Condition Monitoring Report

 Objective:

Plant has been operating effectively until it starts showing uncertainties and
breakdowns which in turn causes a company direct or indirect extra costs. Our
main objective is to identify the root courses of malfunctions (mechanical)
through thermal, and vibration analysis method of nondestructive method of
machine inspections and provide the appropriate plan to rectify identified causes
of failures and prevent them before they can actually occur.

CV-1 (Screen feeder)

1. Thermal Analysis
Component Tail Pulley
SNU513-611
Image FLIR0009
Max Temperature 8.2 deg.c
Distance 1.0m
Thermal resolution 80x60
Emissivity 0.95

(Fig 1) IR Thermal Image (Tail Pulley) showing (Fig 2) Optical Image of a tail pulley
operational thermal signature which indicates
temperature distribution is within the operational
limits
  (Fig 1) IR Thermal Image (Tail Pulley) showing operational thermal signature which
indicates temperature distribution is within the operational limits
 (Fig 2) Optical Image of a tail pulley which shows the environmental condition at which
2. Vibration Analysis
a pulley operates at.

Device Specification

Device VB-8202
Range Velocity:
200mm/s : 0.5 to 199.9mm/s
Acceleration:
200m/s2 : 0.5 to 199.9mm/s2
Display 61mm x 34mm

Measure Results as at 21 September 2018

S/N Mea.PT Measure Point Description Mea. Value(mm/s)

1 TPL 0.2
Tail Pulley
SNU513-611 (L)
2 TPR Tail Pulley 0.2
SNU513-611 (R)
 The vibration of a small machines(Up to 15Kw) should range between 0 and 1.8 mm/s hence this
pulley seems to be in an good condition,

CV-2
3. Thermal Analysis
Component(s)  Gear box
 Motor
 Tail Pulley [SNU513-611]
Image FLIR00
Max Temperature 25.9 deg.c
Distance 1.0m
Thermal resolution 80x60
Emissivity 0.95

(Fig 1) IR Thermal Image (Gear (Fig 1) IR Thermal Image (Drive (Fig 2) IR Thermal Image (Tail Pulley)
Box) showing operational thermal Motor) showing operational showing uneven thermal distribution.
signature which. thermal signature.

 (Fig 1) IR Thermal Image (Gear Box) showing operational thermal signature which
indicates temperature distribution is within the operational limits
 (Fig 1) IR Thermal Image (Drive Motor) showing operational thermal signature indicating
temperature distribution is within the operational limits
 (Fig 2) IR Thermal Image (Tail Pulley) showing uneven thermal distribution along a belt.
Which indicated imbalance of tension.

4. Vibration Analysis

Device Specification

Device VB-8202
Range Velocity:
200mm/s : 0.5 to 199.9mm/s
Acceleration:
200m/s2 : 0.5 to 199.9mm/s2
Display 61mm x 34mm

Measure Results as at 21 September 2018

S/N Mea.PT Measure Point Description Mea. Value(mm/s)

1 TPL Tail Pulley 0.6
(SNU518)(L)
2 TPR Tail Pulley 0.5
(SNU518)(R)
DPL Drive Pulley 3.7
(SNU518)(L)
 DPR Drive Pulley 4.6
(SNU512-510)(R)
MDE Motor (DE) 3.7
MNDE Motor(NDE) 4.1
GB Gear Box 4.4
 The vibration of small machines (Up to 15Kw) should range between 0 and 4.5 mm/s hence tail pulley seems to be in good conditions.
 Drive pulley, motor and gear box however have vibrations ranging close to the boundary which indicates that the machine is operating
within a danger operating zone of vibrations.

CV-3

5. Thermal Analysis
Component(s)  Tail Pulley Pillow Block Bearing [SNU513-611]
 Tail Pulley
Image FLIR00
Max Temperature 10.7 deg.c
Distance 1.0m
Thermal resolution 80x60
Emissivity 0.95

(Fig 2) IR Thermal Image (Bearing) (Fig 2) IR Thermal Image (Tail Pulley)

showing operational thermal showing uneven thermal pattern along
signature a belt.

 (Fig 2) IR Thermal Image (Bearing) showing operational thermal signature which indicates temperature
distribution is within the limit but basing on the operation speed, the temperatures are higher than
expected.
 (Fig 3) IR Thermal Image (Tail Pulley) showing uneven thermal pattern along a belt. Which indicate
pulley’s circumference is not even and needs machining for reconditioning. The effect of this pulley may
result in belt wearing off along edges of the belt.
 6. Vibration Analysis

Device Specification

Device VB-8202
Range Velocity:
200mm/s : 0.5 to 199.9mm/s
Acceleration:
200m/s2 : 0.5 to 199.9mm/s2
Display 61mm x 34mm

Measure Results as at 21 September 2018

S/N Mea.PT Measure Point Description Mea. Value(mm/s)

1 TPL Tail Pulley 1.1
(SNU518)(L)
2 TPR Tail Pulley 0.6
(SNU518)(R)
DPL Drive Pulley 1.9
(SNU518)(L)
DPR Drive Pulley 1.8
(SNU512-510)(R)
MDE Motor (DE) 2.8
MNDE Motor(NDE) 2.8
GB Gear Box 2.9
 The vibration of small machines (Up to 15Kw) should range between 0 and 4.5 mm/s hence tail pulley seems to be in good conditions.
 Drive pulley, motor and gear box however have vibrations ranging close to the boundary which indicates that the machine is operating
within a danger operating zone of vibrations.

