Machinery Condition Monitoring : Principles and Practices book cover
1st Edition

Machinery Condition Monitoring
Principles and Practices

ISBN 9781138748255
Published July 26, 2017 by CRC Press

FREE Standard Shipping
USD $84.95

Prices & shipping based on shipping country


Book Description

Find the Fault in the Machines

Drawing on the author’s more than two decades of experience with machinery condition monitoring and consulting for industries in India and abroad, Machinery Condition Monitoring: Principles and Practices introduces the practicing engineer to the techniques used to effectively detect and diagnose faults in machines. Providing the working principle behind the instruments, the important elements of machines as well as the technique to understand their conditions, this text presents every available method of machine fault detection occurring in machines in general, and rotating machines in particular.

A Single-Source Solution for Practice Machinery Conditioning Monitoring

Since vibration is one of the most widely used fault detection techniques, the book offers an assessment of vibration analysis and rotor-dynamics. It also covers the techniques of wear and debris analysis, and motor current signature analysis to detect faults in rotating mechanical systems as well as thermography, the nondestructive test NDT techniques (ultrasonics and radiography), and additional methods. The author includes relevant case studies from his own experience spanning over the past 20 years, and detailing practical fault diagnosis exercises involving various industries ranging from steel and cement plants to gas turbine driven frigates. While mathematics is kept to a minimum, he also provides worked examples and MATLAB® codes.

This book contains 15 chapters and provides topical information that includes:

  • A brief overview of the maintenance techniques
  • Fundamentals of machinery vibration and rotor dynamics
  • Basics of signal processing and instrumentation, which are essential for monitoring the health of machines
  • Requirements of vibration monitoring and noise monitoring
  • Electrical machinery faults
  • Thermography for condition monitoring
  • Techniques of wear debris analysis and some of the nondestructive test (NDT) techniques for condition monitoring like ultrasonics and radiography
  • Machine tool condition monitoring
  • Engineering failure analysis
  • Several case studies, mostly on failure analysis, from the author’s consulting experience

Machinery Condition Monitoring: Principles and Practices presents the latest techniques in fault diagnosis and prognosis, provides many real-life practical examples, and empowers you to diagnose the faults in machines all on your own.

Table of Contents


Machinery Condition Monitoring

Present Status

Fault Prognosis

Future Needs

Principles of Maintenance


Reactive Maintenance

Preventive Maintenance

Predictive Maintenance

Enterprise Resource Planning

Bath Tub Curve

Failure Modes Effects and Criticality Analysis (FMECA)

Fundamentals of Machinery Vibration


Single Degree-of-Freedom Motion

Forced Vibration Response

Base Excitation

Force Transmissibility and Vibration Isolation

Tuned Vibration Absorber

Unbalanced Response

Characteristics of Vibrating Systems

Vibration of Continuous Systems

Mode Shapes and Operational Deflection Shapes

Experimental Modal Analysis



Simple Rigid Rotor-Disc System

Unbalance Response and Critical Speed

Journal Bearings

Oil Whirl and Oil Whip

Squeeze Film Dampers

Condition Monitoring in Large Rotor Systems

Digital Signal Processing


Classification of Signals

Signal Analysis

Frequency Domain Signal Analysis

Fundamentals of Fast Fourier Transform

Computer-Aided Data Acquisition

Signal Conditioning

Signal Demodulation

Cepstrum Analysis




Measurement Standards

Measurement Errors

Calibration Principles

Static and Dynamic Measurements

Frequency Response

Dynamic Range

Basic Measuring Equipment


Force Measurements

Rotational Speed

Noise Measurements

Temperature Measurements

Laser-Based Measurements

Current Measurements

Chemical Composition Measurement

Ultrasonic Thickness Measurement

Data Recorders

Vibration Monitoring

Principles of Vibration Monitoring

Misalignment Detection

Eccentricity Detection

Cracked Shaft

Bowed and Bent Shaft

Unbalanced Shaft



Bearing Defects

Gear Fault

Faults in Fluid Machines

Noise Monitoring


Acoustical Terminology

Noise Sources

Sound Fields

Anechoic Chamber

Reverberation Chamber

Noise Measurements

Noise Source Identification

Electrical Machinery Faults


Construction of an Electric Motor

Faults in Electric Motor

Fault Detection in Electric Motors

MCSA for Fault Detection in Electrical Motors

Instrumentation for Motor Current Signature Analysis

Fault Detection in Mechanical Systems by MCSA

MCSA for Fault Detection in any Rotating Machine

Fault Detection in Power Supply Transformers

Fault Detection in Switchgear Devices



Thermal Imaging Devices

Use of IR Camera

Industrial Applications of Thermography

Applications of Thermography in Condition Monitoring

Wear Debris Analysis


Mechanisms of Wear

Detection of Wear Particles

Common Wear Materials

Oil Sampling Technique

Oil Analysis

Limits of Oil Analysis

Other Methods in Condition Monitoring


Eddy Current Testing

Ultrasonic Testing


Acoustic Emission

Machine Tool Condition Monitoring


Tool Wear

Sensor Fusion in Tool Condition Monitoring

Sensors for Tool Condition Monitoring

A Tool Condition Monitoring System

Other Manufacturing Operations

Engineering Failure Analysis


Overview of Failure Analysis

Failure Modes

Failure Analysis

Failure Analysis Sampling Guide

Case Studies


Bend Pulley Failure Analysis

Root Cause Analysis of Torsion Shaft Failure in a Cement Plant

Failure Analysis of a Conveyor System Support Structure

Vibration Measurements on a Motor-Multistage Gearbox Drive Set




View More



Amiya R. Mohanty has been a faculty member at the Indian Institute of Technology Kharagpur, India, since 1996, and is currently a professor of mechanical engineering. He has a B.ScEngg (Hons) in mechanical engineering from the National Institute of Technology, Rourkela. He holds a master’s degree in machine design specialization from the Indian Institute of Technology, Kharagpur, and a PhD in the area of noise control from the University of Kentucky in the United States. Prof. Mohanty is a fellow of the Acoustical Society of India. He has consulted more than 50 companies, and published more than 100 journal articles.


"This book brings together condition monitoring content in a single text, a definite improvement over the single discipline-based texts that are currently on the market. The approachable writing style and limited use of equations make the text desirable reading for the practitioner, not just the academic reader. …The signal processing sections provide a succinct and effective overview to a subject matter that baffles the typical mechanical engineering or engineering technology student. The examples focus on real data and how to set up DSP for good practical results."
—Nancy L. Denton, Purdue University, West Lafayette, Indiana, USA

"The author presents an unbiased coverage of signal processing and instrumentation, without unwarranted focus on any particular technique, process, instrument or piece of equipment. …This work is obviously based on extensive knowledge and experience as an engineering researcher and consultant. …Like the author, I have struggled to find one suitable resource book on this broad subject. In my opinion, this book will solve that problem for a significant number of instructors as well as practitioners of machine condition monitoring."
—Chris Mechefske, Queen’s University, Ontario, Canada