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timeline for making profit: Investors will need an indication of when they expect some return on their investment so you need to provide some reasonable timelines of when that will be Faculty: Engineering and Construction Course Title: Level Instructions for the use of this cover sheet (1) A cover sheet is required for every activity including presentations (2) Please complete all sections below (3) Attach the cover sheet to your activity. Student name: Unit Name: Condition monitoring and fault diagnosis (R/601/1422) Unit No: 50 Assessment No: 1 of 2 Title: Condition Monitoring Hand out date: 02/12/15 Hand in date: 03/02/15 LO Learning outcome (LO) AC In this assessment you will have the opportunity to present evidence that shows you are able to: Task no. Evidence (Page no) 1 Understand the concepts of condition monitoring 1.1 Describe the causes of failure and breakdown in plant and equipment and explain the use of statistical data for analysing such failure/breakdown 1, 3 1.2 Describe plant and machinery monitoring arrangements and explain the relative merits of each arrangement 2 1.3 Provide a computer data analysis printout of machine operating parameters 3 1.4 Explain how condition monitoring may be integrated within normal plant and machinery, control and data acquisition systems 4 2 Understand the nature and use of condition monitoring techniques 2.1 Explain the nature of the condition monitoring techniques used to monitor temperature and vibration and to detect leakage, corrosion and cracks 5 2.2 Analyse an overall system for plant and machinery condition monitoring and report findings 6 Learner declaration I certify that the work submitted for this assignment is my own and research sources are fully acknowledged. Student signature: Date: Activity designed by Assessed by Name: Richard Wray Name: Date: 21/09/15 Date: Internally Moderated by Internally Verified by Name: J. Pointer Name: Date: 09/11/15 Date: In addition to the above PASS criteria, this assignment gives you the opportunity to submit evidence in order to achieve the following MERIT and DISTINCTION grades Grade Descriptor Indicative characteristic/s Contextualisation M1 Identify and apply strategies to find appropriate solutions Complex information/data has been synthesised and processed. Complex information has been used to determine the potential failure point of the engineering system. The data has been used correctly to obtain an accurate solution. Appropriate method and technique has been demonstrated. (Task 3) M2 Select/design and apply appropriate methods/techniques A range of methods and techniques have been applied. Consideration has been given to the selection of CM techniques and application to an engineering system. Reasoned judgements are made about the factors affecting the positioning of sensors. Strategies have been applied to find the appropriate solution. (Task 2) M3 Present and communicate appropriate findings A range of methods of presentation have been used and technical language has been accurately used. The slides prepared have an appropriate structure and approach to demonstrate how a solution has be obtained to the problem posed by the assignment scenario (figure 1). The materials have been prepared, present and communicate at the appropriate technical level. (Task 7) D1 Use critical reflection to evaluate own work and justify valid conclusions Realistic improvements have been proposed against defined characteristics for success. The application of the proposed CM system design meets the defined criteria. (Task 7) D2 Take responsibility for managing and organising activities Substantial activities, projects or investigations have been planned, managed and organised. The Gantt Chart is been developed to show a realistic plan and is annotated to show progress made. The assignment has been completed on time. Autonomy has been demonstrated and deadlines met independently. (Task 8) D3 Demonstrate convergent/lateral/creative thinking Problems have been solved. Decisions have been taken and appropriate techniques have been used to analyse the current system CM data. (Task 6) Purpose of this assignment This assignment will give you the opportunity to demonstrate your knowledge of maintenance strategies and condition monitoring systems. You will investigate the design and application of condition monitoring techniques and systems. In addition you will collect and analyse condition monitoring data. Scenario You are working as a junior engineer for a marine maintenance company. The company has completed the installation of two electrically driven centrifugal pumps (see figure 1) on board a container ship. The pumps will be operated in a duty/standby configuration and supply cooling water to the ship’s engines. The maintenance department are now assessing the new equipment to determine the most appropriate intervention strategy. Regarding the application of condition monitoring, you have been asked to complete the following tasks in readiness for a presentation to the maintenance manager on whether this is an appropriate strategy. Figure 1. Cooling water system supply pumps Task 1 : (LO 1: 1.1) i) Before determining the operational characteristics