Schedule of Events

Registration

DAY 1

WS1: Practical vibration analysis workshop: Interactive and challenging case studies (Full Day)

Scott Dow, Senior Instructor, Mobius Institute

The Practical Vibration Analysis workshop, presented by Scott Dow, will provide an opportunity to sharpen your diagnostic skills and strengthen your depth of knowledge. This is no ordinary conference workshop. You will be challenged. You will be made to think. And you will learn essential skills that all vibration analysts must have to confidently diagnose the trickiest fault conditions (that might otherwise leave you frustrated and even embarrassed). Rather than teaching you how to diagnose faults, you will actually try to diagnose faults yourself. You will either learn from your mistakes or gain confidence from your victories.

During the workshop you will be grouped in a small team of three vibration analysts and given access to a range of information and data. You can ask for additional information, and you can perform additional tests, but everything you do will cost “points”. The aim is for your team to solve each of the diagnostic challenges (while being coached by Scott) and “beat” the other teams.

Scott has years of experience in vibration analysis and training (he is a senior Mobius Institute instructor) and the case studies you will solve have been chosen to include a range of difficulties and applications. So whether you are Category I or Category IV, you will gain a lot from this workshop.

Unfortunately, space is strictly limited and the available places will be taken quickly, so please register soon.

Here are some testimonials from people have been through this experience previously (during our “Vibration Analyst Flight School” courses).

“Experience is the best teacher and this class provides the opportunity to gain experience and learn from mistakes without the pain of having to explain why you made those mistakes to upper management.”
Eugene Begley, Cat I

“There is nothing as valuable as learning from experience. Taking difficult problems, trying to solve them and then having someone walk you through the solution is priceless.”
Sheldon Bayles, Cat II

“This class was one of the best I’ve ever attended due to the practical, hands-on approach.”
Dan Fiscus, Cat III

A mechanical engineer by trade, Scott Dow has been working in the vibration world for over 25 years. During that time, he has worked extensively as a field analyst and as a trainer, teaching formal classes and also mentoring clients individually and in small groups. During the mid-90s, Scott developed an innovative training technique based on recreating interesting and educational case studies he had encountered. Students would receive the actual data to analyze and were free to request any field tests they thought would help them diagnose the problem, which eventually they would have to do in the form of a submitted report that was assessed in light of the actual (known) case fault(s). In practice, this method has proven to be highly successful, allowing students to bridge the divide between theory and successful application of that theory in identifying machinery faults. You can find this case study technique being used as an important part of Mobius’ new class on Time Waveform Analysis (TWA).

Scott currently owns his own business, CBM Consultants, with one of his primary duties being  the Principle Instructor for Mobius Institute North America. When he is not conducting Mobius classes, he continues to mentor both individuals and small groups with either on-site or remote support for database setup, building analysis skills, field testing and more.

AMWS2: Ferrography and oil analysis provides an early warning of bearing failures

KNV Subrahmanyam, Chief Technology Officer, AIMIL Ltd

Lubricants are the life blood of oil wetted machinery. As an important element of predictive maintenance technologies, in-service oil analysis can provide trace information about machine wear condition, lubricant contamination as well as lubricant condition. Reliability engineers and maintenance professionals can make maintenance decisions based on the oil analysis results. The immediate benefits of in-service oil analysis include avoiding oil mix up, contamination control, condition based maintenance and failure analysis, etc. In-service oil analysis always supports and acts as a value addition to the Predictive, Proactive Maintenance techniques in detecting the early stages of machinery components damage which can help controlling/avoiding the damage in critical machinery components.
This session explains how used oil analysis and ferrography is being conducted on critical equipments and followed by case studies on oil analysis and ferrography in diagnosing the diffrent machine components wear at an early stages. Detailed case histories about diesel engines, heavy duty gear boxes, Steam Turbines, Slow speed bearings etc in industrial sectors like cement, railways, shipping and power plants will be explained on how the failure modes were detected using oil analysis and ferrography.

K.N.V.Subrahmanyam, Chief Technical Officer-Oil Analysis Testing Services at Aimil Ltd, Mechanical Engineer and MBA in Oil & Gas Management and Certified Category III Machinery Lubricant Specialist from International Council for Machinery Lubrication, USA. Over 16 years of practical experience in used oil analysis, Ferrography and lubrication management and started my career as Lubricant and Wear Debris Analyst and has rich Industrial lubrication experience in using Ferrogrpahy/Wear debris analysis. Published technical papers on Ferrography & Oil analysis importance in the equipment reliability and well renowned lubrication specialist in India. Actively working with Condition monitoring society of India, Tribology society of India, STLE & Noria Corportaion. Professional trainer for Lubrication training’s for Noria India and Middle east. Delivered professional lubrication training programs over 50 and conducts regular lubrication awareness programs in Indian industries.

AMWS3: Practical Signal Processing for Optimizing Benefits of Vibration Analysis

Dr. Suri Ganeriwala , President, Spectra Quest Inc. Tony Barlow, Chevron

This workshop will provide attendees with the fundamental principles of digital signal processing in a simplified manner without resorting to the underlying complex mathematical structure.  Students will learn how to utilize their existing vibration analysis tools to extract the maximum information from the vibration signal. The benefits will include how to determine the sampling rate, resolution, max frequency, and how to distinguish if you are missing a frequency component in your selected resolution, etc.  I will also, present the new developments such as Spectra Kurtosis, Cepstrum Analysis, order tracking, and demodulation techniques.

Attendees will be able to perform computer simulation exercises involving different waveforms, frequency spectra, resolution, frequency lines, aliasing, effects of leakage and ways to compensate, various window functions, data smoothing by averaging, and modulations.    You will learn how to set up your data collector to maximize the benefits.  SpectraQuest simulation software will be available to clarify important concepts.

Please bring you laptop to install a copy of Signal Processing Simulation software-free for thirty days!

Dr. Suri Ganeriwala is the founder and President of SpectraQuest Inc. Suri has over 30 years of industrial and academic experience in machinery vibration diagnostics and control, signal processing and viscoelastic materials characterisation. Suri has worked for Philip Morris, Firestone and Martin Marietta Aerospace. He has developed a unique method of instruction using the SpectraQuest machinery fault simulator (MFS), which is his creation from concept to completion. He has authored over 50 papers and articles in journals, magazines, conference proceedings and books. He obtained a PhD in Mechanical Engineering from the University of Texas, Austin, USA. Suri serves on the MFPT Board of Directors and is Leader of the Signal Analysis Forum.

