Schedule of Events – Singapore

There is no doubt that condition monitoring provides many benefits; reduced costs, improved safety, increased production, and more. But there is a great deal more that can be achieved. Many of the faults detected with condition monitoring are avoidable. Our goal should be to eliminate the root causes of those faults. But that is easier said than done. This workshop will briefly discuss the benefits of reliability improvement over condition monitoring, explain the differences in the strategy, and then explain, in detail, how to make the transition. The topics will include:

1. The difference between reliability improvement and condition monitoring
2. The benefits of reliability improvement over condition monitoring
3. Tier 1 reliability improvement: Taking a purely technical approach: shaft alignment, precision balancing, precision lubrication, improved maintenance practices, etc.
4. Tier 2 reliability improvement: Improving work management and spares management
5. Tier 3 reliability improvement: A step by step approach to gaining approval, changing the culture, gaining control over maintenance, and achieving best practice defect elimination, following a detailed roadmap
   1. Justifying and selling the reliability improvement program
   2. Proving the concept with pilot projects
   3. Developing a culture of reliability
      1. Engaging senior management to achieve top-down drive
      2. Engaging the “plant floor” to achieve bottom-up drive
      3. Engaging the operators in the reliability improvement process and to improve operating practices
   4. Breaking out of the reactive maintenance cycle
   5. Developing an asset management strategy
   6. Continuous improvement: measuring and reporting on the benefits of the program with KPIs and benchmarking

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.

There is no doubt that condition monitoring provides many benefits; reduced costs, improved safety, increased production, and more. But there is a great deal more that can be achieved. Many of the faults detected with condition monitoring are avoidable. Our goal should be to eliminate the root causes of those faults. But that is easier said than done. This workshop will briefly discuss the benefits of reliability improvement over condition monitoring, explain the differences in the strategy, and then explain, in detail, how to make the transition. The topics will include:

1. The difference between reliability improvement and condition monitoring
2. The benefits of reliability improvement over condition monitoring
3. Tier 1 reliability improvement: Taking a purely technical approach: shaft alignment, precision balancing, precision lubrication, improved maintenance practices, etc.
4. Tier 2 reliability improvement: Improving work management and spares management
5. Tier 3 reliability improvement: A step by step approach to gaining approval, changing the culture, gaining control over maintenance, and achieving best practice defect elimination, following a detailed roadmap
   1. Justifying and selling the reliability improvement program
   2. Proving the concept with pilot projects
   3. Developing a culture of reliability
      1. Engaging senior management to achieve top-down drive
      2. Engaging the “plant floor” to achieve bottom-up drive
      3. Engaging the operators in the reliability improvement process and to improve operating practices
   4. Breaking out of the reactive maintenance cycle
   5. Developing an asset management strategy
   6. Continuous improvement: measuring and reporting on the benefits of the program with KPIs and benchmarking

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.

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.

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.

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.

There is no doubt that condition monitoring provides many benefits; reduced costs, improved safety, increased production, and more. But there is a great deal more that can be achieved. Many of the faults detected with condition monitoring are avoidable. Our goal should be to eliminate the root causes of those faults. But that is easier said than done. This workshop will briefly discuss the benefits of reliability improvement over condition monitoring, explain the differences in the strategy, and then explain, in detail, how to make the transition. The topics will include:

1. The difference between reliability improvement and condition monitoring
2. The benefits of reliability improvement over condition monitoring
3. Tier 1 reliability improvement: Taking a purely technical approach: shaft alignment, precision balancing, precision lubrication, improved maintenance practices, etc.
4. Tier 2 reliability improvement: Improving work management and spares management
5. Tier 3 reliability improvement: A step by step approach to gaining approval, changing the culture, gaining control over maintenance, and achieving best practice defect elimination, following a detailed roadmap
   1. Justifying and selling the reliability improvement program
   2. Proving the concept with pilot projects
   3. Developing a culture of reliability
      1. Engaging senior management to achieve top-down drive
      2. Engaging the “plant floor” to achieve bottom-up drive
      3. Engaging the operators in the reliability improvement process and to improve operating practices
   4. Breaking out of the reactive maintenance cycle
   5. Developing an asset management strategy
   6. Continuous improvement: measuring and reporting on the benefits of the program with KPIs and benchmarking

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.

