the machine vibration analysts newsletter featured...
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THE MACHINE VIBRATION ANALYSTS NEWSLETTER
FEATURED THIS ISSUE
Featured Article
4 Double Anniversary: 35 years in the industry 20 years of Mobius Institute
Featured Lesson
8 The Importance of Proper Shaft Alignment
Video Spotlight
12 Rough Alignment
Series 4 | Issue 9 | February 2019
S E E B A C K C O V E R F O R D E T A I L S
A N N O U N C I N G T H E F U L L T O U R S C H E D U L E
Mobius Quick
Contact
About Mobius InstituteMobius Institute is a worldwide provider of reliability improvement, condition monitoring and precision maintenance education to industrial plant managers, reliability engineers and condition monitoring specialists, allowing plants to be successful in implementing reliability improvement and condition monitoring programs. Mobius delivers training via public, in-plant and online education programs.
Mobius Institute Board of Certification is an ISO/IEC 17024 and ISO 18436-1 accredited certification body providing globally recognized certification to reliability professionals, vibration analysts, ultrasound analysts and thermal imaging specialists.
Mobius further contributes to the condition monitoring industry by hosting the CBM Conference and the www.CBMconnect.com media site worldwide.
Key Contacts at Mobius InstituteFounder & CEO - Jason Tranter - [email protected] Co-founder & CFO - Georgina Breedon - [email protected] Chief Operating Officer - Bill Partipilo - [email protected] Marketing & Communications Director - Dean Lofall - [email protected] CBM Conference Director - Becky Partipilo - [email protected] Certification Manager - Roberta Clark - [email protected]
IN THIS ISSUE
4 FEATURED ARTICLE
A Double Anniversary: 35 years in the industry, 20 years of Mobius Institute
7 SCHOLARSHIP AWARDS
Meet the 2018 Q4 and Grand Prize Winners!
8 FEATURED LESSON
The Importance of Proper Shaft Alignment
11 THINK RELIABILITY
Asset Criticality Ranking
12 VIDEO SPOTLIGHT Rough Alignment
13 UPCOMING COURSES
See a listing of upcoming Mobius Institute courses
15 VIBRATION ANALYST HALL OF
FAME
Recognizing our Vibration Superheroes
16 TRAINING PARTNERS
Highlighting Mobius Authorized Training Organizations around the world
MOBIUS INSTITUTE - FOUNDER & CEO
Jason Tranter, BE (Hons), CMRP, VA-IV Jason Tranter is the founder and CEO of the Mobius Institute and the Mobius Institute Board of Certification. Jason is the author of the majority of Mobius’ reliability, condition monitoring and precision maintenance training materials, and is a member of ISO TC108/SC5. After running a vibration consulting and software development company in Australia in the mid-’80s, Jason sold his business and moved to the United States as the director of product development at a leading condition monitoring product & services company. Since starting Mobius Institute, he has had numerous articles published and has delivered presentations, workshops and webinars all over the world.
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FEATURED LESSON
A Double Anniversary: 35 years in the industry,
20 years of Mobius Institute
CONTINUED ON PAGE 5
Twenty years ago my wife and I started Mobius Institute. What an incredibly journey it has been. But the fun really began in 1984. Yes, it seems soooo long ago, but that was when I personally got started in condition monitoring. In 1986 we started a company called ARGO that was focused on vibration analysis; in 1990 we sold to DLI Engineering and moved from Melbourne, Australia to a beautiful town near Seattle; and in 1999 the Mobius journey began.
I would like to say that the CBM and reliability world has significantly changed, but I think we all know that it hasn’t. Yes, the technology has improved immeasurably, but what goes on in the majority of industrial facilities has not.
“Why monitor our pumps; we have spares, and many are redundant?” That was a question posed to me at a waste water plant 35 years ago. That worried me. I am still worried. That could easily be a statement made in regard to critical assets today.
Why is it so?
It is human nature to enjoy solving problems. In addition to the pride of being able to say “I fixed that”, you can clearly demonstrate the benefit. If it was costing $10,000 an hour while it was down, and now it is running, you just saved the company a good chunk of money. And it doesn’t hurt if you get paid extra during overtime, and if your supervisor pats you on the back in thanks.
