AF Condition Monitoring (M) Sdn Bhd

Your Preferred

Condi on

Monitoring

Service Provider

Co. No. 318985-V

AF CONDITION MONITORING (M) SDN BHD

15-1, Jalan Kenanga 9 / 4

Bandar Sri Damansara

52200 Kuala Lumpur

Malaysia

Tel. +60-3-6273 4078 / 9

Fax. +60-3-6273 4080

email: [email protected]

www.afcm.com.my

Condi on Monitoring Services

“We provide 24 hours on call services, 7 days a week, to fulfill our customer needs ”

Cer0fied to ISO 9001:2008

Cert No AR4928

“We provide 24 hours on

call services, 7 days a

week to fulfill our

customer needs”

Our Professional Services: Condition Monitoring Services: • Vibration Analysis and Monitoring • Infrared Thermography • Ultrasound Detection • Consultation Advance Vibration Measurement and Analysis • Orbit Plot • Polar Plot • Bode Plot • Shaft Centerline • Operational Deflection Shape • Modal Analysis Maintenance Services: • In-Situ Balancing • Precision Laser Alignment • Balancing • Instrumentation Training: • Certification Vibration Analyst Category I

and II Course - Mobius Institute, Australia • Setting up Condition Monitoring

Programme

AF Condition Monitoring (M) Sdn Bhd incor-porated in 1995 also known as AFCM is the industry’s most trusted partner for integrated plant reliability maintenance or condition monitoring. Our Condition Monitoring Service model strive continuously for improving plant availa-bility, less breakdowns and reducing mainte-nance costs. AFCM provides products, ser-vices, training and support to suit all the re-quirements of plant maintenance. We are your Predictive Maintenance or Condition Monitoring Specialists, providing a combina-tion of CBM tools.

AFCM is a single-point solution for all plant maintenance needs and have proven track record of implementing the most cost effective and efficient condition based monitoring programs. AFCM draws on a wealth of practical ‘hands-on’ experience and engineering / scientific expertise to offer a range of Condition Monitoring packages to meet your needs.


Vibration Equipment • 2 Channel Analyzer— Commtest VB3000 and VB7 • 16 Chanenl Analyzer— IOTech ZonicNook/618E Infrared Thermography • FLIR PM695 • FLIR P65 Ultrasound Detector • UE Ultraprobe • SDT Portable Shaker • Modal Shop Modal Analysis and ODS Software • MEScope Ver5.1

Hydro power plant Oil and Gas Power generation

Pipeline Petrochemical and oil refinery

Manufacturing and Building


Company name : AF Condition Monitoring (M) Sdn Bhd Directors 1. Ahmad Fawzal bin Md Noor 2. Sara binti Dalib 3. Dzulhikam bin Dalib Registration : 318985-V Incorporated on : 6 October 1994 Paid up capital : RM 500,000 Authorized capital : RM 500,000 Equity : 100% Bumiputera Office : 15-1, Jalan Kenanga 9/4 Bandar Sri Damansara 52200 Kuala Lumpur, Malaysia Telephone : +60-3-6273 4078 / 4079 Fax : +60-3-6273 4080 E-mail : [email protected] Website : www.afcm.com.my Company secretary : Mohd Fawzi bin Abdol Rahim (LS 007010) Auditor : Yusof Suffian & Co. (AF 1894) Principal banker : Maybank Berhad Taman Tun Dr Ismail Branch Our services 1. Vibration Analysis and Monitoring 2. Advance Vibration Analysis 3. Infrared Thermography 4. Ultrasound detection 5. Balancing and alignment 6. Modal analysis 7. Operating Deflection Shape (ODS) 8. Certification Vibration Analyst Category I and II Course - Mobius Institute, Australia 9. Setting up condition monitoring programme. 10. Condition Monitoring or CBM consultancy