WS1: Practical vibration analysis workshop: Interactive and challenging case studies (Full Day)

Scott Dow, Senior Instructor, Mobius Institute

The Practical Vibration Analysis workshop, presented by Scott Dow, will provide an opportunity to sharpen your diagnostic skills and strengthen your depth of knowledge. This is no ordinary conference workshop. You will be challenged. You will be made to think. And you will learn essential skills that all vibration analysts must have to confidently diagnose the trickiest fault conditions (that might otherwise leave you frustrated and even embarrassed). Rather than teaching you how to diagnose faults, you will actually try to diagnose faults yourself. You will either learn from your mistakes or gain confidence from your victories.

During the workshop you will be grouped in a small team of three vibration analysts and given access to a range of information and data. You can ask for additional information, and you can perform additional tests, but everything you do will cost “points”. The aim is for your team to solve each of the diagnostic challenges (while being coached by Scott) and “beat” the other teams.

Scott has years of experience in vibration analysis and training (he is a senior Mobius Institute instructor) and the case studies you will solve have been chosen to include a range of difficulties and applications. So whether you are Category I or Category IV, you will gain a lot from this workshop.

Unfortunately, space is strictly limited and the available places will be taken quickly, so please register soon.

Here are some testimonials from people have been through this experience previously (during our “Vibration Analyst Flight School” courses).

“Experience is the best teacher and this class provides the opportunity to gain experience and learn from mistakes without the pain of having to explain why you made those mistakes to upper management.”
Eugene Begley, Cat I

“There is nothing as valuable as learning from experience. Taking difficult problems, trying to solve them and then having someone walk you through the solution is priceless.”
Sheldon Bayles, Cat II

“This class was one of the best I’ve ever attended due to the practical, hands-on approach.”
Dan Fiscus, Cat III

A mechanical engineer by trade, Scott Dow has been working in the vibration world for over 25 years. During that time, he has worked extensively as a field analyst and as a trainer, teaching formal classes and also mentoring clients individually and in small groups. During the mid-90s, Scott developed an innovative training technique based on recreating interesting and educational case studies he had encountered. Students would receive the actual data to analyze and were free to request any field tests they thought would help them diagnose the problem, which eventually they would have to do in the form of a submitted report that was assessed in light of the actual (known) case fault(s). In practice, this method has proven to be highly successful, allowing students to bridge the divide between theory and successful application of that theory in identifying machinery faults. You can find this case study technique being used as an important part of Mobius’ new class on Time Waveform Analysis (TWA).

Scott currently owns his own business, CBM Consultants, with one of his primary duties being  the Principle Instructor for Mobius Institute North America. When he is not conducting Mobius classes, he continues to mentor both individuals and small groups with either on-site or remote support for database setup, building analysis skills, field testing and more.

PMWS2: An animated introduction to fluid-film bearing vibration analysis workshop

Jason Tranter, Founder & CEO, Mobius Institute

Orbit plots, centerline plots, full-spectrum plots, Bode plots and polar plots hold critical information, but how do you interpret them, and where does the data come from? This workshop will answer those questions using the famous Mobius animations and simulators. After explaining the proximity probe and keyphasor measurements (including direct, compensated and filtered data), we will explain each of the plot formats and cover a number of fault conditions: unbalance, preload, looseness, rubs, oil whirl and oil whip. We will also discuss a little about the bearings (spherical, elliptical and tilt-pad) and rotor dynamics (mode shapes, criticals, phase shift). It will be animated and interesting, and a great introduction for Category III and IV training/certification.

Jason Tranter (BE Hons) has been involved with condition monitoring and vibration analysis since 1984. In 1986 Jason formed his Australian company, ARGO, which was heavily involved in vibration monitoring and systems development. In 1990 he sold that company and the “ALERT” product line to DLI Engineering in Seattle (now AzimaDLI). Jason was in charge of product development, and later in charge of vibration products. In 1996 Jason returned to Australia and for the next three years he developed the ExpertALERT (EAV), DCX data collector, and DCX Online products for DLI Engineering. In 1999 Jason formed Mobius and began the development of the iLearnInteractive series of computer-based products for vibration and alignment training and analysis, including iLearnVibration, iLearnAlignment and Interpreter. These products have been used by thousands of people in over 90 countries to learn and become certified. Mobius was awarded the Victorian Regional Exporter of the year and was a finalist in the Australian Export Awards for 2007 and 2008. In 2005 Jason formed the “Mobius Institute” for expanded distance learning and public courses, and courses that comply with ISO and ASNT standards for certification. Mobius has offices in Australia, the United States and Costa Rica, and training centers in over 40 countries. In 2010 Jason formed the Mobius Institute Board of Certification, a not-for-profit organization to make it possible for vibration analysts anywhere in the world to achieve certification per ISO 18436-1. Jason has delivered technical papers around the world, and has had articles published in numerous international magazines and journals.

PMWS3: Time signal analysis of ultrasound signals workshop

Tom Murphy, Corporate Training Manager, SDT Ultrasound Solutions

In the “old days” of vibration, time signal analysis was what you did – generally on an oscilloscope from a signal recorded on a tape recorder. The modern world of vibration seems to think that time signal analysis is complicated. If you are in this category, you need to attend this workshop. Going from the very simple steps of one and then two sine waves, learn how to understand the wealth of diagnostic information that is in that time signal. The course will focus on ultrasound signals, but if you need some help just for vibration you will find this course useful.

Degree in Acoustics Chartered Engineer Certified Reliability Leader 34 years in vibration measurement, 23 years using IR and 17 years using ultrasound. Tom Murphy has worked in the field of vibration measurement and specifically condition monitoring for most of his professional life. He now assists Companies to develop or re-vitalise their programs with a clear focus on the overlap between the various technologies.

DAY 2

STREAM 1

1S1: Case Study: Detection of bearing outer and inner ring severe flaking fault through vibration analysis

Zaheer Abbas Khan, Senior CBM Engineer, Plant Asset Efficiency Solutions

Case Study contains the complete comprehensive detection of severe flaking fault on bearing outer and inner ring through vibration analysis. There are two rolls of paper machine which encountered this problem.Timely and successful diagnosis through vibration analysis saved machine from highly unwanted downtime of approximate 24 hours. Case Study has complete vibration spectrums before and after bearing replacement. Replaced bearing pictures are also added in case study. Case Study gives a great information and practical knowledge regarding how to detect the bearing outer and inner ring faults.

I am a Condition Monitoring and Reliability Professional having almost 9 Years of Experience.I exhibit ability to implement and strengthen continuous improvement using reliability tools, predictive maintenance Techniques (Vibration analysis, Lube oil analysis, Acoustic, etc.) and experience executing FMECA, RCA and Criticality Analysis. Have Worked for almost all sectors e.g. Paper,Cement,Power,Fertilizers and Oil and Gas etc.