Now contrast that with reliability improvement and condition monitoring. With the possible exception of the CBM analyst being able to warn everyone of pending failure, true reliabil-ity improvement can go unnoticed. When failure doesn’t
occur, and equipment performance meets targets, there may not be that pat-on-the-back moment. Being proactive doesn’t provide the same rewards as being reactive.
What is the answer?
We have to be able to “sell” reliability. We must stop rewarding reactive behavior, and start rewarding proactive behavior. Rather than focusing solely on the “technology” of reliability improvement (CBM, RCFA, RCM, etc.) we must also address culture change and the business of reliability. If we can measure and communicate the benefits, in dollars, safety, and tons-per-day of output, then we may get people’s attention.
This was the problem in 1984, and it is still the problem 35 years later. Most people, especially management, don’t recognize the amazing benefits of having equipment that performs as desired. Actually, that’s not correct. What people don’t understand is that their facilities can be transformed so they do perform as desired.
What is the real answer?
So what is the solution? I am convinced that education (with the associated change in behavior) is the only way forward.
We started Mobius because it was frustrating developing hi-tech vibration monitoring systems when the available training was unable to explain how it worked, how machines
By Jason Tranter, Founder of Mobius Institute
VIBRATION MATTERS - FEBRUARY 2019 THE VIBRATION ANALYST’S NEWSLETTER 4
FEATURED ARTICLE
failed, how to analyze the data, and so on. I was fortunate to have application, software, and technology experience so I decided to move into training and cer-tification. Animations, simulations, e-learning, pre- and post-course training and other techniques made a difference. We have now trained
30,000 analysts in our courses, and many more via iLearnVibration and Webinars/YouTube (we have over 1,000,000 views without involving kittens ;) ). And we can offer real certification; accredited and audited to Interna-tional Standards Organization (ISO) standards.
But we needed to change. Many years ago, probably around 2010, we also transformed our business to help our customers transition from reactive (condition monitoring is very often reactive in nature) to proactive. We need to detect and solve problems, but we also need to work hard at preventing them.
So we created iLearnReliability. I have to confess, it has been a tougher ‘sell’ than expected... e-learning is not for everyone, but we also tried to create training for the
entire organization. Sure, the reliability engineers, CBM analysts, and maintenance technicians need training, but so do the operators, production management, procure-ment staff, and other management and engineering staff. So iLR provides toolbox talks, manager briefings, skills training, and more.
So while we can happily say that thousands have been trained, it is just the tip of the iceberg. So that is why ARP was born.
Stepping it up a notch
Being madly passionate about the benefits of quality (non-commercial) education, and accredited, indepen-dent certification, and being unsatisfied with the options available around the world, a group of like-minded industry professionals got together to define the Asset Reliability Practitioner scheme. We are just getting started, but the reaction has surpassed all my hopes. In 2019 we will have courses in multiple languages and in multiple countries.
Without making this a sales pitch, ARP has three unique benefits: it provides a growth path (from Category I to III); it recognizes experience in addition to knowledge (Cat IIx and IIIx); and it involves the “plant-floor” (ARP I) to achieve site-wide buy-in, and management (ARP III) for true leadership. With our signature animated training, pre-course videos, and all the rest, I believe it will make a meaningful difference around the world. To infinity and beyond
Yes, I borrowed that phrase, but I can proudly say that Mobius is now helping a significant community around the world. In 2018 we trained over 5,000 vibration analysts from 180 countries in our official courses, and many more via our other forms of training, including ARP. Plus we conducted four international CBM Conferences (formerly IMVAC), plus we launched CBM CONNECT; a fantastic web-site to continue learning and share experience.
Our future
From a Mobius perspective, we hope you give us the opportunity to continue to educate and certify you. We know what a difference it can make to be confident in your job, to have opportunities for improvement, and to be recognized for your knowledge and experience. Via our courses, publications, on-line, and conferences, and via our qualified network of 100 partners in 60 countries, we are going to continue to work to improve what we do so you can achieve your personal goals.
Thanks for your support over the past 20 years!
t
FEATURED ARTICLE CONT’DFEATURED ARTICLE continued
THE VIBRATION ANALYST’S NEWSLETTER 5
Vibration Analysis
Thermography Oil Analysis & Wear Particle
Motor Testing Ultrasound Lubrication Alignment & Balancing
Condition Monitoring
Management
Join the global CBM community where professionals learn and exchange
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2018 Q4 Award Recipients
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www.mobiusinstitute.com/scholarship
Submit your application now!