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.

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.

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.

The Certified Maintenance & Reliability Professional (CMRP) program is the leading credential for certifying the knowledge, skills and abilities of maintenance, reliability and physical asset management professionals.

The CMRP is the only certification program of its kind accredited by the American National Standards Institute (ANSI), which follows the globally-recognized ISO standards for its accreditation purposes. The test is a thorough examination of a broad scope of expertise measured against the universal standard. It was developed to assess professionals’ aptitude within the five pillars of the SMRP Body of Knowledge (BoK), which include: Business & Management, Equipment Reliability, Manufacturing Process Reliability, Organization & Leadership, and Work Management.

Exam Registration

The Certified Maintenance & Reliability Technician (CMRT) program is the leading credentialing program for the knowledge, skills and abilities of maintenance and reliability technicians.

The certification assesses the knowledge and skills of those responsible for preventative, predictive and corrective maintenance – multi-skilled individuals who play a critical role in the success of organizations worldwide. Earning the CMRT credential indicates that you have achieved a level of ability consistent with the requirements for competence on the job as a multi-skilled maintenance and reliability technician.

The CMRT exam tests competency and knowledge of specific tasks within four (4) domains: Maintenance Practices, Preventative and Predictive Maintenance, Troubleshooting and Analysis, and Corrective Maintenance.

Exam Registration

The International Council for Machinery Lubrication (ICML) is a vendor-neutral, not-for-profit organization founded to facilitate growth and development of machine lubrication as a technical field of endeavor. Among its various activities, ICML offers skill certification testing for individuals in the fields of machine condition monitoring, lubrication and oil analysis.

Skilled based testing and Certification. Certification is the mark of a professional. It helps to ensure that individuals who practice a craft, be it lubricant analysis or medicine, have a defined measure of skills. For the field of machine lubrication, formal certification serves the following three vital purposes:

• Create a formal framework of knowledge
• Raise the profile of those working in the field
• Provide managers with assurance of skills

ICML currently provides certification for the Machine Lubricant Analyst (MLA), Machine Lubrication Technician (MLT) and Laboratory Lubricant Analyst (LLA). ICML is honored that these ICML certifications have been pioneered into ISO 18436-4 and 18436-5 Standards. ICML also regarded the National Commission for Certifying Agencies (NCCA) guidelines in the development of its certification programs.

Exam Registration

The Mobius Institute Board of Certification (MIBoC) is ISO/IEC 17024 and ISO 18436-1 accredited, providing vibration analysts certification according to ISO 18436-1 and ISO 18436-2. MIBoC is an impartial and independent entity that is directed by scheme and technical committees to ensure that its certification meets or exceeds the requirements defined by the applicable International Organization for Standardization, ISO 18436 standards.

For vibration analysts who have completed their training at the ISO Category I, II, III or IV level with an approved training provider and meet prior certification and experience requirements, MIBoC will conduct ISO certification examinations at IMVAC. Prior registration with Mobius Institute is required at least 10 days in advance.

Exam Registration

Shaft alignment is often overlooked in the maintenance process. It is something that is done in a hurry, just before you have to start up the equipment again with the production manager breathing down your neck. Yet poor alignment is responsible for over 50% of all failures in rotating machinery. Even though shaft alignment is so important to the whole maintenance process there are seldom written down guidelines and procedures for alignment. In this presentation we will present the shaft alignment fundamentals and teach the 5-step alignment procedure. If correctly followed you will increase your success rate in alignment and improve on your equipment’s up time.

Leif Törngren, 57, with over 30 years experience in laser technology started his career as an electronic design engineer at the first Swedish laser alignment company. In 1997 he joined Easy-Laser AB as a software engineer and have been there since. Leif Törngren is now the Technical Supervisor of Easy-Laser.

