non-destructive
Evaluation (NDE)
The Monitoring of Industrial Processes Using Ultrasound ..... 494
B C Haywood. C B Scruby and K A Stacey
Condition Monitoring of British Gas Pipelines .499
M1Thomas
Novel Application of COMADEM Techniques
Research on Quantitave Ferrography Technology .................................................... 508
Xu Xiaodi. Qiao Yufei and Huo Yuxiang
Wear Detection of a Vane Using a Novel Flowmeter Phenomenon ............................... 513
K Watkins and J Watton
Condition Monitoring Using Conventional Process Instrumentation ............................. 520
P J Hurren, J E Amadi-Echendu and E H Higham
Condition Monitoring of Bends in Pneumatic Conveying Systems ................................. 525
R M Henry and M S M AJ-FaysaJe
Stress Wave Sensing - A New Measurand for Condition Monitoring ............................. 530
T J Holroyd and S King
Novel Adaptive Control Schemes for Peripheral Milling ............................................ 535
F Gajendran and M A Joseph
A New Technique for Condition Monitoring of Rolling Element Bearings
Using a Portable Data Collector ........................................................................... 539
G A Ratcliffe
Continuing Education and Training in COMADEM
On Condition Monitoring and Maintenance ............................................................ 545
TMEZaal
Computer-based Training in Statistical Quality Control ............................................. 550
D Holmes. K McKelvie. D Meehan. A Price and D Rush
A Project to Examine the Use of Open Learning Techniques in COMADEM .................. 555
RHarding
Author Index .................................................................................................. 559