CORPORATE INFORMATION

Directors 1. Ahmad Fawzal bin Md Noor No 17, Jalan Saga 8/1 Bandar Sri Damansara 52200 Kuala Lumpur 2. Sara binti Dalib No 17, Jalan Saga 8/1 Bandar Sri Damansara 52200 Kuala Lumpur 3. Dzulhikam bin Dalib No 139, Jalan Indah 5, Selayang Indah 68100 Batu Caves Selangor Auditor : Yusof Suffian & Co. (AF 1894) 8-2, Level 2, Jalan Bangsar Utama 9, Bangsar Utama, 59000 Kuala Lumpur Company secretary : Mohd Fawzi bin Abdol Rahim (LS 007010) No 1, Jalan Kesuma 7/24 Bandar Tasik Kesuma 43700 Beranang Selangor

Condition Monitoring allows the operators of industrial plant or equipment to assess its condition while it is in service. It thus allows defects to be detected and addressed before they lead to major breakdowns. Maintenance can be planned and organized in the most cost effective way. Availability can be increased by avoiding unnecessary mainte-nance downtime and Allowing equipment with known defects to be operated while its condition is continuously monitored. Condition Monitoring can demonstrate rapid payback by: Decreasing routine maintenance - Only defective equipment need to be taken out of service Improving maintenance scheduling - Faults can be quantified and maintenance scheduled to deal with most critical first Decreasing downtime for repair - Diagnosis of nature and location of fault while equipment is in service allows rapid repair once the equipment is taken off-line Increasing availability - Reduction of scheduled outages. Prevention of damage cause by major failures. Ability to run plant safely with known detects Early fault detection - Defects are detected well before catastrophic failure Occurs


Vibration is simply the motion of a machine or machine part back and forth from its position of rest. With few exceptions me-chanical troubles in a machine cause vibra-tion. A lot can be discovered about a ma-chine’s condition and problems by simply noting its vibration characteristics.

The real significance of the characteristic of vibration lies in the fact that they are used to detect and describe the unwanted motion of a machine. Therefore, the characteristics might be considered to be symptoms used to diagnose inefficient operation or impending trouble in a machine. Since vibration amplitude is a measure of the severity of the trouble in a machine, but how much vibration is too much? It is important that our objective should be to use vibration checks to detect trouble in its early stages for scheduled correction. The goal is not just to find out how much vibra-tion a machine will stand before failure, but to get a fair warning of impending trouble so it can be eliminated before failure.

Most common problems which we know produce vibration are: • Unbalanced of rotating parts

• Misalignment of couplings and

bearings • Bent shafts

• Worn, eccentric or damage

gears • Bad drive belts and drive

chains • Bad bearings

• Cavitations

• Electromagnetic forces

• Resonance

• Looseness and soft foot

• Etc.

Our Advance Vibration Measure-ment and Analysis: • Orbit Plot • Shaft Centerline • Bode Plot • Polar Plot • Operational Deflection Shape

(ODS) • Modal Analysis


An orbit plot generates a two-dimensional im-age of the shaft center motion. An unfiltered orbit plot displays the shaft motion based on even-angle signal data. The unfiltered plot shows the direct motion of the shaft center and displays all orders. A fil-tered orbit plot displays the shaft motion based on vector signal data. The filtered plot shows the synchronous motion of a particular order. The following illustration shows a filtered orbit plot and the typical setup for monitoring a ro-tating shaft with an orbit plot.

Use a shaft centerline plot to display changes in radial rotor position with respect to a stationary bearing over a range of time or speed. The DC gap voltage from two orthogonally-mounted proximity probes determines the averaged position change. The following illustration shows a typical shaft centerline plot of a machine startup.

Shaft Centerline plot can show misalignment


Any physical system can vibrate. The frequencies at which vibration naturally occurs, and the modal shapes which the vibrating system assumes are properties of the system, and can be determined analytically using Modal Analysis. Analysis of vibration modes is a critical component of a design, but is often overlooked. Structural elements such as complex steel floor systems can be particularly prone to perceptible vibration, irritating building occupants or disturbing sensitive equipment. Inherent vibration modes in structural components or mechanical support systems can shorten equipment life, and cause premature or completely unanticipated failure, often resulting in hazardous situations. Detailed fatigue analysis is often required to assess the potential for failure or damage resulting from the rapid stress cycles of vibration.