Timely detection of the occurrence of cavitation in pumps is very important as it can  cause  pitting,  erosion,  and  loss  of  pump  performance.     Attempts  to determine a unique signature of cavitation using vibration, acoustic emission, audible-acoustics, and higher order non-linear modeling techniques have been elusive.   This paper presents the results of an experimental study undertaken first to understand the structure of cavitation and develop an effective means for detection of it.  Tests were performed at SpectraQuest facility in Richmond, VA. using a fully instrumented test stand on a small centrifugal pump.  We measured vibration, pressure, audible sound, motor current and the force due to cavitation of  a  centrifugal  pump.    A  special  force  transducer  capable  of  measuring fluctuating forces exerted by cavitation process on the pump casing was developed to understand the dynamics of cavitation phenomenon and signatures of a centrifugal pump operating under different cavitation conditions. Two of the abnormal operating conditions studied were the formation of tiny air bubble (initiation of cavitation) and then fully developed cavitation. Experiments were also run with a transparent LEXAN cover using colored water to observe the cavitation.   A Video was also taken for observing and developing an understanding of cavitation mechanism. Vibration, force, audible sound, and dynamic pressure were analyzed to detect cavitation.

It was found that the pump has higher vibration amplitude in the axial direction than in the radial direction.   This may be due to lower stiffness in the axial direction.  From the experiments, it was also determined that significant amount of air bubbles will increase vibration component associated with the impeller vane pass frequency. Cavitation seems to excite high frequency structural resonances.   Also, a fully developed cavitation may reduce the impeller vane pass frequency vibration amplitude.   The force spectra did not provide any measurable information of cavitation. In addition, real world case studies will be provided. Presentation will also provide basic physics of cavitation; its damaging effect if not detected in a timely manner and step that can be taken to minimized it occurrence.

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.

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.

Haider Ali holds chancellors silver medal in mechanical engineer degree and has a combined experience of 5 years in rotating machinery diagnostics in addition to maintenance/overhaul experience of turbo machinery (centrifugal compressors and steam turbines) and retrofits of gas-turbine components. He is widely recognized for his work on BCL compressors and tandem dry gas seals installation and troubleshooting.

Haider joined Engro Fertilizer in 2013 and has since been the integral part of the diagnostics team for the World’s biggest single train Ammonia Urea complex. Haider is a VA-II certified Vibration analyst.

CM programs is still to just detect, diagnose and report the faults. The CM data when collected properly and systematically, have so much more potential to provide useful information about root cause of the fault as well as ways of resolving the core of the issue to stop repetition of failures. This allows the CM programs to integrate with engineering and maintenance functions, by helping reduce their workload and provide much higher return of investments in condition monitoring program.

This presentation will demonstrate the ways of collecting and using CM data for this purpose, through several real life case studies and provide a way to document the process. Some of these cases will also demonstrate integration of various condition monitoring techniques in identification and resolving the root cause. Various stakeholders of the condition monitoring program will benefit from this presentation in learning ways of utilizing their instrumentation and knowledge towards achieving the reliability improvements in the equipment and processes.

Tarun Motwani holds a Bachelor’s degree in Mechanical Engineering, MBA-Finance, VA Cat IV certificate, with 26 years of industrial experience. He is working as Senior Engineer- condition Monitoring in Visy paper, and has worked in in various type of industries, including petrochemicals, mining, steelmaking, pulp & Paper, food processing building products etc. His skill set includes vibration analysis, IR Thermography, Oil Analysis, Airborne Ultrasonics, Motor testing and Root Cause Failure Analysis, and technical delivery in these technologies. His past certifications include ASNT Level III in IR, Level II certification in oil analysis, Level I certification in UT. He is currently involved in automated integration of different condition monitoring technologies, to optimize their usage in ever expanding online systems and by even moderately skilled personnel in all these technologies.

Starting a vibration condition monitoring program for the two largest Deepwater Oil and Gas platforms comes with challenges. This presentation will look at four challenging cases we encountered.

1. A Ballast Pump showing inner race bearing faults even though it seldom runs – why?
2. Mist Eliminator Blowers for gas turbine exhaust experiencing repeated bearing failures – why?
3. Unbalance and structural problems on critical Atlas Copco compressors. Balancing reduced vibration levels but fluctuating vibration levels persisted – why?
4. The utilization of ODS on a Vacuum Pump and Deaerator mixer – why it was done and what was found that benefitted the site.

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.

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.

