This thesis presents the design and experimental evaluation of an in-line, active ultrasound, condition monitoring setup for the detection of contamination in offshore bearing grease. This process is divided into three distinct research steps. First of all, the influences that affect ultrasound propagation through a bearing grease sample have been investigated through various laboratory experiments. Next, a practical, real-world experiment using a linear bearing has been designed and conducted with the aim of determining the applicability of such an in-line condition monitoring setup. Lastly, the performance of the in-line active ultrasound setup has been evaluated, improvements have been proposed and an overall condition monitoring strategy has been devised.

During the laboratory experiments, various influences on ultrasound wave propagation have been investigated. First of all, design-specific parameters, such as the distance between the sensors, the test-setup material, and the scalability of the measured output voltage have been investigated. Next, the effects of temperature fluctuations, air bubble fluctuations, water contamination and iron particle contamination on the attenuation and velocity of waves for active ultrasound spectroscopy were investigated. It has been shown that air bubble concentration and temperature fluctuations influence the attenuation of the ultrasound in the grease sample. Therefore, the temperature should be kept constant throughout the other experiments. Additionally, the air bubble concentration should be managed through a constant resting time throughout the other experiments. Moreover, it has been shown that a condition monitoring setup employing active ultrasound spectroscopy is able to determine water contamination and iron particle contamination. The highest sensitivity of this contamination detection is located in the first percentage of contamination concentration, showing an amplitude drop of about 0.5dB/mm to 1dB/mm and a change in speed of sound of about 5\% to 15\%. It is however, difficult to differentiate between the different types of contamination using only the attenuation and velocity spectroscopy methods.

The practical, real-world experiment using an operational Huisman linear bearing has illustrated the applicability of using an in-line grease condition monitoring setup in such an environment, by evaluating obstacles such as spatial constraints, location constraints, flowability of the grease and surrounding noise. It has been shown that these obstacles pose minimal challenges for the successful implementation of an in-line grease monitoring setup for effective condition monitoring of offshore bearing grease.

The evaluation of the improved in-line active ultrasound condition monitoring setup has highlighted the strengths and weaknesses of implementing such a setup for offshore applications. A possible combination of the proposed grease condition monitoring method with Acoustic Emission monitoring offers

Highly-loaded low-speed roller bearings are commonly used in the offshore machinery, for example in turret moorings systems of Floating Production Storage and Offloading (FPSO) units and in slew bearings in heavy-lifting cranes. Safe and reliable operation and structural integrity can be ensured by monitoring the condition of the bearing. Condition monitoring based on acoustic emission (AE) has shown good potential for monitoring the health of highly-loaded low-speed bearings. With the increase in potential and proven condition monitoring methods, the need for lifetime predicting methods is increasing.
In this thesis, the feasibility of a digital twin (DT) concept is tested to make lifetime predictions of a highly-loaded low-speed roller bearing. The developed DT uses a combination of the Paris model and an AE-based model presenting the current state of the bearing. In the remaining useful life (RUL) prediction, the final crack size and total number of load cycles are determined based on an integrated form of the Paris model. Three different forms were tested for the RUL prediction.
The Paris model and the AE-based model showed good agreement in a benchmark case, based on which the two models were combined. The AE-based prediction was tested for hits and counts, with the counts yielding into better results due to a better fitting of the model constants. The linear RUL based on the number of load cycles resulted in the best prediction. The developed DT showed good potential in making lifetime predictions of highly-loaded low-speed roller bearings and enrichment of future DTs with prognostic information.

Highly-loaded low-speed roller bearings are frequently used in equipment offshore e.g. slew bearings in crane, sheave bearings and FPSO turret bearings. Reducing maintenance costs, increasing productivity, ensuring safety of people and structural integrity and longevity assurance of equipment can be achieved by the condition monitoring of highly-loaded low-speed roller bearings.

Currently, very limited research is performed in the field of condition monitoring with acoustic emission (AE) monitoring for highly-loaded low-speed (<10 rpm) bearings with naturally developed damage. Acoustic emission monitoring has shown promising results in early stage and real time identification of defects according to literature. Furthermore, contamination of wear particles in lubricant shows an increase in AE activity according to literature.

In this research, the applicability of AE monitoring for damage assessment of highly-loaded low-speed roller bearings is investigated in a full scale duration test. Furthermore, the influence of contaminated lubricant with steel particles is investigated in the contamination test to study the feasibility of real-time detection of contaminated lubricant during operations and as a supporting technique for wear debris analysis in lubricant.

From the results, an increase in AE activity expressed in hit-rates is observed for a wide frequency band of 40 - 580 kHz during the duration test where the basic rating lifetime (L10) is consumed from 40% to 50%. Wear development in the bearing is observed during visual inspection and has been quantified with lubrication analysis.
A safety limit and a limit if the bearing is at risk for the AE activity has been defined with the results of the baseline and duration test. This research suggests that AE monitoring can be applied on highly-loaded low-speed bearings to assess the damage for representative operational conditions.

From the results of the lubricant contamination test, an increased AE activity with respect to higher lubricant contamination levels were observed. Furthermore, with a proper choice of the SNR-level, there is no masking effect of acoustic emission signals due to contaminated lubricant. The results of the contamination tests, indicates the possibility of detecting contaminated lubricant with AE monitoring.