Detailed seismic qualification also requires an understanding of the natural vibration modes of a system, as the large amount of energy acting on a system during seismic activity varies with frequency. Detailed modal analysis determines the fundamental vibration mode shapes and corresponding frequencies. This can be relatively simple for basic components of a simple system, and extremely complicated when qualifying a complex mechanical device or a complicated structure exposed to periodic wind loading. These systems require accurate determination of natural frequencies and mode shapes using techniques such as Finite Element Analysis. AF Condition Monitoring is a consulting engineering firm based at Damansara, Kuala Lumpur providing services in the fields of condition monitoring, modal analysis and operational deflecting shapes (ODS)


It is well known that in the case of many types of variable speed machines, there usually are certain speeds at which the machine performs poorly, either evidenced by excessive vi-bration levels or poor quality of the product. A good example of this is found in the paper industry, where production capacity is reduced because the machine may not safely be op-erated at certain speeds.

The primary reason for the erratic behavior of complex machines at different speeds is that mechanical resonances in the structure are excited when forcing frequencies approach a natural frequency of the structure. A large machine will have a great many modes of vibra-tion, each one at a particular natural frequency, and it is usually very difficult to determine by inspection how and where the structure is moving at any resonant condition.

Operating Deflection Shape analysis (ODS), is a technique where vibration measurements are made at many locations on a machine, and transfer functions are calculated between a reference location and all the other sensor locations. These TRFs contain phase and ampli-tude information about the motion of the machine when it is running. The operation of the machine itself provides the excitation forces for the measurement. Unlike FRF measure-ments, no external excitation is used for ODS.

After the measurements are made, a computer program examines all the data and produc-es a series of animated 3-D pictures on the screen that shows the motion of the machine parts at selected frequencies. The ODS analysis provides information to the designer about how to modify the structure to solve the vibration problem by pointing out the locations and directions in which the excessive motion is occurring.


Typical Applications and experiences; • Power Distribution lines • Substations • Transformers • Transformer Bushings • Capacitor Connections • Fuse Clips • Bus Connections • Circuit Breaker • Motor & Generator • Thermal Overload • Conductor Fatigue • Connection and Contacts

IR Thermography are divid-ed into four areas; • electrical • mechanical • refractory/insulation • steam system

Infrared (IR) thermography is playing an increasingly important role in facility maintenance. This technique of produc-ing pictures, called thermograms. It is a non-contact means of identifying electrical and mechanical components that are hotter than they should be, often an indication of areas of impending failure - and it indicates excessive heat loss which is usually a sign of faulty or inadequate insulation.

An IR survey of electrical equipment will identify problems caused by current/ resistance relationships. Generally, a hot spot will be generated in an electrical circuit as a result of either a loose, oxidized, or corroded connection or a malfunction of the component itself.

The heat generated at the point of increased resistance is conducted away by the adja-cent conductor and air. When this occurs, the thermo gram will shows hot area at the connection, and gradual tapering off of tem-perature as the distance from the connection increases.


Mechanical application usually involve rotating equipment. Excessive heat can be generated from friction caused by faulty bearings, inadequate lubrication, misalignment, misuse, and normal wear. Equipment that can be checked using IR includes gears, shafts, coupling, V-belts, pulleys, chain drive system, conveyors, air compressors, vacuum pump, and clutch. IR value in mechanical inspection is saving time by pinpointing the problem area rather than indicating the cause of the overheating. Combination with vibration analysis can then be used to find the cause of the problem.

IR inspection of refractory and insulation materials are based or the assumption that if a uniform temperature Exist inside a vessel, the exterior surface temperature is a direct function of heat conduction through the insula-tion and external wall.

Localized moisture in the insulation or even wear in the refractory can be identified and located by the thermogram as a hot spot because of the non-uniform heat conductance from the vessel’s interior to its outside surface. An IR refractory/insulation survey may include batch and continuous furnaces, heat treat-ment furnaces, ovens, dryers, kilns, boilers, ladles, hot storage tanks, and insulated pipe

An IR survey can be highly effective in locat-ing steam line leaks, insulation defects on steam distribution lines, and defective steam traps. Thermography can also save time and money by locating and mapping leaks in underground steam lines.