Tim Sundström, born 1964 in Sweden, has a M.Sc. degree in Applied Physics and Electrical Engineering from Linköping University, Sweden. For over twenty years, he has been specializing in electronics development and has held managerial positions in the field since 1992. In 2001, he joined SPM Instrument as head of Research and Development, where he has been deeply involved in SPM HD development and field evaluations.

Discussion of vibration patterns and thechnical theory on 3 case studies.

1. A steam turbine generator experiences synchronous dry rub during normal operation which is detected early using online system1.
2. A gas turbine generator ungoing in-situ balancing using portable vibration analyser ADRE 408 (one shot balancing).
3. A CID FAN experiences 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.

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.

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!

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.

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!

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.

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.

Degree in Acoustics Chartered Engineer Certified Reliability Leader 33 years in vibration measurement, 22 years using IR and 16 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.

Case Study: Critical Problems on Centrifugal Fans

All the equipment at a large steel plant was commissioned except for 3 centrifugal fans,which delayed the full plant commissioning by 6 months due to the vibration problems. During this time, the consultant responsible for the commissioning was suffering huge financial losses due to liquidated damages under the contract.

Through this time, the fans had been dismantled several times by the fan manufacturer with static and dynamic balancing preformed but the problems were not resolved. Vibration amplitudes were recorded at at 90 mm/s (normal limit of 4.5 mm/s). Operation of the fan at such destructively high vibration levels was deemed unsafe. As such, only short runs were allowed,during which time 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.

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.

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.

Case Study: Critical Problems on Centrifugal Fans

All the equipment at a large steel plant was commissioned except for 3 centrifugal fans,which delayed the full plant commissioning by 6 months due to the vibration problems. During this time, the consultant responsible for the commissioning was suffering huge financial losses due to liquidated damages under the contract.

Through this time, the fans had been dismantled several times by the fan manufacturer with static and dynamic balancing preformed but the problems were not resolved. Vibration amplitudes were recorded at at 90 mm/s (normal limit of 4.5 mm/s). Operation of the fan at such destructively high vibration levels was deemed unsafe. As such, only short runs were allowed,during which time 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.

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.

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.

John is a Dutch citizen who has been based in Indonesia for the past 25 years. He currently serves as a Technical Advisor and Business Partner for a local company.

Before moving to Indonesia in 1993 John held positions as Service Manager and General Manager for South East Asia for a leading private US based company involved in Rotating Machinery Protection and Diagnostics Systems and Services.

The Entrepreneur in him led to a venture into Indonesia joining with his Indonesian partner to start a company and represent his previous employer. Since then this company has taken on several high tech multi-national companies that now rely on John’s experience, knowledge and skills for their representation. The business model of the ‘Local Subsidiary’ of these niche businesses has been providing products and services to the various industries in and around Indonesia.

John studied Electrical Engineering in Rotterdam before embarking on a career as a Rotating Machinery Specialist. Throughout his career he has continued his education in the technical.  He is also a Certified Category IV Vibration Analyst.

John has extensive International Management and Marketing experience and an understanding of a wide range of technologies which he uses to provide the company with direction and support on a regular basis.

This presentation starts by discussing a particular case study looking at the methods, techniques and steps taken in diagnosing the problem. It then asks the question as a vibration analysts are we doing our job correctly, is there more we can/should do, and with respect to the case study presented what we did next. The presentation then concludes by looking at how the analysis and findings of this case study was documented and integrated into a more comprehensive VA/CBM reporting metrics. The audience will be questioned throughout this presentation, such that their thoughts / ideas / view can be shared.

Mr. Dean Whittle is the founder and managing director of Reliability Maintenance Solutions (RMS) Ltd. based in the United Kingdom. During Mr. Whittle’s more than 36-year career he has held various roles in electro/mechanical engineering ranging a five-year apprenticeship through various shop floor/field services roles to district manager for a world-leading supplier of Reliability-Based and Condition-Based Maintenance products and services. During the past twenty-five years he has been committed to implementing plant reliability and condition monitoring improvement programs throughout UK industry; covering power, paper, petro-chemical, pharmaceutical, automotive, quarries, film/plastic, food, electronic, service and engineering manufacturing industries.

