FAILURE PREVENTION TECHNOLOGY TO IMPROVE THE BOTTOM LINE. Proceedings of. THE 56th Meeting. of the

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1 FAIRE PREVENTION TECHNOLOGY TO IMPROVE THE BOTTOM LINE Proceedings of THE 56th Meeting of the SOCIETY FOR MACHINERY FAIRE PREVENTION TECHNOLOGY VIRGINIA BEACH, VIRGINIA April 15-19, 2002 Compiled by HENRY C. and SALLIE C. PUSEY and W. R. HOBBS X BIBLIOT CO ISITA1 LL. ;> z 3 cc o HAM Ui -r* "6 X U rvg c u A Publication of the (Society for Machinery Failure Prevention Technology (MFPT) (A Division of the Vibration Institute)

2 MFPT56 PREFACE MFPT SOCIETY BOARD OF DIRECTORS vii viii FEATURED PAPERS Failure Prevention in the 21 SI Century 3 R. L. Eshleman What Every Reliability Professional Should Know 13 R. L Schuyler DATA FUSION Hydroelectric Generator Condition Monitoring: How Market-Driven Operation can Affect Unit Behavior 29 T. J. Walter, G. B. Hirschman, M. K. Krikorian and A. J. Westmacott Shipboard Demonstration of a Machinery Monitoring System 39 L D. Johnson and T. A. Merdes Machine Learning Methods for Helicopter HUMS 49 S. Menon and R. Hamza Conceptual and Tool Advances in Machinery Preventive Diagnostics 57 D. M. Ghiocel and J. Altman Fusion-Based Prognostics/Diagnostics for Oil-Wetted Components in Gas Turbine Engines 67 R. F. Orsagh, M. J. Roemerand C. J. Klenke Application of Cluster Analysis for the Diagnosis of Rotating Machines 81 L del Castillo, M. Artes and J. C. Garcia-Prada FAIRE ANALYSIS METHODS AND PRACTICES Metallography..A Look Inside 93 M. Pepi Detection of Thermal Damage in X2M Steel Components Using Barkhausen Noise Analysis Techniques 103 V. Champagne, P. Sincebaugh and M. Pepi OPEN SYSTEMS ARCHITECTURE FOR CBM A Framework for Next Generation Machinery Monitoring and Diagnostics 115 M. Lebold, K. Reichard, P. Hejda, J. Bezdicek and M. Thurston Open System Architecture for Condition-Based Monitoring - A CORBA/XML Implementation Gilbertson and B. Chidambaram

3 MIMOSA/OSA-CBM Proposed Information Standard Paves the Way for Wireless e-diagnostics 139 R. Lally and A. Rabiner Autonomous Agent Architecture for Industrial Distributed Control 147 F. Maturana, R. Staron, P. Tichy and P. Slechta Pump Diagnostics Using an Open Systems Architecture 157 F. M. Discenzo, D. Chung, J. Bezdicek, P. Hejda, D. Cernohorsky and O. Flek FAIRE ANALYSIS LESSONS LEARNED Chloride Contamination Leads to TI-6AL-4V Blackhawk Compressor Impeller Failures 169 W. Ziegler Effects of the FLASHJET Paint Removal Process on the Fatigue Properties of Al 7075-T6 and Al 2024-T3 179 J. Campbell, V. K. Champagne, S. M. Grendahl, W. W. Ziegler and J. E. Catalano Diesel Engine Valve Failures 189 D. Morehouse, J. Porter, J. Hiltz and M. Brauss INDUSTRIAL CASE HISTORIES I Industrial Case Histories 205 K. R. Guy PROGNOSTICS Integrating Prognostic Modules into Existing Naval CBM Systems 253 C. S. Byington, M. J. Roemer, M. J. Watson, K. Grieb, M. S. Lebold, J. C. Banks and T. Galie Enhancing Gear Physics-of-Failure Models with System Level Vibration Features 263 G. J. Kacprzynski, M. J. Roemer, C. S. Byington, G. A. Modgil, A. Palladino and K.P. Maynard Development of the Asset Health Management System for the Marine Corps Advanced Amphibious Assualt Vehicle 277 J. C. Banks, K. M. Reichard and M. S. Brought Probabilistic Modeling Techniques for Optimal-Cost Risk-Based CBM Strategy 287 D. M. Ghiocel Using Modeling to Predict Vibration from a Shaft Crack 299 J. H. Maxwell and D. A. Rosario GEAR DIAGNOSTICS Spur Gear Root Fatigue Crack Prognosis via Crack Diagnosis and Fracture Mechanics 311 C. J. Li and S. Choi IV

4 Gear Crack Detection Using Tooth Analysis 321 H. J. Decker Principal Components Analysis of Triaxial Vibration Data from Helicopter Transmissions 331 I.Y. Turner and E. M. Huff A Comparison of Residual Signal Extraction Techniques for Gear Fault Detection - Physics and Signal Processing 343 K. M. Reichard, K. T. McClintic and M. S. Lebold Evaluation of Standard Gear Metrics in Helicopter Flight Operation 353 M. Mosher, A. H. Pryorand E. M. Huff Detection of Gear Tooth Pitting Using Instrumental Variable Autoregressive Modelling 367 W. Wang SENSORS Wireless LAN Technology for Prognostics and Health Monitoring 377 G.W. Nickerson and L Watt An Intelligent Wireless Data Gathering System for Condition Based Maintenance 389 C. McLean and D. Wolfe Fiber Optic Sensors for Health Monitoring of Machinery, Infrastructure and Aircraft 399 K. R. Cooper, B. A. Childers, S. Poland, K. Furrow, T. Wavering and K. A. Murphy Machinery Sensor and Control System Failures - A Case History and Analysis 409 R. C. Tate and C P. Nemarich Feasibility of Corrosion Sensors for Condition Based Maintenance of Depleted Uranium Penetrators (from MFPT 55) 417 P. F. Buckley and J. V. Kelley THE BUSINESS CASE FOR CONDITION BASED MAINTENANCE Real Options Analysis as a New Economic Tool Linking CBM Investments to Business Strategy 429 F. M. Discenzo Enhanced Reliability Analysis and Capabilities of the Turbo-X Program for Maintenance Optimization 439 R. Orsagh, M. J. Roemer and S. Hesler Predictive Maintenance - The Effect on a Company's Bottom Line Part 1 - The Global View 453 B. Johnson and J. H. Maxwell Part 2 - Calculating Avoided Cost 469 S. Johnson and J. H. Maxwell

5 DIAGNOSTIC TECHNIQUES Condition Monitoring for Life Extension of Fast, High Density Battery Charging 485 J. D. Kozlowski, T. A. Hay, A. K. Garga and M. J. Watson Examination of Successful Modal Analysis Techniques Used for Bladed-Disk Assemblies 495 R. F. Orsagh and M. J. Roemer The Future Role of Current Analysis in Predictive Maintenance 507 N. P. Bethel and J. R. Nicholas, Jr. Prediction of Machine Performance Using Recurrent Neural Networks 517 M. A. Essawy INDUSTRIAL CASE HISTORIES II Vibration Cases by Classifications 527 C. Jackson May the Force NOT be With You 553 C. Jackson AUTHOR INDEX 563 VI