STREAM 2

2S1: Case Study: Opportunity, challenges and risk of machine health monitoring market in Asia Pacific 2022

Madhavendra Saxena , Associate Professor, Global Institute of Technology

Machine Health Monitoring Provides Detailed Information About The Health Of Plant Machinery, Machine Health Monitoring Market Is Projected To Cross $3.20 Billion by 2022. The Factors That Are Driving Vibration monitoring is expected to lead the global machine condition monitoring market between 2016 and 2022. Vibration monitoring plays a critical role in plant operations because of its diverse applications in different types of critical machinery. The automotive industry is witnessing enormous growth in the number of units produced in a day. The Growth of the Market includes the use Of Wireless Communication Technology, Growth in HVAC Systems market, Rising Trend of Smart Factory or Industry and Transition from Preventive to Predictive Maintenance. “There Is A High Demand For This Market And it is Expected To Increase In Future” The machine condition monitoring market for the automotive industry will grow at a high rate between 2016 and 2022. The growing level of mechanization and automation in the manufacturing sector today has led to increased focus of players towards the efficiency of plant and hence the production processes.  Asia Pacific region is emerging market for the condition monitoring system, and is anticipated to represent substantial growth during the forecast period, particularly in regions such as China and India. Japan is other significant region and expected to contribute major share in the global condition monitoring system market.

STREAM 1

1S2: Case Study: Cooling water pump gearbox failure and remedial actions

Haider Ali, Machinery Engineer, Engro Fertilizers Asad Akram Awan, Machinery Engineer, Engro Fertilizers

Cooling water pumps are the life line of any petrochemical plant.

This case study expounds failure of gearbox installed on a cooling water pump with a rated capacity of 16240 m3/h at 47.5 meter of head. Bevel type gearbox is used to transfer work from horizontal stream turbine to vertical centrifugal pump. The unit was commissioned in 2010 and runs in parallel to 03 other identical pumps.

After 2.5 years of continuous operation, the unit developed an abnormal noise with slightly higher impacting (vibration waveform) on the gearbox. However upon inspection, increased back-lash (still in recommended limit) was observed on the unit and the machine was kept in operation.

During a startup in March 2014, high cyclic impacting was observed in vibration waveform which indicated gearbox wear/damage. Upon inspection leading edge teeth of the bevel gearbox was found broken. Further investigation revealed increased back-lash and change in contact area of the gears.

Case study covers the difficutly in data collection on the unit coupled with the vibration analysis that lead to the discovery of broken tooth. The case study also includes RCA of GB failure and the remedial action taken on similar units installed on site.

This Case study will be helpful to similar operating industries regarding the unique operational experience.

STREAM 2

2S2: Case Study: Successful condition monitoring - Teamwork of vibration analysts, maintenance and operations

Arun Kumar, General Manager - Maintenance & Reliability, HPCL- Mittal Energy Limited Anurag Chopra, Manager - Reliability (Rotary), HPCL- Mittal Energy Limited

Objective: To share practical aspects of vibration analysis & impress upon that a successful & effective trouble shooting & resolution is a joint participation of analysts maintenance & operations.

Scope: The paper/presentation shall detail out following:
Sharing of experiences with back up data that  in case of  typical vibration problem solutions, how much cases are resolved with vibration signatures alone & how much resolved with integrating past machine history, past maintenance work history, operation parameters and active involvement  of reliability, maintenance and operation staff. How a condition monitoring program should be designed for a process industry shall also be discussed.

Supported by interesting case studies:
Case study 1: In a refinery, unintentional removal of some unwanted/spared equipment led to sharp rise in vibration of other / neighboring equipment on the same platform and putting back the same weight led to reduction of vibration within satisfactory limits. Here the area maintenance supervisor played important role in directing the trouble shooting towards changes made on the platform equipment leading  to high vibrations on the neighboring equipment

Case study 2: Change in pumping media temperature by few degrees centigrade, led to sharp rise in vibration levels . In some pumps handling same  media at same temperature, no change in vibration. Here pump operator assisted the vibration analyst in arriving on exact cause of vibrations on pump.

Case study 3 :  It’s about gas turbine, in captive power plant of refinery, where in-situ balancing had to be carried out on a refurbished rotor to resolve problem of high vibrations faced on restart of gas turbine after its overhauling and putting refurbished rotor. The root cause was error made during assembly of rotor while its refurbishing and maintenance staff helped the vibration analyst to arrive at root cause.

Conclusion: At the end healthy discussion, we will highlight the practical side of condition monitoring & sharing of experiences.

STREAM 1

1S3a: (20 min.) Case Study: Deepwater Oil Offshore Challenges in Vibration Condition Monitoring

Ramos Jolito Jr., CBM Specialist, ROTADYN Solutions Inc. & Firm Synergy Sdn Bhd Holdings

The opportunity to starts a Vibration Condition Monitoring Program for the two largest Deepwater Oil and Gas platform in comes with a challenge. The experience I gained from years of practice in vibration condition monitoring helps a lot and as an active trainer in Reliability and Maintenance practices such as Vibration Analysis, Balancing, Alignment and other CBM techniques.

Here of lists of cases we encounter and other information expected from this sharing session:

  1.  Ballast Pump bearing showing exactly fault at harmonics of inner race, this happens even though it is seldom running. Why?
  2.  Mist Eliminator Blowers (MLO) Blowers for GE gas turbine exhaust application keeps on failing on bearing. Vibration survey able to detect this and further investigation on the failed bearing reveals more information about the source.
  3.  Unbalance problem mixed with structural problem are challenging for the Atlas Kopco™ compressors. These are small axial blower for inter and after cooling system and they are critical. Balancing reduced the vibration level although fluctuating vibration still persist, why and how do we solved this?
  4.  Operating Deflection Shape was utilized to determine the movement of Vacuum Pump and Deaerator mixer, why we did it and how did we get a benefit from it.
  5.  Lastly, a sharing of our practices in setting up a database and routine for Deep Water platform which also applies on different industries.

Graduated with a Degree in Mechanical Engineering and continued study in Masters of Engineering Management from Mapua University.
A certified ISO Category III instructor for Mobius Institute in Philippines and Malaysia. Successfully facilitated certification trainings in Vibration Analysis and practical hands-on workshops in Shaft Alignment and Machine Balancing.
Certifications includes:
• Vibration Analyst ISO Category Level III
• Certified Maintenance and Reliability Professional (CMRP)
• Machine Lubricant Analyst ISO Category Level II
• Thermography Level I
Jolito worked in cement plant and helped developed a successful condition monitoring program there, after 6 years he moved to Emerson Process Management Asia Pacific Pte Ltd in Singapore and lead the Vibration Condition Monitoring team for Shell Eastern Petroleum – Pulau Bukom overseeing more than 3,000 rotating equipment ensuring reliable operations. In 2014, he then moved to Malaysia to start develop Vibration Condition Monitoring Program for Shell Deepwater Platforms.
He founded Rotadyn Solutions Inc. (www.,rotadynsolutions.com) in the Philippines to help improve the practices Vibration Condition Monitoring and Maintenance & Reliability as well.