Ultrasonic detection is the most versatile technology available today. Most common prob-lems which we can use ultrasonic detections are: • Leak detection • Bearing condition monitoring • Ultrasound based lubrication • Steam trap inspection • Valve and hydraulic • Pump cavitations • Boiler, heat exchanger and condenser leaks • Reciprocating compressor • Electrical inspection • Tightness integrity– Wind noise & water

leaks

Compressed air leaks are the most expensive utility waste in manufacturing. Turbulence from leaks creates white noise with a strong ultrasonic component. Scan an area and hear the turbulent rushing sound through the headphones. Ultrasonic equipment pinpoints all pressurized gas and vacuum leaks regardless of ambient background noise. Finding leaks can save hundreds of thousands of dollars.

Roller bearings produce ultrasonic friction as the internal rolling elements turn against the raceway. Likewise, the friction absorbing properties of grease means a well-lubricated bearing produces less friction than a bearing that lacks lubrication. True digital RMS readings from the ultrasonic equipment provide accurate and reliable advanced warning of impending failures to rotating equipment.

AVM - Acoustic Vibration Monitoring trends high frequency bearing energy to determine proper lubrication intervals and predict when the bearing is entering its FIRST stages of wear. Over lubricating bearings can damage seals, build pressure on the bearing, and cause premature failures. Over greasing an electric motor can push lubricant into the windings causing shorts and more severe damage. Under lubricating bearings negatively affects the lifespan of rotating machinery also. The ultrasonic equipment advanced digital detection techniques opens up communications between bearing and lubricator. Let the bearing tell you how much grease is enough.


Rising energy costs make steam an expensive utility too ex-pensive to waste. A typical failure rate is 30-40% of a facility’s steam trap population. Failed traps also contribute to contaminated, poor quality steam and dangerous water ham-mer. Ultrasonic testing gives the inspector an “inside view” of the trap. The ultrasonic detector translates high frequency ul-trasonic noise to audible frequencies localized to the source of contact. The inspector will not be disturbed from ambient par-asite noise downstream. Temperature measurements up-stream and downstream of the trap can often provide alerts to failed traps.

Internal blockage or leaks in valves can be discovered precise-ly while the system is on-line. Troubleshooting hydraulic cir-cuits to find internal leakage is fast and easy with the ultrasonic detection. With the ultrasonic equipment in contact mode take sample readings along the circuit. Technicians can clearly define the direction of flow, and more importantly, the source of trouble even in high noise areas. Internal leakage across seals on hydraulic rams produce microscopic bubbles of oil which in turn pop as they pass from pressure side to non-pressure side. These small explosions produce ultrasound energy which is easily detected in the ultrasonic equipment’s headset. Tune the frequency of the detector to eliminate com-peting ultrasounds.

Cavitations is usually the result of a pump being asked to do something beyond its specification. Small cavities of air devel-op behind the vanes. These pockets have a destructive effect on the pump’s internal components, including pitting and scarring the surface of the vanes. With the ultrasonic equip-ment in contact mode, isolate the pump vanes and listen for small air pocket explosions. Comparing similar pumps will help the uninitiated, but with some experience an operator will quickly be able to detect pump cavitations.


Use the ultrasonic equipment to scan for external pressure or vacuum leaks in boilers, heat exchangers, and condensers. Listen for the same rushing sound that is associated with compressed gas and vacuum leaks. All pipe connections, flanges, seals, and access doors should be inspected as part of regular PM. Tube leaks in condensers and heat exchangers can be inspected using either the pressure method, the vacuum method, or the bi-sonic transmitter

Reciprocating compressor valves open and close to allow internal combustion motors to breath. When these valves become dirty, or carbonized, their efficiency is reduced. A valve that is seating properly should be quiet while defective valves are characterized by the familiar rushing or turbulent sound of a leak. Signals from valves can be analyzed with software.

Corona discharge, arcing, tracking, damaged line bushings, and other potentially dangerous and wasteful conditions in high voltage systems produce ultrasound as a warning of future failure. By itself, or as a compliment to Infrared Imaging, Ultrasonic Detection has become the technology of choice for electrical inspections. Electrical faults emit ultrasound at the site of the problem.

Quality control applications were developed for the transportation sector to improve the tightness of vehicles. The method consists of flooding the interior of a volume with microscopic ultrasound waves. Due to their properties these waves can penetrate small holes. Using the detector on the outside of the volume inspectors can quickly pinpoint the source of defects that could become potential sites of water leaks or wind noise.


