Portable Vibration Shaker Demonstration & Advance Analysis Presentation

1. Portable Vibration Shaker Demonstration & Advance Analysis Presentation AF Condition Monitoring Sdn. Bhd. 15-1, JalanKenanga 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

2. #1: Ahmad Fawzal M. Noor #2: Ahmad Syahid A. Fawzal • 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 • Head of Mechanical Department • MSc. Computational Fluid Dynamics (Cranfield, UK) • Vibration Analyst Category II • Certified SolidWorks Associate Certificate (CSWA) Speaker/Presenter

3. 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. ABOUT US CLIENTS AIM: To provide our client with consistent condition monitoring services and training for enhancing their plant efficiency and reliability. Water Utility JabatanBekalanAir N.Sembilan JabatanBekalan Air Melaka Electrical & Power Generation TNB Generation TNB Distribution Kapar Energy Ventures JimahEnergy Ventures Pahlawan Power Panglima Power Oil & Gas Petronas Gas PetronasPenapisan Petlin Manufacturing Industry CIMA LAFARGE ANSELL Pulp & Paper Pascorp Industry GentingSanyen

4. Demonstration Portable Vibration Shaker

5. Motivation Vibration Shaker • Check sensor sensitivity • Verify sensor linearity • Test alarm and trip limit • Evaluate vibration system integrity

6. Presentation Advance Analysis

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

9. Our advance vibration analysis allows in-depth understanding on machine behaviour. • 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 • . Advance Vibration Analysis Polar plot Orbit plot Bode plot Shaft Centreline

10. Now, pointing out the locations and directions of structure excessive motion is easier then before • 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 Structure Analysis ODS of tandem IG fan with high vibration due to combination problem

11. Now, pointing out the locations and directions of structure excessive motion is easier then before • 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.   Structure Analysis APPLICATIONS Operating machinery Mechanical 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

12. Find leaking valves long before detection by conventional methods or conservative instrumentation. • 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. Valve Leak Detection APPLICATIONS Manual Operated Valve Actuated  Valve Shut-Down Valve (SDV) Safety relief valve (PSV) Ball valve Plug valve Gate and globe valves Slimline Double Block & Bleed (SDBB) and Needle valves Butterfly valve, wafer and lug type Check valves, dual plate, piston, swing and non slam type

13. “Search for a peak to detect your leak” - Midasmeter • 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. Valve Leak Detection How to determine the valve condition using MidasMeter

14. Determine your piping design is subjected to or free from any dynamic vibration force based on your design specification is crucial. • 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. Piping Dynamic Vibration

15. Determine your piping design is subjected to or free from any dynamic vibration force based on your design specification is crucial. • 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. Piping Dynamic Vibration ODS of a gas export line, including the supporting structure Improvement of piping support to reduce vibration

16. Evaluate the strength and stiffness of a product/design by calculate the component stress and deformations. • 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) Finite Element Analysis (FEA) Structure stress due to machine horizontal motion Factor of safety of pressure vessel design

17. CFD is a powerful engineering tool for predicting real complex-physics process behaviour. • 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. Computational Fluid Dynamics (CFD) Wind loading of offshore structure

18. CFD is a powerful engineering tool for predicting real complex-physics process behaviour. • We offer Computational Fluid Dynamics (CFD) services for: • 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 Computational Fluid Dynamics (CFD) Helideck assessment based on CAP 437 threshold of 2degC above ambient Exhaust gas dispersion (left: before, right: after)

19. CFD is a powerful engineering tool for predicting real complex-physics process behaviour. • Fire & Combustion Modeling • Flare hot venting • Hydrocarbon fire risk modeling (safety) Computational Fluid Dynamics (CFD) Flame shape and shroud surface temperature for two different fuel and wind ratios ESDV pit jet fire modelling

20. CFD is a powerful engineering tool for predicting real complex-physics process behaviour. • Flow Assurance (3D multiphase flow evaluation, not empirical 1D tools) • Slug catcher optimization • Separator design evaluation • Heat Exchangers & Heat Dissipation Computational Fluid Dynamics (CFD) Waste Heat Recovery Unit (WHRU) Optimization Colour contours of gas, oil and water in a separation tank

21. Session Q & A