STREAM 2

2S3: Accurate condition monitoring of ultra-low and low speed machines

Tim Sundstrom, Manager of Strategic Sales & Application, SPM Instrument AB

Vibration Enveloping has been a valuable tool for the vibration analyst for decades, it provides an earlier fore-warning time compared to the traditional overall velocity measurements.

By using state of the art digital signal processors and innovative algorithms it’s possible to produce results that takes the vibration envelope method to new levels.
Many of the mission critical machines found in the industry today are running with low or ultra-low speeds. It has been seen as very challenging or even impossible to accurately monitor the condition of such machines using vibration based methods.
HD Technology is the perfect choice for condition monitoring of these machines but also to increase the pre-warning times for machines running at more “normal” speeds.
The presentation will cover the fundamentals of bearing damage processes and explain the new technology including plenty of real world examples.

1S3b: (20 min.) Case Study: Vibration Field Diagnostic and Challenge

Khairil Safuandy Md Salleh, Senior Engineer CbM, TNB Janamanjung Sdn. Bhd.

Discussing on vibration pattern and technical theory on 3 field case study.
1.) Steam turbine generator synchronous dry rub during normal operation early detection using online system1 platform pattern and historical database.
2.) Gas turbine generator in-situ balancing using portable vibration analyser ADRE 408 one shot balancing.
3.) CID FAN high vibration during loading (rubbing).

Khairil Safuandy is a graduate as Bachelor in Electrical Engineering Malaysia University with 9 years’ experience in CbM & PdM at Malaysia power plant. He is responsible for Vibration PdM, Thermography PdM, Oil Sampling PdM and Ultrasound PdM. Professional certificate training: Vibration Analyst VCat IV MOBIUS, Vibration Analyst VCat III Vibration Institute, Level 2 Thermographer ITC, Level 3 MLA NORIA & Level 1 Airbone Ultrasound Inspector SDT.  Khairil has a strong knowledge with GE Bently Nevada, EMERSON & FLiR software hardware. Trainer or speaker of external/internal CbM&PdM forum/conference & technical certificate training.

STREAM 1

1S4: Applying finite element modal analysis to structure vibration assessment and correction

Roengchai Chumai, Principal Engineer, Machinosis Company Limited

Finite element modal analysis or frequency analysis has been well known as an effective numerical calculation and simulation method to find natural frequency and associated mode shape of object or structure. However, its result accuracy is questionable without field vibration measurement data and model calibration. In addition, getting complete boundary condition such as geometry dimensions of structure, material property, and contact/support property of assembly parts is not very straightforward in many cases as experienced and skilled analyst is required for model simplification while still maintains acceptable results. This presentation will discuss on how to apply this method in conjunction with conventional vibration analysis work, experimental modal analysis or operating deflection shape analysis of machine structures and pipework identifying resonance problem and proposing structure modification for correction. Example works and case study of various applications and field operation constraints will be presented with success results.

Keywords: finite element modal analysis, frequency analysis, experimental modal analysis, operating deflection shape analysis, structure vibration, resonance

Roengchai Chumai is founder and technical director of Machinosis Company Limited, a consulting and engineering company in the field of machinery condition monitoring and diagnostics located in Rayong, Thailand. He started his career with Bently Nevada (Thailand) Limited in 1999 as a machinery diagnostics engineer before the company was taken over by General Electric in 2002. He is responsible for machinery vibration testing, analysis and troubleshooting, field balancing, rotor dynamics modeling and analysis. He was a technical leader of machinery diagnostics group for Asia region including Australia and New Zealand in 2008 until he left the company in 2015.  He holds a bachelor degree in mechanical engineering from King Mongkut’s University of Technology Thonburi and a master degree in management science from Asian University. He is a certified vibration analyst Cat. IV according to ISO standard and a member of ASME.

STREAM 2

2S4: Isolators – How on earth does putting springs under a machine reduce vibration?

Jason Tranter, Founder and CEO, Mobius Institute

Everyone knows that if you put a mass on a spring it will bounce. Bouncing is normally bad – as a rule, machines don’t like to bounce. But when we want to stop vibration from transmitting from a machine to the floor where it can disrupt people, harm quality, impact sensitive medical equipment, and cause additional vibration (and when we want to protect sensitive equipment from being vibrated) we mount it on springs!

These springs, called isolators, are designed in a special way to minimize vibration transmission – come to the presentation and all will be revealed.

STREAM 1

1S5: Case Study Challenge: Test your analysis skills in a case study presentation that asks you, the audience, to decide what to do next

Scott Dow, Senior Instructor, Mobius Institute

Vibration is nothing more than a tool – an information tool – and there is a step by step approach to diagnosing machinery problems. Know your forcing frequencies, identify patterns of harmonics and/or sidebands, conduct appropriate field tests and so on. In this entertaining presentation, Scott Dow leads the audience through the process of solving a case study with a twist: through the use of polling devices, the audience will decide what the next step will be. Scott will present the actual question, take questions on the equipment and, eventually, poll the audience on the next step. Check for looseness? Soft foot? Collect higher resolution data? YOU, the audience, decides. Join the fun and see how well you do!

STREAM 2

2S5: Acoustic vibration monitoring

Tom Murphy, Corporate Training Manager, SDT Ultrasound Solutions

Ultrasound is gaining increasing acceptance in the world of rotating machinery condition monitoring either because of its capability, versatility, simplicity or a combination of all three. There is no doubt that considering ultrasound as the advancement of the screwdriver in the ear appeals to many engineer and technician alike.

In this presentation the operation of a modern-day ultrasound system is explained along with how that instrument can record a signal which can be used for analysis and diagnostics.

Ultrasound detects friction, impacting and turbulence. These three characteristics exhibit themselves in many of the traditional defects we try to locate using vibration analysis. Ultrasound is therefore an ideal assistant in that process of detection and identification.

There are two operating modes for ultrasound: airborne and structure borne. Airborne ultrasound is frequently labelled as the tool for air leaks, steam leaks and electrical inspections. However, ultrasound has many applications in the rotating machinery world in this airborne mode. In this presentation you will hear mechanical looseness, coupling misalignment and defective bearings all of which have been identified using airborne ultrasound.

Contact ultrasound appears on many vibration wallcharts as one of the ways to detect Stage 1 bearing failures – and rightly so. Friction and high frequency intermittent clicks and pops are the key characteristics of these early failures which are easily detected using ultrasound. In this presentation you will hear bearing defects and see how those defects can be diagnosed using standard vibration analysis methods.