Imbalance is the most cause of rotating machinery vibration and causes much as the mechanical wear. The forces and resultant vibration caused by inade-quately balanced rotors destroy bearings and seals, damage foundations, transmit noise and increase your maintenance costs. Wear and mechanical failures can be substantially reduced if new rotors are not only balanced in the shop but also checked following installation and dy-namically balanced in place, if necessary. If your machine installations suffers from excessive and persistent vibrations that resist standard repair procedures, multi-plane couples imbalance may be the problem. Our dynamic balancing service can help you restore your machine to smooth operation.

Advantages of dynamic in-situ balanc-ing over shop balancing are: • It costs less because the machine does

not need to be disassembled • All components of the machine are balanced as an assembly. This is superior to shop balancing where each rotating assembly is balanced separately, and the combined balance may not be satisfactory • Since in-situ balancing is performed under normal operating conditions, the final results are not affected by re-assembly or loading.


Misaligned machinery results in vibration and prema-ture wear of bearings, seals and couplings. Misaligned equipment can also affect the availability of the plant and result in increased energy consumption. Machines with rotating shafts are designed to run under optimal conditions. Misalignment increases forces which are detrimental to machinery reliability and cause deterioration in machinery performance. Some of the auxiliary equipment is critical to plant operations, causing production loss when not available. Since misalignment is one of the leading causes of equipment breakdown, the ability to easily measure, align and document is a necessity. Laser alignment helps you to align fast, easy and precise. If there is a need for measuring offset caused by temperature or other dynamic forces, the same laser measurement system can be utilized to make the-se measures.

Benefits: • Reduced vibration levels • High accessibility • Troublefree operation • Faster installations and setups • Minimized downtime • Reduced energy consumption • Reduced maintenance cost • Documentation Advantages: • Easy to learn and use • Fast – align with live values • Precise

Misalignment can be expensive. Reduction in energy consumption and unplanned downtime can be achieved through precision alignment of machinery.


The list below provides a brief areas covered by our condition monitoring packages; • Specification, set-up and implementation of condition monitoring programmes • Acceptance testing of machinery or equipment at commissioning • Off-line and on-line Vibration Monitoring Instrumentations • Certified Vibration Analyst Training • Run-up and Coastdown Measurement • Representative for; • - Mobius Institute Australia (Vibration Training) • - 01db Metravib, France (Off-line and Online Vibration System) • Portable and On-line Vibration and Electrical Predictive

Maintenance System from AREVA, France


Maintenance is now changing as time past by. The changing is due to increasing Mechanization, greater equipment complexity, new maintenance techniques and chang-ing views on maintenance organization and responsibilities. There have been explosive growth in new maintenance concepts and techniques. The challenge that are faced by maintenance people nowadays are not only to lean what these techniques are, but also to be able to decide which are worthwhile. If we make the right choice, it is possible to improve maintenance performance and at the same time even reduce maintenance cost. If we make the wrong choice, new problems would be arise while existing problems only getting worse.

Ahmad Fawzal b Mohd Noor MSc Condition Monitoring (U.K.)

Managing Director


Vibration Electrical Generation / Power Utility TNB Generations Vibration analysis contract for 4 power stations SJSAA, Kapar Vibration analysis of gas turbo generators & pumps Prai Power Station Vibration analysis of steam turbo generators Connaught Bridge Vibration analysis of gas turbo generators SJSI, Pasir Gudang Vibration analysis of ID fan, FD fan & pumps TNBG Hydro Bersia Power Station Vibration analysis of hydro turbo generator PROJASS Engineering Vibration analysis of mini hydro turbo generator Temenggor Power Station Vibration analysis of hydro turbo generator Oil & Gas PETRONAS Gas Vibration analysis of turbines & pumps Water Utility JBA N. Sembilan Vibration analysis of water pumps Perbadanan Air Melaka Vibration analysis of water pumps Pulp & Paper PASCORP Paper Ind. Vibration analysis of rotating machineries

