Portable Vibration Shaker Demonstration & Advance Analysis Presentation

AF Condition Monitoring Sdn. Bhd. 15-1, Jalan Kenanga SD 9/4, Bandar Sri Damansara 52200 Kuala Lumpur, Malaysia.W: www.afcm.com.my | E. admin@afcm.com.my | T: +603-62734078 | Fax: +603-62734080

Speaker/Presenter

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Head of Mechanical Department

MSc. Computational Fluid Dynamics (Cranfield, UK)

Vibration Analyst Category II Certified SolidWorks Associate

Certificate (CSWA)

#2: Ahmad Syahid A. Fawzal#1: Ahmad Fawzal M. Noor

Managing Director MSc. Condition Monitoring

(Southampton, UK) Vibration Analyst Category III Infrared Thermography Level II Ultrasound Level I Partial Discharge Level I Certified Mobius Institute

(Australia) Trainer

ABOUT USAIM: To provide our client with consistent condition monitoring services and

training for enhancing their plant efficiency and reliability.

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CLIENTS

Electrical & Power Generation

TNB GenerationTNB Distribution

Kapar Energy VenturesJimah Energy Ventures

Pahlawan PowerPanglima Power

Oil & GasPetronas Gas

Petronas Penapisan

Petlin

Established in 1994 and ISO QMS 9001:2008 qualified since 2009 Appointed as a vendor under Vendor Development Program TNB since 1997, to implement

condition monitoring for their generation, transmission and distribution divisions. Approved Training Partner for Mobius Institute, Australia – Certified Vibration Analyst More than 20 years experience in condition monitoring disciplines:

Pre & Post Overhaul Vibration Analysis Vibration Sensor and System Verification Root Cause Machinery Failure Analysis Evaluating Machine Condition and Performance

Dedicated to R&D in order to continuously improve our analysis, simulation and test method.

Water UtilityJabatan Bekalan Air

N.SembilanJabatan Bekalan Air MelakaManufacturing Industry

CIMALAFARGEANSELL

Pulp & PaperPascorp IndustryGenting Sanyen

PORTABLE VIBRATION SHAKERDemonstration

Vibration Shaker

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Motivation

Check sensor sensitivity Verify sensor linearity Test alarm and trip limit Evaluate vibration system integrity

 

ADVANCE ANALYSISPresentation

Overview

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We are always expending our speciality! And now, we are offering several other services that will help your plant reliability program works. 

Overview

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Advance Service

Advance Vibration Analysis

Structure Analysis Operational Defection Shape

(ODS) Modal Analysis

Valve Leak Detection Detection Detection and Quantify

Piping Dynamic Vibration Flow Induced Vibration (FIV)

Analysis Acoustic Induced Vibration (AIV)

Analysis Pulsation Induced Vibration (PIV)

Analysis

We are always expending our speciality! And now, we are offering several other services that will help your plant reliability program works. 

Finite Element Analysis (FEA) Structural Analysis (Static) Non-Linear Stress Analysis Buckling Analysis Vibration Analysis (Frequency)

Computational Fluid Dynamics (CFD) Ventilation & Gas Dispersion Flow Assurance Heat Exchangers & Heat

Dissipation Fire & Combustion Modeling

Advance Vibrati on Analysis

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With years of experience in vibration field, AFCM also provide a wide range of advance analysis services such as:  Structure vibration analysis. Diagnostic analysis of reciprocating and turbo machinery Synchronous vibrations and balancing of rotating machinery Asynchronous vibrations, rotordynamic instabilities and fluid

hydrodynamic interactions.

Our advance vibration analysis allows in-depth understanding on machine behaviour.

Shaft Centreline

Bode plot

Polar plot

Orbit plot

Structure Analysis

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We employ two methods of structure analysis utilising vibration as follow: Operational Defection Shape (ODS) Modal Analysis

Operating Deflection Shape (ODS) Provides information on how the machine structure move during operational How?

Vibration measurements are collected at several locations on a machine Transfer functions are calculated between reference locations to other

sensor locations. Animate

Now, pointing out the locations and directions of structure excessive motion is easier then before

ODS of tandem IG fan with high vibration due

to combination problem

Structure Analysis

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Modal Analysis Determines the fundamental vibration mode shapes and corresponding

frequencies at which vibration naturally occurs analytically. Approach:

Operational Modal Analysis (OMA) Experimental Modal Analysis (EMA)

This helps us (and our client) to adjust their equipment accordingly in order to reduce system vibration that cause by resonance.  