STREAM 1

1S6a: (20 min.) Case Study: Vibration Monitoring with Wireless MEMS-Based Accelerometers Technology

N Satheesh Kumar, Research Fellow, SMRT - NTU Corp Lab

Currently, very expensive PZT-based wired accelerometers are used for vibration measurement of MRT tracks. They take much effort to set up and could only be mounted in limited number and over a limited time duration. Low cost wireless accelerometers are emerging on the market. This presentation introduces the development of the MEMS based low cost, high endurance, wireless accelerometers as a viable solution to aid condition monitoring maintenance of SMRT moving and fixed assets.

A compact MEMS based sensor node would greatly improve condition monitoring of railway tracks and trains because it allows a big array of sensors to be mounted at several strategic locations. This array will allow vibration measurements to be monitored in real time in the “cloud” from a remote location. Product specifications for the sensor node package are specifically developed for railway application while ensuring the Bill Of Material cost for the sensor node and gateway is within $40USD and $60USD respectively. This product is expected to be market disruptive as a typical vibration sensor node and gateway currently costs $900USD and $1100USD respectively.

STREAM 2

2S6: Visualising Vibration – A ‘Gamechanger’ for Troubleshooting, Diagnostics and RCA

Stuart Walker, Reliability Engineer, Reliability Maintenance Solutions Ltd

Motion amplification is a breakthrough technology using non-contact optical sensors to measure vibration on machines and structures. It is unprecedented in vibration analysis technologies and adds a new dimension to any problem solving of bodies undergoing motion. Using video playback in near real time of the subject, the user can quickly understand issues at their root cause.

Overview of Motion Amplification (MA) technology, how it processes signals, presents the data in video format, time waveforms and FFTs. Technical requirements of the technology highlighting the importance surrounding lighting, measured frequencies and others.

How MA compliments existing VA technologies.

Real world examples showing the data collection process and MA methodology including explanations of real world faults these will cover a range of industries and applications.

Future applications of the science behind MA technology applied to specific VA needs.

Stuart has worked in the Condition Monitoring and Reliability sector for the last 23 years. He started his career working for Dupont as a Mechanical and Production Technician after completing a four year apprenticeship. It was here he was introduced to Condition Based Monitoring and setup a successful program at one of DuPont’s UK sites. He utilized technology’s such as Vibration analysis, Oil Analysis and IR Thermography moving the site from a time based maintenance strategy to a predictive and proactive one.  Stuart then worked for a Reliability Consultant company for a number of years implementing and running a number of other successful CBM programs across the UK.

In 1999 he setup Reliability Maintenance Solutions Ltd with his colleague Dean Whittle. Together they have successfully grown the company over the last 18 years. RMS provides reliability consultancy, training, service, and products to a number blue chip companies across the UK, Europe and Middle East. Stuart has worked in many industry sectors including Oil & Gas, Petrochemical, Power and Paper. He is currently working on projects introducing and implementing the new Motion Amplification Technology within RMS and across a wide range of Industries at home and abroad.

1S6b: (20 min.) Case Study: Critical Problems of Centrifugal Machines

Profulla Kumar Pal, Mechanical Engineer, Dynamic Engineering Services

Case Study: Critical Problems of Centrifugal Machines
Introduction:   
                    Commissioning of a Project in Steel Plant was delayed by 6 months for 3 Fans. 
                    The critical problem was solved not only by theory but with the application of 
                    practical knowledge. 

Equipment : Centrifugal fan , 2880 rpm, directly coupled, overhung type, Closed impeller  Drive= 120 KW Motor
MOC : Casing : Stainless Steel             Impeller : Special alloy.
Supplier     : A reputed Manufacturer in India.  Impeller was imported from Germany..
Fluid handled : Inflammable Gas Mixture.

Case History:
All the equipments of a Project in a large Steel Plant were erected and commissioned except for 3 Nos. of Centrifugal fans. The handing over of the Project costing Rs.100 crores was delayed by 6 months due to the vibration problems in the above fans and the Consultant  had been suffering from huge financial losses due to Liquidated Damages for the contract.

The Fans had been dismantled several times by the Manufacturer, statically and dynamically balanced but the problems were not solved. The vibrations were abnormally high at at 90 mm/s. against normal  limit of 4.5 mm/s.

My observation and action: 
Operation of the fan at abnormally high vibration was very unsafe. However, with utmost precaution to avoid any fire hazard, the fan could be started temporarily for initial reading. However, due to unsafe condition, the fan could be run for frequency analysis. The problems of resonance, looseness, unbalance and insufficient suction were detected and solved stage by stage.  Finally the vibrations came down from 90 mm/s to 2.3 mm/s . This was a very challenging job.
The presentation reveals why the diagnosis could not be carried out by the Manufacturer and how it was solved.

Mr. Profulla Kumar Pal is a Mechanical Engineer who has headed various Maintenance Departments and Project Department of Indian Industries. He has got wide experience in the field of Maintenance Management of Continuous Process Plants. He represented India for UNIDO Fellowship Programme at Italy. For the last 22 years he has been working as a Consultant for Predictive Maintenance Programme of Power Plants, Steel Plants, Sugar Mills and various Continuous Process Plants in Eastern India. He has richly contributed to the various Industries by rendering his services for Higher Efficiency and Better Productivity. He has solved many critical problems of Centrifugal Machines during its commissioning or during Maintenance. He is a Chartered Engineer and Life Member of various Professional Organisations. He is a Visiting Faculty of an Engineering College at Kolkata.
He has received a National Award in India for his contribution to the Industries for improvement of Productivity.

DAY 3

KN2: Keynote: Making Vibration Analysis Count

Jason Tranter, Founder & CEO, Mobius Institute
Every vibration analyst knows how important our craft is. There is no doubt that every company with rotating machinery needs vibration analysts. But actually, in some people’s minds, there is a doubt… Some see us only as bearers of bad news. Some see us as a source of confusing data and inconclusive reports. Some don’t believe in the philosophy of condition-based maintenance. And too many totally ignore our repair and improvement recommendations. So what should we do? Keep working in the knowledge that we know we are doing a good job and ignore the issue? Or can we go further? Can we be more proactive? This presentation will discuss these issues and make it clear why our services can be misunderstood and undervalued, but then propose some changes we can make so that we deliver greater value and we are recognized for the critical service we provide.