In-situ Balancing TNB Generation S/B Connaught Bridge Balancing of 100MW Gas Turbine SJSAA, Kapar Balancing of 110MW Generator and CWP SJSI, Pasir Gudang Balancing of ID Fan SJ Sg Piah Balancing of Hydro Turbo generators PETRONAS Gas Balancing of cooling tower Hospital K. Terengganu Balancing of cooling towers PASCORP Paper Inds. Balancing of pumps & rollers

Alignment Pascorp Paper S/B Alignment of rollers and pumps

Transformer Oil Test ABB Power Generation Dissolved Gas Analysis of transformer oil at Kuala Langat Power Station TNB Generation Dissolved Gas Analysis of transformer oil at SJSI,


Thermography Power Utilitiy TNB Generation SJSI, Pasir Gudang Thermography survey of electrical installations Prai Power Station Thermography survey of electrical installations TNB Transmission Seberang Jaya Thermography survey off all 275/132/33KV substations at Kedah, P.Pinang & Perlis Thermography Survey of 132KV Joints at Pinang Bridge TNB Distribution Selangor Thermography survey off 33/11KV electrical installations Metro Thermography survey off 33/11KV electrical installations Putrajaya Thermography survey off LV electrical installations Perak Thermography survey of electrical installations Melaka Thermography survey of electrical installations for all sub-stations Negeri Sembilan Thermography survey of electrical installations for all sub-stations Johor Thermography survey of electrical installations Kedah Thermography survey of electrical installations Pulau Pinang Thermography survey of electrical installations Pulau Langkawi Thermography survey of electrical installations TNBD Alor Setar Thermography survey of 33KV overhead lines Oil & Gas PETRONAS Penapisan Thermography survey of electrical installations PETRONAS Gas Thermography survey of boilers and pipings Thermography survey of electrical installations PGB, Export Terminal Thermography survey of gas storage tanks Others ABB Power Thermography survey of electrical installations Kuala Langat P. Station Thermography survey of gas turbine thermal block Sengkang Power Thermography survey of electrical installations South Sulawesi PERTAMA Kompleks Thermography survey of electrical installations CIMB Bank Thermography survey of electrical installations KWSP Thermography survey of electrical installations JKR Elektrik Pahang Thermography survey of electrical installations Henkel Oleochemicals Thermography survey of electrical installations Genting Sanyen Paper Thermography survey of electrical installations

Training Sengkang Power Setting up in-house Vibration Monitoring Programme South Sulawesi Pascorp Paper Practical Alignment Course SJSI, Pasir Gudang Practical Balancing Course TNBG Power Introduction to Vibration Analysis Plants DBKL Vibration & Alignment Course PUSPATRI Certified ISO and ASNT Vibration Analyst course for Graduates Industrial Skill Enhancement Programme (INSEP) ANSEL In-house Vibration Training for the staff at Malaysia, Thailand, India and Sri Lanka

Instrumentations ITM, Shah Alam Supply dynamic shaker to mechanical lab. SJSI, Pasir Gudang Supply balancing package Calibration of vibration analyzer PUSPATRI Supply equipments for Vibration Lab

Others Southampton Institute Design the layout for implementing a permanent condition monitoring system in the Advanced Manufacturing Lab. TNBG Verification of vibration transducer and vibration online system for SJSSAA Kapar, SJ Perai, SJSAS Manjung and SJSI Pasir Gudang

Contracts TNB Generation Vibration analysis and thermography scanning for 5 power stations; 1. Stesen Janakuasa Gelugor, 2. Stesen Janakuasa Sultan Ismail, Paka 3. Stesen Janakuasa Sultan Iskandar, Pasir Gudang 4. Stesen Janakuasa Serdang 5. Stesen Janakuasa Manjung TNB Distribution Thermography and ultrasound scanning for all 33kV and 11kV sub-stations in Selangor, WP Kuala Lumpur and Putrajaya Kapar Energy Venture Vibration analysis for rotating machineries TNB REMACO Condition monitoring contract

Ground borne Monitoring

Angkasaraya Dev. Ground borne vibration monitoring program in construction of Ramlee Car Ramp and connecting tunnel


AF Condition Monitoring (M) Sdn Bhd

Documents

Transcript of AF Condition Monitoring (M) Sdn Bhd