of the cooling water system, a complete understanding of the equipment’s operation and materials of construction is required (see figure 2). Describe the construction and principle of operation of both the three phase ac motor and the centrifugal pump. ii) From your research into the operation of the cooling water pump and motor system, identify the potential problems and faults that could occur with this equipment in the marine environment. For each potential failure, identify the probable causes and how these could be detected using a condition monitoring system. Figure 2. Cooling water system motor and pump Task 2 (LO 1: 1.2, M2) i) Design an appropriate condition monitoring system for the cooling water pumping equipment. Explain the positioning of specific sensors to ensure meaningful measurements can be taken that will fully characterise the equipment’s operation. ii) Explain the merits and limitations of each condition monitoring system, and the choice of component parts, including sensors, signal transmitters, indicators and data loggers. Task 3 (LO 1: 1.1, 1.3, M1) To support the assessment of the new pumping equipment you are required to analyse historical condition monitoring data from an existing system (see figure 3). Tables 1 and 2 below shows the vibration and temperature data gathered from the motor and pump bearings over a 12 week period. Figure 3. Cooling water system motor and pump bearing configuration Table 1. Vibration Data Table 2. Temperature Data   Motor Back Bearing (mm/s) Motor Front Bearing (mm/s) Pump Bearing (mm/s)   Motor Back Bearing (⁰C) Motor Front Bearing (⁰C) Pump Bearing (⁰C) Week 1 20 12 25 Week 1 34 23 37 Week 2 16 10 5 Week 2 25 23 42 Week 3 21 13 24 Week 3 44 28 41 Week 4 18 21 9 Week 4 44 42 45 Week 5 7 25 18 Week 5 35 26 43 Week 6 22 5 11 Week 6 30 25 35 Week 7 21 11 16 Week 7 27 28 38 Week 8 20 17 20 Week 8 31 40 37 Week 9 12 12 22 Week 9 28 38 35 Week 10 17 23 13 Week 10 32 42 41 Week 11 17 22 17 Week 11 37 23 40 Week 12 25 25 20 Week 12 28 43 38 i) Analyse this data to determine if it indicates any emerging fault conditions within the equipment. Comment on the results. ii) The manufacturer of the existing pumping system state that the bearing temperatures should not rise above 45 ⁰C and bearing vibration should not exceed 30 mm/s. Apply appropriate trending techniques to the data and evaluate the results to predict any potential equipment failures and the weeks that the manufacturer recommended limits could be exceeded. What action would you take to prevent this happening. Task 4 (LO 1: 1.4) i) The condition monitoring process can take the form of on-line or off-line systems. Explain the different approaches and associated issues with each, including advantages and disadvantages. ii) Assessing the system for leaks, corrosion and cracks through the application of on-line monitoring could present challenges to the maintenance engineer. Propose appropriate Condition Monitoring methods and techniques to meet these challenges. iii) Alternative maintenance strategies that could be adopted for this system include run to failure (RTF) and planned preventative maintenance (PPM). Explain these strategies and how condition monitoring could be used to support both RTF and PPM. Task 5 (LO 2: 2.1) i) Select an appropriate sensor for each of the following applications and explain its construction, and principle of operation. a) Temperature monitoring b) Vibration monitoring c) Leak detection d) Detecting corrosion and cracks ii) In addition, identify a commercially available sensor for each. Include manufacturer, model number and cost. Achievement Summary Qualification HND in Marine Engineering Assessor name Richard Wray Unit Number and title Unit 50: Condition monitoring and Fault Detection Student name Criteria Reference To achieve the criteria the evidence must show that the student is able to: Achieved? (tick) LO 1 1.1 Describe the causes of failure and breakdown in plant and equipment and explain the use of statistical data for analysing such failure/breakdown 1.2 Describe plant and machinery monitoring arrangements and explain the relative merits of each arrangement 1.3 Provide a computer data analysis printout of machine operating parameters 1.4 Explain how condition monitoring may be integrated within normal plant and machinery, control and data acquisition systems LO 2 2.1 Explain the nature of the condition monitoring techniques used to monitor temperature and vibration and to detect leakage, corrosion and cracks 2.2 Analyse an overall system for plant and machinery condition monitoring and report findings Higher Grade achievements (where applicable) Grade descriptor Achieved? (tick) Grade descriptor Achieved? (tick) M1: Identify and apply strategies to find appropriate solutions D1: Use critical reflection to evaluate own work and justify valid conclusions M2: Select / design and apply appropriate methods / techniques D2: Take responsibility for managing and organising activities M3: Present and communicate appropriate findings D3: Demonstrate convergent/lateral/creative thinking Assignment Feedback Formative Feedback: Assessor to Student Action Plan Summative feedback Feedback: Student to Assessor Assessor signature Date Student signature Date