Skip to content
Open
Show file tree
Hide file tree
Changes from all commits
Commits
File filter

Filter by extension

Filter by extension

Conversations
Failed to load comments.
Loading
Jump to
Jump to file
Failed to load files.
Loading
Diff view
Diff view
11 changes: 11 additions & 0 deletions field-guides/README.md
Original file line number Diff line number Diff line change
@@ -0,0 +1,11 @@
# Condition Monitoring — Field Guides

Practical guides for technicians taking readings on the Mechbase marine demo routes.

| Guide | Sensor / Instrument | Measurement |
|---|---|---|
| [Vibration](vibration.md) | TE Connectivity WVS wireless tri-axial accelerometer | Velocity (mm/s RMS) |
| [Thermography](thermography.md) | FLIR Edge series handheld thermal camera | Surface temperature (°C) |
| [Ultrasound](ultrasound.md) | Handheld ultrasonic detector | Signal level (dB) |

Each guide covers the instrument, how to set it up and take a reading correctly, and how to enter the result in Mechbase.
Binary file added field-guides/images/te-wvs-sensor.jpg
Loading
Sorry, something went wrong. Reload?
Sorry, we cannot display this file.
Sorry, this file is invalid so it cannot be displayed.
79 changes: 79 additions & 0 deletions field-guides/thermography.md
Original file line number Diff line number Diff line change
@@ -0,0 +1,79 @@
# Thermography — Field Guide

Camera: **FLIR Edge series** handheld (visual + thermal, MSX enhancement, FLIR ONE app)

---

## How the camera measures temperature

Thermal measurements show the **surface** temperature of the target. Accuracy depends on three factors:

| Factor | What to watch |
|---|---|
| **Distance to target** | Closer = better spatial resolution and spot size. Get as close/zoomed as safely possible. |
| **Ambient temperature** | Note ambient; it is the reference for ΔT calculations. |
| **Emissivity** | How efficiently the surface radiates heat (see below). |

### Emissivity

- **Matte / painted / oxidised surfaces** — good emitters; the camera's default ~0.95 setting is a fair approximation.
- **Bare / glossy / shiny metal** — poor emitters; the default setting will under-read. Apply a strip of high-emissivity tape or a dab of matt paint over the spot, **or** manually set the known emissivity in the camera before reading.

---

## Camera setup

1. Power on; let the camera warm up briefly.
2. Set the **temperature range** to suit the expected target (e.g. a wider range for electrical gear under fault conditions).
3. Choose a suitable **colour palette** (e.g. Iron or Rainbow for electrical; Greyscale for quick scans).
4. Enable **MSX** and set the MSX distance to match the target distance — this overlays visual detail on the thermal image for easier interpretation.
5. Use the **adjustable measurement spots** to track the hottest and coldest points in the frame. The camera periodically auto-calibrates (mechanical shutter click + brief freeze) — this is normal; wait for it to complete before reading.

---

## Inspection technique

### General

- Inspect under **normal / representative operating load** — an unloaded circuit or idle machine hides faults.
- Keep the **view angle within ~30° of perpendicular** to the target surface to limit reflection error.

### Electrical (switchboards, distribution panels)

1. Open the inspection cover or use an IR window where required (PPE: arc-flash rated).
2. Scan **busbars, breakers, incoming terminals, and all connections**.
3. Compare the **same component across all three phases** — a phase running hotter than its siblings under similar load indicates a loose or corroded connection, an overloaded circuit, or a failing device.
4. Note the hottest spot temperature (°C) and the ΔT above ambient or the reference phase.

### Mechanical (motors, bearings, pumps)

1. Scan **bearing housings** and **couplings**.
2. Compare each bearing housing against its pair or against its known baseline.
3. A bearing running hotter than its baseline or its paired housing suggests a lubrication or wear issue.

---

## Judging severity

Judge findings by **ΔT** (temperature rise over a reference point — ambient air, the established baseline, or a similar phase / component), not by absolute temperature alone.

| ΔT (over reference) | Typical severity |
|---|---|
| < 10 °C | Monitor — recheck at next route interval |
| 10–30 °C | Investigate — plan corrective action |
| > 30 °C | Act promptly — potential imminent failure |

*These are general guidelines; the Mechbase route item shows the configured limit band for this specific point.*

---

## Safety

- Do **not** point the camera at the sun or laser sources.
- For live electrical panels, maintain safe working distance and use appropriate PPE; use an IR window or a non-contact safe zone wherever possible.

---

## Recording the reading in Mechbase

Open the assigned **Route** → tap the **Measurement Item** for this thermal point → the item shows the limit band (minor alert: ~65 °C; major alert: ~90 °C in this demo). Enter the **maximum spot temperature** (°C) observed at the target and confirm.
73 changes: 73 additions & 0 deletions field-guides/ultrasound.md
Original file line number Diff line number Diff line change
@@ -0,0 +1,73 @@
# Ultrasound — Field Guide

Instrument: **Handheld ultrasonic detector** (contact/stinger probe + airborne horn; outputs a dB reading for manual entry)

---

## Three main applications

| Application | Probe | What you are detecting |
|---|---|---|
| **Bearing condition** | Contact / stinger probe on bearing housing | Structure-borne ultrasound from rolling-element wear or inadequate lubrication |
| **Leak detection** | Airborne horn | Compressed-air, steam-trap, and valve leaks |
| **Electrical** | Airborne horn | Partial discharge, arcing, and corona in switchgear |

---

## Bearing condition checks

1. Fit the **contact (stinger) probe** firmly to the bearing housing at the designated spot — same location and orientation every visit.
2. Adjust the instrument's frequency / sensitivity to the manufacturer's recommended setting for rotating-equipment surveys.
3. Listen through the headset and read the **dB level** displayed.
4. Record the value; compare to this point's baseline (see Interpretation below).