CV-4

7. Thermal Analysis
Component(s)  Tail Pulley [SNU513-611]
Image FLIR00
Max Temperature 10.8 deg.c
Distance 1.0m
Thermal resolution 80x60
Emissivity 0.95
 (Fig 2) IR Thermal Image (Bearing)
showing operational thermal
signature

 (Fig 2) IR Thermal Image (Pulley) showing even operational thermal signature which indicates
temperature distribution is within the limit and the pulley should be working as requires

8. Vibration Analysis

Device Specification

Device VB-8202
Range Velocity:
200mm/s : 0.5 to 199.9mm/s
Acceleration:
200m/s2 : 0.5 to 199.9mm/s2
Display 61mm x 34mm

Measure Results as at 21 September 2018

S/N Mea.PT Measure Point Description Mea. Value(mm/s)

1 TPL Tail Pulley 0.2
(SNU518)(L)
2 TPR Tail Pulley 0.3
(SNU518)(R)
DPL Drive Pulley 1.0
(SNU518)(L)
DPR Drive Pulley 0.9
(SNU512-510)(R)
MDE Motor (DE) 1.1
MNDE Motor(NDE) 1.7
 GB Gear Box 1.4
 The vibration of small machines (Up to 15Kw) should range between 0 and 4.5 mm/s hence tail pulley seems to be in good conditions.
 Drive pulley, motor and gear box however have vibrations ranging close to the boundary which indicates that the machine is operating
within a danger operating zone of vibrations.

 MAINTENANCE PLAN

In order to achieve the aim set, the following routine maintenance routine plan
could be helpful if followed:
NB: The plan was developed based on the user manual, expected and experienced atmospheric
conditions, as well as test results prior to inspections and tests conducted.

S/N Definition Operations Time Intervals Comment Recommendation

Weekly Monthly Quarterly Half
Yearly
CV1  Grease and condition inspection of 
bearings and replace if necessary
Due to exposure
 Check belt tension and adjust if necessary.
to extreme
 Visual inspection. Check shaft and bearing
housings for signs of damage and/or wear weather
 Replace bearings/dust seals/distance rings  conditions, CV(s),
should be
thoroughly
 Replace motor seals  inspected
regularly and be
CV2  Grease and condition inspection of  greased/lubricate
bearings and replace if necessary
d with
 Check belt tension and adjust if necessary.
lubricants/grease
 Visual inspection. Check shaft and bearing
housings for signs of damage and/or wear with high
temperature
 Replace bearings/dust seals/distance rings  properties.

 Replace motor seals 

CV3  Grease and condition inspection of 

bearings and replace if necessary
 Check belt tension and adjust if necessary.
 Visual inspection. Check shaft and bearing
housings for signs of damage and/or wear
 Replace motor seals 
  Replace bearings/dust seals/distance rings 

CV4  Grease and condition inspection of 

bearings and replace if necessary
 Replace motor oil seals
 Check space between belt and sensor
duct for material deposits. Clean if
necessary.
 Check belt tension and adjust if necessary.
 Visual inspection. Check shaft and bearing
housings for signs of damage and/or wear
 Replace bearings/dust seals/distance rings 

 Replace motor seals 

SLIME  Check motor coupling and alignment and  . Due to exposure

adjust if required.
PUMP  Check all fitting for proper tightness to
to extreme
prevent leakages, tighten loose nuts, bolts weather
and fasteners conditions, CV(s),
 Check for audible knocking sound in a
pump should be
 Grease and condition inspection of  Excessive thoroughly
bearings and replace if necessary vibration inspected
 and an regularly and be
increase in
bearing
greased/lubricate
temperatur d with
e may lubricants/grease
indicate with high
imminent
temperature
failure
 properties.
Check for excessive play in area of the 
pulley.
 Inspection of discharge pressure

TOMRA
 Check oil and oil levels  Lubrication should
 Check running noise for possible only be carried out
Conveyors bearing damage with the lubricant
Gear Box  Check and replace the rubber buffers, specified on a data
if necessary
sheet provided with a
 Touch up or renew the surface  manual
coating

Conveyor  Measure the brake disk thickness 

 Measure and adjust working air gap
Motor  Inspect the switch contacts and
replace them if necessary
 Check motor rolling bearing and 
change if necessary
 Replace motor oil seals
 Clean motor cooling air ducts
  Check and clean air filter  This
 Clean condensation drain hole operation
can be done
in varying
time
depending
on visual
observation
s
Vibration  Bearings Thermal and mechanical  To be done regularly
Feeder vibration inspection to avoid breakdowns

bearings  Varying period depending on the Swiveling  Single shift

operation and type of bearing type of operation:
bearings lubrication
with no every 6
grease months
nipple are  Two shift
employed in operation:
(e.g Tail lubrication
Pulley) every 4
conveyers months
so greasing  Three shift
should be operation:
done strictly lubrication
by every 2
technicians. months