Now, pointing out the locations and directions of structure excessive motion is easier then before

APPLICATIONS

Operating machineryMechanical structures with/without rotating components (e.g. turbines, engines and gas

compressors)

 Large civil engineering structures (e.g. bridges and buildings subjected to ambient loads)

Maritime structures (e.g ships and offshore structures)

Compressor and motor base displacement

magnitude

Valve Leak Detecti on

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APPLICATIONS

Detection of erosion damage in the body and trim of a bypass valve. May avoid:

the potentially catastrophic loss of containment of hazardous fluid which lead to: emergency shutdown, and subsequent loss of production.

product losses to the flare and fugitive emissions excessive valve damage due to prolonged leakage

Able to detect and estimate the size of valve leaks during operation.

Shut-Down Valve (SDV)

Safety relief valve (PSV)

Manual Operated Valve

Actuated  ValveBall valvePlug valve

Gate and globe valvesSlimline Double Block & Bleed (SDBB) and

Needle valves

Butterfly valve, wafer and lug type

Check valves, dual plate, piston, swing and non slam type

Find leaking valves long before detection by conventional methods or conservative instrumentation.

Valve Leak Detecti on

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Find the leak (Detection) Scrutiny of all available valve on site to identify through-valve leakage. Equipment is Intrinsically Safe (IS) for use in hazardous/gaseous

environments. Measure the leak (Quantify)

Quantitative equipment is used to quantify the internal valve leak rate.

“Search for a peak to detect your leak” - Midasmeter

How to determine the valve condition using MidasMeter

Piping Dynamic Vibrati on

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Vibration in piping induce cracks and leaks due to fatigue failure of the pipe. May lead to major disaster if lack of mitigation action taken.

Under collaboration with VibraTec who is French leader of vibration and acoustics, we are able to predict set of piping vibration as below:  Flow Induced Vibration (FIV) – vibration caused by kinetic energy of

turbulent fluid Acoustic Induced Vibration (AIV) – vibration caused by restricted orifice such

as relief valve, control valve or orifice plate. Pulsation Induced Vibration (PIV) – vibration caused by mechanical

equipment transmission. Our set of calculations are from Energy Institute (EI) Guide lines: Guide

Lines for the Avoidance of Vibration Induced Fatigue Failure in Process Pipe Work.

Determine your piping design is subjected to or free from any dynamic vibration force based on your design specification is crucial.

Piping Dynamic Vibrati on

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The main causes of these problems can be: Harmonic piping system response due to:

Incorrectly installed supports, Missing supports, Structures too soft to support the pipes.

Pulsating flow due to high excitations produced by process machines and: Incorrectly designed pulsation dampers, Missing pulsation dampers or restricted orifices.

Determine your piping design is subjected to or free from any dynamic vibration force based on your design specification is crucial.

ODS of a gas export line, including the supporting structure

Improvement of piping support to reduce vibration

Finite Element Analysis (FEA)

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Employ finite element method (FEM) to calculate component displacements, strains, and stresses under internal and external loads. 

Common design goal is excellent product performance and factor of safety (FoS).

Finite Element Analysis (FEA) services are: Structural Analysis – constant (static) or dynamic load. Linear and Non-Linear Stress Analysis Vibration Analysis (Frequency)

Evaluate the strength and stiffness of a product/design by calculate the component stress and deformations.

Factor of safety of pressure vessel design

Structure stress due to machine horizontal

motion

Computati onal Fluid Dynamics (CFD)

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CFD provides a detailed understanding of flow distribution, pressure losses, heat transfer, particulate separation, collection efficiency, etc.

Typically applied to: Design evaluation, verification and optimization Performance evaluation Problem solving, what-if scenarios Study off-design operating conditions

CFD simulation is a guidance and reduce testing cycle but does not a replacement.

CFD is a powerful engineering tool for predicting real complex-physics process behaviour.

Wind loading of offshore structure

Computati onal Fluid Dynamics (CFD)

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We offer Computational Fluid Dynamics (CFD) services for:a. Ventilation & Gas Dispersion

Heating, Ventilation and Air-Conditioning (HVAC) Gas detector location and suitability assessment Exhaust gas dispersion Flare cold venting Smoke propagation Helideck assessment

Exhaust gas dispersion (left: before, right: after)

Helideck assessment based on CAP 437 threshold of 2degC above ambient

CFD is a powerful engineering tool for predicting real complex-physics process behaviour.

Computati onal Fluid Dynamics (CFD)

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b. Fire & Combustion Modeling Flare hot venting Hydrocarbon fire risk modeling (safety)

Flame shape and shroud surface temperature for two different fuel and wind ratios

ESDV pit jet fire modelling

CFD is a powerful engineering tool for predicting real complex-physics process behaviour.

Computati onal Fluid Dynamics (CFD)

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c. Flow Assurance (3D multiphase flow evaluation, not empirical 1D tools) Slug catcher optimization Separator design evaluation

d. Heat Exchangers & Heat Dissipation

Colour contours of gas, oil and water in a separation tank

Waste Heat Recovery Unit

(WHRU) Optimization

CFD is a powerful engineering tool for predicting real complex-physics process behaviour.

Q & ASession