portable vibration shaker demonstration & advance analysis presentation af condition monitoring...
TRANSCRIPT
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. [email protected] | T: +603-62734078 | Fax: +603-62734080
Speaker/Presenter
2
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.
3
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
Vibration Shaker
5
Motivation
Check sensor sensitivity Verify sensor linearity Test alarm and trip limit Evaluate vibration system integrity
Overview
7
We are always expending our speciality! And now, we are offering several other services that will help your plant reliability program works.
Overview
8
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
9
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
10
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
11
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
12
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
13
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
14
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
15
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)
16
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)
17
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)
18
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)
19
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)
20
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.