TABLE OF CONTENTS

Description Page No.

LIST OF FIGURES i

LIST OF TABLES iii

NOMENCLATURE iv

CHAPTER-I OBJECTIVE AND SCOPE OF THE PROJECT 1-2

1.1 Introduction 1
1.2 Objective of the project 2
1.3 Organization of the work. 2
CHAPTER-II LITERATURE REVIEW 3-9
2.1 Introduction 3
2.2 Summery 9
CHAPTER-III MAINTENANCE STRATEGIES 10-17
3.1 Introduction 10
3.2 Classification of Maintenance Strategies 10
3.2.1 Breakdown maintenance 10
3.2.2 Preventive maintenance 11
3.2.3 Predictive maintenance 12
3.3 Condition Monitoring 14
3.3.1 Introduction 14
3.3.2 Condition monitoring techniques 15
CHAPTER-IV BASICS OF VIBRATION 18-35
4.0 Introduction 18
4.1 What causes vibration? 19
4.2 What is Machine Vibration? 19
4.3 Vibration and machine life 20
4.4 Characteristics of vibration 23
4.4.1 Vibration frequency 23
4.4.2 Vibration amplitude 25
4.4.3 Spike energy 27
4.4.4 Phase 29
4.5 Instruments for Vibration detection and analysis 29
4.5.1 Introduction 29
4.5.2 The vibration transducer 29
4.5.3 DATAPAC 1500 33

CHAPTER-V VIBRATION ANALYSIS 36-66

5.1Introduction 36
5.2 Define the problem 36
5.3 Determine machine details 37
5.4 Visual inspection 38
5.5 Probing studies 39
5.6 Obtain Horizontal, Vertical and Axial Spectrums (FFT’s)
at each bearing of the Machine Train 40
5.7 Determining if the vibration is Directional or Non-Directional 51
5.8 Identifying the Most Common machinery Problems 55
5.8.1 Vibration due to Unbalance 55
5.8.2 Bent shaft problems 56
5.8.3 Shaft with a kink or bend close to the bearing 58
5.8.4 identifying a simple shaft bow 59
5.8.5 Vibration due to Misalignment 60
5.8.6 Vibration due to looseness 61
 5.8.7 Vibration due to eccentricity 63
5.8.8 Vibration due to resonance 64
5.8.9 Vibration due to defective rolling element bearings 64
5.9 Vibration Analysis 65
5.9.1 Introduction 65
5.9.2 Dominant Frequency 65
CHAPTER-VI ARTIFICIAL NEURAL NETWORKS 67-78
6.1 Introduction 67
6.1.1 Background 68
6.1.2 Models 69
6.1.3 The network in artificial neural network 69
6.1.4 Learning 70
6.1.5 Employing artificial neural networks 71
6.1.6 Applications 72
6.1.7 Real life applications 72
6.2 pattern classification network 72
6.3 back propagation algorithm 73
6.4 application of Ann to vibration analysis 74
6.4.1 Reasons for Applying Ann 74
6.4.2 Developing an ANN system 74
6.4.3 Test rig simulation 76
6.4.4 Simple fault simulator 76
6.4.5 FEM simulation 76

6.4.6 Problems developing diagnostic expert systems 77

6.4.7 Advantages of applying ANN’s for fault detection 77

CHAPTER-VII CASE STUDY 79-95
BOILER FEED PUMP 4B
7.1 Description of the Equipment 79
7.2 specifications 80
7.3 Experimentation 81
7.4 Data collected before rectification 81
7.5 analysis of data 83
7.6 Spectrums analysis before rectification 84
7.7 Observations from the Spectrums 87
7.8 Conclusions 87
7.9 Action taken 88
7.10 Data collection after rectification 88
7.11 Spectrums after rectification 89
CHAPTER-VII APPLICATION OF ANN TO FAULT RECOGNITION ON BOILER
FEED PUMP 95-116
8.1 Network specifications 95
8.2 Training of the network 95
8.3 Results from ANN Program 96
CHAPTER-IX RESULTS AND DISCUSSIONS 99-101
9.1 vibration spectrum analysis 99
9.2 Summary of Ann Results 100
9.3 Correlation of the Mathematical and Ann Analysis 101
CHAPTER-X CONCLUSIONS 102
REFERENCES 103-104
APPENDIX 105
i. Code Used To Detect the Faults 105
ii. Paper Published Based On This Work 121