Mr. Whittle shares his expertise as an approved trainer for both the British Institute of Non-Destructive Testing (BINDT) and Mobius Institute ISO-18436 accreditation programmes, and as a speaker at a number of conferences.

Additionally, Mr. Whittle is an active member in a number of accredited institutes and committees:

• ISO TC108 / SC5 Condition Monitoring & Diagnostics of Machine Systems
• Mobius Institute Board of Certification (MIBoC) Technical Committee
• The British Institute of NDT Council Member
• The British Institute of NDT Condition Monitoring Technical Committee
• The British Institute of NDT Vibration Analysis Working Group
• British Standards Institute – BSi Technical sub-committee GME/21/5 – Mechanical vibration and shock and Condition monitoring – Vibration of machines

British Standards Institute – BSi Technical sub-committee GME/21/7 Mechanical vibration and shock and Condition monitoring – Condition monitoring.

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.

John is a Dutch citizen who has been based in Indonesia for the past 25 years. He currently serves as a Technical Advisor and Business Partner for a local company.

Before moving to Indonesia in 1993 John held positions as Service Manager and General Manager for South East Asia for a leading private US based company involved in Rotating Machinery Protection and Diagnostics Systems and Services.

The Entrepreneur in him led to a venture into Indonesia joining with his Indonesian partner to start a company and represent his previous employer. Since then this company has taken on several high tech multi-national companies that now rely on John’s experience, knowledge and skills for their representation. The business model of the ‘Local Subsidiary’ of these niche businesses has been providing products and services to the various industries in and around Indonesia.

John studied Electrical Engineering in Rotterdam before embarking on a career as a Rotating Machinery Specialist. Throughout his career he has continued his education in the technical.  He is also a Certified Category IV Vibration Analyst.

John has extensive International Management and Marketing experience and an understanding of a wide range of technologies which he uses to provide the company with direction and support on a regular basis.

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.

Tim Sundström, born 1964 in Sweden, has a M.Sc. degree in Applied Physics and Electrical Engineering from Linköping University, Sweden. For over twenty years, he has been specializing in electronics development and has held managerial positions in the field since 1992. In 2001, he joined SPM Instrument as head of Research and Development, where he has been deeply involved in SPM HD development and field evaluations.

How can we use high-quality vibration readings not only for condition monitoring but also to optimize production processes? Machine learning and Industry 4.0 are important concepts in order to increase production flow and to ensure product quality. In this presentation, HD technology has been used to extract information from critical machines in the mining and pulp and paper sectors. By using vibration data in a non-conventional way, it is possible to extract parameters important for the understanding of machine behavior. These parameters are exported via a Rest API interface for the machine learning process itself.

The presentation will introduce HD condition monitoring technology, the Rest API interface, and show practical results.

Tim Sundström, born 1964 in Sweden, has a M.Sc. degree in Applied Physics and Electrical Engineering from Linköping University, Sweden. For over twenty years, he has been specializing in electronics development and has held managerial positions in the field since 1992. In 2001, he joined SPM Instrument as head of Research and Development, where he has been deeply involved in SPM HD development and field evaluations.

Case reference we had with our customer while performing online vibration condition monitoring identified issue with bearing, decided to schedule and maintain this particular blower.  We have done a pre and after vibration, alignment and energy monitoring and realized a drop in power usage after proper installation and commissioning of blower.

We will share process charts with data and some pictures provided by our customer.

This presentation discusses how condition monitoring techniques can be used in a systematic way to increase machine availability, reduce damages and achieve 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 implement 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 based on the criticality analysis but there are more factors than criticality ranking to consider. This presentation covers how to start a condition monitoring program from scratch and the 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.

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.

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 method 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. Originally called InterActive Training when it was introduced, the cases have recently been updated and the classes are now being offered by Mobius as Analyst Flight School. Scott currently owns his own business, CBM Consultants, with one of his primary duties being a Senior Instructor for the Mobius Institute N.A. 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.

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

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!

Mr. Dean Whittle is the founder and managing director of Reliability Maintenance Solutions (RMS) Ltd. based in the United Kingdom. During Mr. Whittle’s more than 36-year career he has held various roles in electro/mechanical engineering ranging a five-year apprenticeship through various shop floor/field services roles to district manager for a world-leading supplier of Reliability-Based and Condition-Based Maintenance products and services. During the past twenty-five years he has been committed to implementing plant reliability and condition monitoring improvement programs throughout UK industry; covering power, paper, petro-chemical, pharmaceutical, automotive, quarries, film/plastic, food, electronic, service and engineering manufacturing industries.