Jason Tranter (BE Hons) has been involved with condition monitoring and vibration analysis since 1984. In 1986 Jason formed his Australian company, ARGO, which was heavily involved in vibration monitoring and systems development. In 1990 he sold that company and the “ALERT” product line to DLI Engineering in Seattle (now AzimaDLI). Jason was in charge of product development, and later in charge of vibration products. In 1996 Jason returned to Australia and for the next three years he developed the ExpertALERT (EAV), DCX data collector, and DCX Online products for DLI Engineering. In 1999 Jason formed Mobius and began the development of the iLearnInteractive series of computer-based products for vibration and alignment training and analysis, including iLearnVibration, iLearnAlignment and Interpreter. These products have been used by thousands of people in over 90 countries to learn and become certified. Mobius was awarded the Victorian Regional Exporter of the year and was a finalist in the Australian Export Awards for 2007 and 2008. In 2005 Jason formed the “Mobius Institute” for expanded distance learning and public courses, and courses that comply with ISO and ASNT standards for certification. Mobius has offices in Australia, the United States and Costa Rica, and training centers in over 40 countries. In 2010 Jason formed the Mobius Institute Board of Certification, a not-for-profit organization to make it possible for vibration analysts anywhere in the world to achieve certification per ISO 18436-1. Jason has delivered technical papers around the world, and has had articles published in numerous international magazines and journals.

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1S7a: (90 min.) Just because Unbalance is the most common vibration problem it isn't always so!

John van Zwienen, Director, Romaco Pte Ltd

It is widely recognized that Unbalance is one of the most common vibration problems affecting rotating machinery. However it appears that this fact often gets in the way of properly diagnosing vibrations that occur at 1X running speed frequency. Many times a balance effort is started after the vibration on a machine is measured at 1X Synchronous Frequency and only when this does not deliver the expected results other possibilities are considered.

Vibration Analysis work requires a good knowledge of the fundamentals of rotor behavior. Knowing what the expectations are with regards to Synchronous (1X) motion of the rotor should be the starting point of any analysis of any vibration problems. This means that as much data and information as possible should be collected and used to consider all the factors that can affect the synchronous rotor response.

This presentation is based on the author’s recent experiences where he was requested to assist with balancing work and none of these cases actually proved to be a balancing problem.
In all cases high 1X Vibration amplitude was measured and in all cases balance work had been attempted but did not produce the expected results.

Proper knowledge of Fundamental Rotor behavior coupled with collecting enough data/information to compare against “what is expected” should allow analysts to make clear distinctions between unbalance and other 1X vibration problems.

Using the simple 1X = Unbalance approach is a gamble with pretty good odds. However for high speed critical machines which are often the main ‘money makers’ in a plant, taking risks should be avoided as this approach can become VERY expensive. Proper analysis, of what appears to be a fairly simple and common problem, is required to avoid costly mistakes.

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2S7a: (20 min.) Case Study: Bearing Problem or Scratch On Shaft?

Rao Vamsidhar, Assistant General Manager, Visakhapatnam Steel Plant

In high speed turbo machinery supported on journal bearings,  proximity probes are used for measuring the shaft vibration. The proximity probes measure shaft relative vibration. Sometimes, only by using spectrum, the shaft vibration will be misleading . To confirm whether there is any vibration issue from the bearing or any scratches on the shaft (probe tracking area), time waveform and orbit can be used. The following examples show how shaft scratches were identified by using time waveform and orbit.

2S7b: (20 min.) Case Study: Misalignment detection using vibration analysis

Rao Vamsidhar, Assistant General Manager, Visakhapatnam Steel Plant

Vibration analysis is used to identify faults in rotating machinery thereby increasing the availability. The following case study is about solving vibration problem in a critical mill fan in Coke dry cooling Plant. Mill fan is used to circulate gas for cooling of hot coke in the dry cooling chamber.  Misalignment was identified by spectrum analysis/time wave form analysis and the fan was restored in a short time there by avoiding breakdown.

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1S7a: (90 min.) Just because Unbalance is the most common vibration problem it isn't always so!

John van Zwienen, Director, Romaco Pte Ltd

It is widely recognized that Unbalance is one of the most common vibration problems affecting rotating machinery. However it appears that this fact often gets in the way of properly diagnosing vibrations that occur at 1X running speed frequency. Many times a balance effort is started after the vibration on a machine is measured at 1X Synchronous Frequency and only when this does not deliver the expected results other possibilities are considered.

Vibration Analysis work requires a good knowledge of the fundamentals of rotor behavior. Knowing what the expectations are with regards to Synchronous (1X) motion of the rotor should be the starting point of any analysis of any vibration problems. This means that as much data and information as possible should be collected and used to consider all the factors that can affect the synchronous rotor response.

This presentation is based on the author’s recent experiences where he was requested to assist with balancing work and none of these cases actually proved to be a balancing problem.
In all cases high 1X Vibration amplitude was measured and in all cases balance work had been attempted but did not produce the expected results.

Proper knowledge of Fundamental Rotor behavior coupled with collecting enough data/information to compare against “what is expected” should allow analysts to make clear distinctions between unbalance and other 1X vibration problems.

Using the simple 1X = Unbalance approach is a gamble with pretty good odds. However for high speed critical machines which are often the main ‘money makers’ in a plant, taking risks should be avoided as this approach can become VERY expensive. Proper analysis, of what appears to be a fairly simple and common problem, is required to avoid costly mistakes.

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2S8: High definition gearbox monitoring

Tim Sundstrom, Manager of Strategic Sales & Application, SPM Instrument AB

Gearbox Condition Monitoring has been regarded as a challenging task. The many signal sources from gear-meshes, bearing signals and other process related signals can be hard to interpret. By applying the recently developed High Definition Algorithms to gearbox vibration monitoring it’s possible to reveal the condition of gears and bearings even in complex gearboxes.

The presentation will cover real world gearbox examples where High Definition Technology is combined with Time Synchronous Averaging, Pseudo Tachometer and HD Order Tracking to produce crisp and clear results. With these tools it’s possible to detect tooth surface damages and cracks also in intermediate shafts in a gearbox. The results are visualized with the so called “circular plot” tools that gives an intuitive view of gear condition.

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1S8: Case Study: Vibration Analysis is basically the identification of undesirable Forces

Shivnath Ram, Head - Asset Reliability and Asset Management (ARAM), Jindal Steel and Power Limited

Vibration Analysis is not just matching the defect frequencies or identifying the probable reasons of high vibrations, noise and temperature. It is, in fact, an attempt to identify the undesirable forces that disturb the rotational dynamics of an assembly. No machine is perfectly aligned or perfectly balanced. They can be in the best range of the tolerance limits. It means, the probability of little bit eccentricity, misalignment, unbalance, handling and fitment errors, operational mistakes etc. will always be there. If a machine running at full speed is well within the tolerance limits or acceptable limits of vibration, temperature, noise, current, pressure, flow, speed then it can be said to be a healthy machine. This implies that the rotational dynamics of the machine is balanced and the force generated are getting absorbed or damped effectively at suitable points of interactions (say, bearings, base supports and connecting parts, couplings, damping medium, springs and structures). In this condition, the machine is treated to be Reliable which may exceed its average Service Life without any trouble. If everything is normal then why do machines fail early or not able to run at full capacity sometimes? The machines start showing abnormalities in the form of high vibrations, temperature and noise. Something has caused the machines to behave abnormally. And the reason is undesirable Forces creeping into the system in the form of normal wear & tear; dust depositions; increased clearances; coupling degradation; bolt looseness; thermal shocks; flow disturbances in form of valve settings; cracks; improper lubrication; change in medium density; medium input-output imbalances and many more. Vibration analysis must focus on the creeping into undesirable forces into the system and safe-guard the machine by taking prompt action in resolving the factors in their budding stage only.