**Tip:** ultrasound detects incipient bearing faults earlier than vibration or thermography, especially on slow-speed bearings. It is also the primary tool for identifying lack of lubrication before a bearing overheats.

---

## Leak surveys (compressed air / steam)

1. Fit the **airborne horn** (focusing cone).
2. Sweep the area methodically from a safe distance.
3. Home in on the direction of the **loudest dB reading** — leaks produce a strong high-frequency hiss.
4. Once located, move closer to confirm and note the location, dB level, and estimated leak size.

**On a vessel:** cover compressor discharge lines, air receivers, valve glands, steam traps, and flexible hose connections.

---

## Electrical surveys (switchgear / panels)

1. Fit the **airborne horn**.
2. Hold the instrument near (not inside) the panel or cable tray.
3. Partial discharge, arcing, and corona all produce characteristic ultrasonic signatures.
4. Note the dB level and location of any hot spot.

---

## Interpreting bearing readings — trend-based thresholds

Always compare against the **same point's historical baseline**, not an absolute number.

| Rise over baseline | Indication |
|---|---|
| < +8 dB | Normal variation — continue monitoring |
| ~+8 dB (sustained) | Early / incipient wear or lubrication deficiency — investigate, consider re-lubrication |
| +12–16 dB | Advanced wear — plan maintenance |
| > +16 dB | Imminent failure — act promptly |

A single elevated reading can be caused by load spikes or probe placement variation. Confirm with a second reading before escalating.

---

## Good technique habits

- Use the **same probe, same spot, same pressure** every visit — variability in contact pressure changes the dB reading.
- Take readings when the machine is running under **normal operating load**.
- Note any unusual audible signatures (e.g. grinding, intermittent clicks) that the dB number alone does not capture.

---

## Recording the reading in Mechbase

Open the assigned **Route** → tap the **Measurement Item** for this ultrasound point → the item shows the limit band (minor alert: ~40 dB; major alert: ~50 dB in this demo). Enter the **dB value** displayed on the instrument and confirm.
81 changes: 81 additions & 0 deletions field-guides/vibration.md
Original file line number Diff line number Diff line change
@@ -0,0 +1,81 @@
# Vibration Monitoring — Field Guide

Sensor: **TE Connectivity WVS** wireless tri-axial accelerometer

![TE Connectivity WVS vibration sensor](images/te-wvs-sensor.jpg)

*Note the X/Y/Z axis marker on the hex base (align **X** with the shaft), the
magnetic twist-mount indicator, the threaded/stud base, and the Ex ia IIC (ATEX/IS)
rating for hazardous machinery spaces.*

---

## Mounting method — decision tree (best → temporary)

| Method | Use case | Notes |
|---|---|---|
| **Stud mount** | Permanent monitoring points | Best frequency response; solid metal-to-metal contact; conveys the full spectrum |
| **Epoxy mount** | Permanent; no stud possible | 2-part hard-curing epoxy (e.g. Loctite AA 330). Detach magnetic base, epoxy it to machine, re-thread sensor. |
| **Two-pole magnet** | Curved housings (e.g. motor end caps) | Two feet grip curved surfaces. Gently roll sensor into contact — do not thump it down. Do **not** use a flat magnet directly on a curved surface. |
| **Flat magnet on glued/soldered metal target** | Painted or curved surfaces where direct contact is impractical | Epoxy or solder a small flat metal target to the machine; mount flat magnet on the target. |
| **Flat magnet on clean flat surface** | Temporary spot-checks only | Magnets shift on dirty or irregular surfaces. For trend data, prefer a permanent mount. |

---

## Surface preparation

- Remove **all paint and rust** from the mounting area — multiple paint layers and rust severely dampen or block the signal.
- Vibration must travel through solid, continuous metal; any gap or joint in the path corrupts the reading.
- Target a **robust, flat, fully cleaned bearing-housing area**.

---

## Where to mount — placement

- Mount as close as feasible to the **monitored bearing**.
- Target the **load zone**: the section of the bearing housing that carries the rotating shaft — defects show up earliest there.

**On marine machinery take points at:**

1. Motor non-drive end (NDE) bearing housing
2. Motor drive end (DE) bearing housing
3. Driven-end bearing (pump / compressor / fan / purifier)

---

## What to avoid

Do **not** mount on:

- Thin cooling fins
- Plastic covers or fan shrouds
- Component enclosures

These surfaces resonate at their own frequencies or attenuate the true signal, producing inaccurate data.

---

## Sensor orientation (axis alignment)

The WVS is tri-axial (X / Y / Z axes).

1. Align the **X axis** (marked on the sensor body) with the motor **drive shaft**.
2. Keep the **same orientation on every visit** and across comparable machines.
3. Take readings at the **same physical point** each visit.

Inconsistent orientation makes trend analysis unreliable — today's X reading becomes last month's Y.

---

## Taking the reading

1. Mount the sensor at the designated point using the appropriate method above.
2. Allow a brief settle time after mounting (especially magnetic mounts).
3. Confirm the sensor is paired and transmitting in the WVS app / Mechbase.
4. Note the velocity value (mm/s RMS) displayed.

---

## Recording the reading in Mechbase

Open the assigned **Route** on your device → tap the **Measurement Item** for this point → the item shows the limit band (minor / major alert thresholds). Enter the velocity value (mm/s) and confirm. The system records the timestamp, value, and your user ID automatically.
Loading