Mr. Whittle shares his expertise as an approved trainer for both the British Institute of Non-Destructive Testing (BINDT) and Mobius Institute ISO-18436 accreditation programmes, and as a speaker at a number of conferences.

Additionally, Mr. Whittle is an active member in a number of accredited institutes and committees:

• ISO TC108 / SC5 Condition Monitoring & Diagnostics of Machine Systems
• Mobius Institute Board of Certification (MIBoC) Technical Committee
• The British Institute of NDT Council Member
• The British Institute of NDT Condition Monitoring Technical Committee
• The British Institute of NDT Vibration Analysis Working Group
• British Standards Institute – BSi Technical sub-committee GME/21/5 – Mechanical vibration and shock and Condition monitoring – Vibration of machines

British Standards Institute – BSi Technical sub-committee GME/21/7 Mechanical vibration and shock and Condition monitoring – Condition monitoring.

This presentation will share the experience of setting up a successful vibration analysis data base to capture defects at different coal processing plants on a variety of equipment that includes conveyor pulley bearings, centrifuges, pumps, gearboxes, screen exciter gearboxes and magnetic separators. One site, a brand new 1400 ton/hr capacity plant, has been successfully using condition monitoring for 8 years since commissioning. At another 20M ton/year plant, there have been many defect pick ups. The presentation will also include case findings and explain the related vibration data and parameter settings.

The success at picking up defects in conveyor bearings are 100% to date. On pumps, gear boxes and centrifuges, the fault pick up rate is over 95%. Co-relating data of other CM technologies (thermal imaging and oil analysis) is used for some applications with findings 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 experience at a second processing plant will be included. Further, in setting up the program I used the ISO defined steps. Available ISO standards for CM program will be explained.

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.

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!

Mr. Dean Whittle is the founder and managing director of Reliability Maintenance Solutions (RMS) Ltd. based in the United Kingdom. During Mr. Whittle’s more than 36-year career he has held various roles in electro/mechanical engineering ranging a five-year apprenticeship through various shop floor/field services roles to district manager for a world-leading supplier of Reliability-Based and Condition-Based Maintenance products and services. During the past twenty-five years he has been committed to implementing plant reliability and condition monitoring improvement programs throughout UK industry; covering power, paper, petro-chemical, pharmaceutical, automotive, quarries, film/plastic, food, electronic, service and engineering manufacturing industries.

Mr. Whittle shares his expertise as an approved trainer for both the British Institute of Non-Destructive Testing (BINDT) and Mobius Institute ISO-18436 accreditation programmes, and as a speaker at a number of conferences.

Additionally, Mr. Whittle is an active member in a number of accredited institutes and committees:

• ISO TC108 / SC5 Condition Monitoring & Diagnostics of Machine Systems
• Mobius Institute Board of Certification (MIBoC) Technical Committee
• The British Institute of NDT Council Member
• The British Institute of NDT Condition Monitoring Technical Committee
• The British Institute of NDT Vibration Analysis Working Group
• British Standards Institute – BSi Technical sub-committee GME/21/5 – Mechanical vibration and shock and Condition monitoring – Vibration of machines

British Standards Institute – BSi Technical sub-committee GME/21/7 Mechanical vibration and shock and Condition monitoring – Condition monitoring.

Have you ever wondered why there is a peak at twice line frequency? Have you wondered why that vibration changes in amplitude? This presentation will answer all of those questions and also help you to understand how induction motors work and why we see some other faults in induction motors. Using lthe Mobius simulations and animations, Jason will provide an explanation for how electric motors are powered (even from VFD’s) and why that creates a magnetic force at twice the line frequency (e.g. 100 Hz or 120 Hz in United States and a few other places). Even if you are mechanically oriented and have never considered the electrical side of an induction motor, this presentation will be perfect; finally revealing what is happening inside the motor and why the vibration changes, particularly at twice line frequency.

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.