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2S9a: (20 min.) Case Study: How Precision Alignment and Vibration Monitoring bring about Energy Efficiency and Savings

Shoukat Ali Izhar, Senior CM Engineer, Pruftechnik S.E.A. Pte Ltd

Highlighting, The Importance of Good Maintenance Practices based on CM:
This case study is about one of Pruftechnik Singapore(PTS) client in the healthcare manufacturing industry.
Early this year PTS was contacted, when the OLVMS on dryer inlet fan reached an alarm value of 12mm/secRMS.
After thorough analysis, find out that severe vibration was caused due to pillow block bearings failure.

While schedule for proper shutdown, PTS conducted temporary maintenance steps to prolong the life of machine.
Grease was applied to reduce the impact levels(reduced 7mm/secRMS), in hope that machine would still able to function until the planned shutdown.

Pre-maintenance Preparation
Preparation is done to ensure effective maintenance & safe working procedure.
Chain blocks and scaffolding were setup, and machine was disassembled to check the overall condition.

The Maintenance
Based on the assessment, machine’s shaft would require refurbishment and bearings pillow block would requires replacement.
Precise measurement and mechanical calculation carried out, e.g. shaft run-out and bearings clearance checks, are done to ensure the accuracy.

Laser Alignment
Precision alignment ensuring the smooth and efficient transmission.

Vibration: Quality Assurance
Vibration measurements were taken, starting from 360RPM(30%) to 960RPM(80%).
This gradual increase is essential to ensure the machine is prepared to operate at it’s maximum capacity without shocking it.
Vibration results showed satisfying outcome and thus, didnot need field balancing.

Energy Savings: More Than Vibration
Good maintenance approach help us not only minimize vibration but also reduces the power consumption.

Summary
Implementing good maintenance practices, such as precision alignment and condition monitoring, is indeed beneficial and crucial to ensure long term operation.
With the right people and right tool, one can definitely achieve the best result out of machinery maintenance, which are RAM.
It can potentially guarantee high ROI and maintain productivity competitiveness, as machines will always be operating at their best condition.

2S9b: (20 min.) Continual Improvement in Reliability Roadmap to Achieve Operational Excellence

Muhammad Asadullah, Assistant Manager Technical Services, Uch Power Pvt Ltd

This paper discuss how condition monitoring techniques can be used in a systematic way to increase machine availability, reducing damages and achieving operational excellence.
A complete framework is devised to be implemented to avoid catastrophic accidents and forced outage events. This framework provides a simple and systematic approach to put into process the activities that will ensure the integrity of plant operations. Critical equipment criteria are set, through criticality analysis and analyzing actual active failure mechanisms. Under this framework a formalized schedule is set for conducting condition assessments on the components resulted from criticality analysis. But there are a lot more factors besides criticality ranking. This presentation covers how to start a condition monitoring program from scratch and continual improvement mechanism in this reliability program. Condition monitoring techniques are integrated under a single platform to reap the full results of program.
A report is then generated addressing condition monitoring assessments, component life expectancies and countermeasures to avoid recurrence. RCA is also part of this framework to determine root cause of an incident. This investigation covers actual and worst cause outcome of an event.

Muhammad has a degree in Mechanical Engineer (B.E). Vibration Analyst ISO Level-I Certified by BINDT, ISO CAT-2 and CAT-3 certified by MOBIUS. He was trained as a Machinery Diagnostics Engineer by GE and has been in the diagnostics field since 8 years. Muhammad started with RECoM (A service partner of SKF Pakistan) in 2009. He provided reliability services and trainings to different clients and now is working as Assistant Manager Technical Services at Uch Power Private Limited since 2013. He has been engaged extensively in diagnostics and trainings.

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1S9: VFDs: The vibration analysts's worst nightmare

Scott Dow, Senior Instructor, Mobius Institute

For the average vibration analyst, VFDs are shrouded in mystery, components that, we are told, provide great benefit to the company and the process. What we do know is that they can create great confusion when it comes to analyzing vibration data, throwing the rules we know and rely on into what seems like a state of chaos and doubt. But have those rules really changed, or do we simply need to better understand what, exactly, the VFD is doing and adjust how we approach the analysis process?

This presentation starts with a short primer on what VFDs do and how they do it. After that, we will step through some of the unique frequencies that VFDs generate followed by a series of analysis exercises that clearly illustrate some of the potential vibration-related pitfalls VFDs create along with some simple techniques that will prevent them from making potentially-serious misdiagnoses.

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2S10: Calculating ROI on Predictive Maintenance Programs and link to Key Performance Indicators

Krishnan Shrikanth, Director, S CUBE RELIABLE SOLUTIONS PTE LTD, SINGAPORE

This presentation will focus on the technical and engineering aspects of maintenance and reliability into business terms – essentially into the concept of a financial business case – Return on Investment [ROI]. This will help communicate the strategy and tactics to communicate to top executives and people not directly involved in maintenance, the tremendous business value associated with elevating maintenance and reliability practices in the organization. PdM programs bring value to an organization by detecting potential failure and determining how to correct them before the failure can occur. Many PdM programs are under-resourced or abandoned because the ROI generated by PdM groups is not obvious to management. If PdM programs are measured by their ability to avoid failures, and the resulting Failure Avoided Cost [FAC] are quickly calculated and reported to the management, the ROI will become evident. Additionally, using the results of these savings from each predictive technology, i.e. vibration analysis, oil analysis, thermography, ultrasonic leak detection, etc. a determination can be made to decide if the technology is properly applied and if the frequencies of the inspections are appropriate to produce the highest possible ROI.

As a continuation, leading into the importance of Asset Condition Monitoring [ACM] Key Performance Indicators [KPI’s], which provide evidence that when presented can convince decision makers if the PdM program investment should sustain and new technologies need to be introduced to enhance reliability. Decision makers at all levels from executive to first line leaders need to have continuing information on status of each assets monitored to determine if allocation of resources (e.g. tools, personnel, competencies) is adequate to achieve the goals for which the overall ACM strategy established. Some of the key KPI’s to assess ACM are described further in this presentation and you would see the link to ROI for PdM program implementation. Without the right KPI’s sustainability of ACM programs becomes a challenge, and cuts in PdM program begins and impacts reliability of the organization.

Krishnan has 31 years’ experience in field of manufacturing and operational excellence, asset management implementation through maintenance and reliability management, lean six sigma implementation with focus on value add on business work processes. Lead regional maintenance management, lean six sigma black belt, operations advisory roles and responsibilities for Asia Region.

Krishnan has worked extensively in areas of process safety with focus on Mechanical Integrity and Quality Assurance, Contractor Safety Management, Management of Change, RCM, Lifecycle cost analysis, with relevance to large chemical, petrochemical, refining industries. Applied concepts of lean management with cross-functional and high performance work force development arena.

Worked in India, Kuwait, Syria, Indonesia and Singapore apart from providing consulting services in few other countries like China and South Africa.

Credentials:
•Asset Management ISO 55001 certification from IAM, UK
•Certified Maintenance & Reliability Professional (CMRP) from SMRP USA
•Lean Six Sigma Black Belt with focus in asset management arena
•RCM 2 practitioner / Expert in Routine Maintenance, Improved Equipment Reliability, Project work processes from Sinclair Corporation, USA
•Certified Project team leader academy, DuPont USA
•Independent Technical Expert (Asset Management) of Certification Body Accreditation for SAC (Singapore Accreditation Council)
•Certified Maintenance Excellence Recognition Process (MERP) auditor for Asia region – DuPont USA
•BE Mechanical Engineering, Bharathiar University India
•MBA from Western Michigan University, USA

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1S10: (90 min.) Case Study: Test your skills: Interactive diagnostic challenge session

Dean Whittle, Director/Reliability Engineer, Reliability Maintenance Solutions Ltd

As analysts, we must keen learning and improving our skills. But the best way to learn is to put your knowledge to the test. Rather than just telling you how to diagnose faults, or providing example case studies that you simply listen to, in this session you will be provided with machinery information and data and you will have to make assessments and make decisions. If you get it right – well done! If you don’t, no one will know, but you will have learned an important lesson!

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2S11: Case Study: Setting up a Vibration Analysis Program in Coal Processing Plants

Priyan Perera, Reliability Engineering Specialist, HVL Group

I have set up vibration analysis program for coal processing plants. One brand new 1400 tons/hr capacity plant, Condition Monitoring is being done for last 8 years after commissioning. Also another plant with the capacity of 20M/tons per year. Would like to share the experience of setting up and developing optimim vibration Analysis data base to capture defects. There have been many defect pick ups and presentation will include findings and will explain the related vibration data and parameter settings.
Machines include : Conveyor pulley bearings, Centrifuges, Pumps, gear boxes, screen exciter gear boxes, Magnetic seperators.

​Picking up defects in conveyor bearings are 100% and no failure up to now. Pumps, gear boxes and centrifuge fault pick up rate maintained over 95 %. Co-relating data of other CM technologies (Thermal imaging and oil analysis) used for some applications and findings will be shared in the presentation.

​Once the defect found, further investigations were carried out by doing internal inspection, bearing strip out and failure study.

​Similar expereince of second processing plant will be included. Further, in setting up the program I used the ISO defined steps. Avaialble ISO standards for CM program will be explained.
​Some of the cost/benefit analysis used to justify the program will be explained.
​Setting up optimum data collection and monitoring frequency will be explinaed.
Also, I will explain how co-related with other CM tecnologies of oil analysis and Thermal imaging to further validate the defect and predict failure before replacing the machine components.
Introduction of  CM KPIs of ‘Reduction of missed points’, work order completion rate and Fault pick up rate will be included in the presentation.

Priyan Perera holds a Bachelor’s degree in Mechanical Engineering, MBA, VA Cat IV certificate and Masters of Reliability and Maintenance Engineering from Monash University, Australia. For over 18 years, he has been working in Maintenance, Lubrication and Reliability Engineering fields and has worked for Chevron lubricants – Sri Lanka doing industrial consultancy and lubrication training to Cement, Construction, marine and power generation Industry. His past certifications also include IR Level II, PG Diploma in Electrical Engineering. Since 2010, Priyan has been working as a Reliability Specialist in HVL Group – Hunter Valley, Australia working to coal mining and processing industry. Plant Reliability engineering, Machine Condition Monitoring and Root Cause Failure analysis continue to be integral elements of his daily business.

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1S10: (90 min.) Case Study: Test your skills: Interactive diagnostic challenge session

Dean Whittle, Director/Reliability Engineer, Reliability Maintenance Solutions Ltd

As analysts, we must keen learning and improving our skills. But the best way to learn is to put your knowledge to the test. Rather than just telling you how to diagnose faults, or providing example case studies that you simply listen to, in this session you will be provided with machinery information and data and you will have to make assessments and make decisions. If you get it right – well done! If you don’t, no one will know, but you will have learned an important lesson!

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2S12: Case Study: Basic consideration in successful in-situ Dynamic Balancing of critical rotary Machines

Shivnath Ram, Head - Asset Reliability and Asset Management (ARAM), Jindal Steel and Power Limited

Trouble-shooting through mass Balancing seems to be one of the simplest solutions in rotary machines having high vibrations. Radial force is directly proportional to the mass of the rotating component. So, the results of addition or removal of mass on a rotating component (Impeller, Shaft, Gear-Wheel, Cooling Fan, Coupling Disc, Coupling Bolts, Balancing Disc, Fly-wheel etc.) are instantly visible through the change in overall vibration readings. In most of the cases the vibration readings get reduced. But in some cases, the situation worsens and vibration readings become so high that Equipment is at high risk of Failure and pose safety threats to persons working near-by. Even in such instances of negative outcomes, generally it is found that there were no calculation mistakes in Correction Weight and the Angle of Correction. Yet the results obtained were not in favour. The Vibration Spectrum had also shown high peaks at 1 X RPM. Yet, doing mass Balancing did not let to reductions in vibration levels.  What went wrong? This paper focuses on some of the Basic Points which need to be considered for in-situ Dynamic Balancing of rotary machines. The concept of Balancing the Forces generated by rotating components and shaft is important than just Mass Balancing. Interacting Medium (air, liquid, gas), flow valve conditions, Impeller Design and Impeller physical conditions are important considerations during in-situ Dynamic Balancing. The case-studies elaborated in this paper highlight on the very same considerations.

Interactive Forum / Closing / Giveaways

Even though you can ask questions at the end of each presentation, there is nothing like an open discussion with your peers and the presenters of all of the sessions. Ask any question. Join in with the discussion. You may have an answer that will help someone else. In past conferences, attendees often get as much value from these open discussion forums as they do from the presentations themselves. If you don’t feel comfortable asking a question with the microphone, you can do it through the conference app anonymously. Either way, this is a great opportunity to have those nagging questions answered once and for all.