Janet Jase Kukuma Boroko, Papua New Guinea
“I am so grateful and looking forward to taking up the online courses awarded. It will be the beginning of my career in Reliability Engineering because after completion of the courses I should be in a position to understand better the tasks undertaken in vibration analysis and interpret the results correctly.”
Maria Alejandra Bonilla Diaz Limerick, Ireland
“These certifications will have a strong and direct impact in my daily activities, and this is just the beginning. From what I expect, I will improve not only my theoretical knowledge that will help me to do vibration analysis but also it would improve my techniques about collecting data on field. All this will make turn more reliable all the process and therefore I will be more accurate.”
“I worked very hard on the reference materials and to gain the knowledge from the online learning materials as I believe the knowledge and certification can lead me to the success. All the theories in the online material were described crystal clearly and hence I was able to identify the mistakes and the correct way to diagnose machines using vibration analysis.”
2018 Q4 Award Recipients
We were delighted by the incredible response to our 2018 scholarship offer, we had submissions from prospective vibration analysts from all over the globe. Through our selection process, we have selected the three most deserving recipients for 2018 Q4 and the 2018 Grand Prize winner.
CONGRATULATIONS TO OUR WINNERS
The Top Award recipient not only receives all the benefits of the General Award but also an all-expenses paid trip (registration, hotel and travel expenses) to attend a CBM Conference of their choice.
2018 Grand Prize Winner
Christian FloresPunto Fijo, Venezuela
“I am very grateful for this award, which is an excellent morale-booster that will encourage me to continue doing my best work. I am firmly convinced that I will put all my effort into learning as much as possible to be able to give my contribution to my country in this difficult time. It means a lot to me.”
Mayuri Shanika Sumanadasa2018 2nd Quarter General Award RecipientRatnapura, Sri Lanka
Vibration analysis is an important skill, but being a vibration analyst, with people counting on you to make timely, accurate diagnoses, is a demanding role. Education and accredited certification are key to success, and CBM Conference enables analysts to further their knowledge and meet people who face the same challenges.
Mobius Institute, in association with CBM Conference, would like to help twelve people each year to achieve Category II certifica-tion and benefit from CBM Conferences.
VIBRATION MATTERS - FEBRUARY 2019 THE VIBRATION ANALYST’S NEWSLETTER 7
SCHOLARSHIP AWARDS
The Importance of Proper Shaft Alignment
Bearing damage
Rolling element (anti-friction) bearings are precision components designed to operate with clean lubricant, reasonably constant tem-perature, and axial and radial forces/loads within design guidelines. When a machine is misaligned, the pre-load and dynamic forces are raised considerably.
Misalignment places considerable load on bearings
If you increase the load on a bearing by just 20%, its life is halved. If you double the load on a bearing, you reduce the life to one seventh of its design life. When machines are misaligned, the load on bearings is increased considerably.
We are all under great pressure to increase uptime, reduce costs, and improve product quality. No matter what your role in the organization we can all contribute to these goals. One way you can help is to perform precision shaft alignment on your rotating machinery.
The fact is that misalignment is the root cause of the majority of machine breakdowns: bearing failures, and damaged seals, shafts and couplings. It is widely believed that 50% of machine failures are due to misalignment.
The majority of bearing failures are caused by misalignment
Poor lubrication practices, imbalance, resonances and other factors also contribute to machinery failure, but it is widely agreed that misalignment is the major cause. CONTINUED ON PAGE 9
FEATURED LESSON
VIBRATION MATTERS - FEBRUARY 2019 THE VIBRATION ANALYST’S NEWSLETTER 8
CONTINUED ON PAGE 10
Misalignment has different effects on different types of couplings
The rubber or plastic sleeve between the two hubs in flexible couplings can wear - in fact you will often find a small pile of rubber or plastic under the coupling when you remove the coupling guard.
There is a common misconception: “I use flexible couplings so I do not need to worry about precision alignment”. It is very important to understand that the life of the coupling will be reduced if misaligned, and more importantly, bearings, seals and shafts
will still be under increased load and thus likely to fail prematurely.
Misalignment will reduce the life of flexible couplings
In gear couplings, misalignment results in increased wear on the mating teeth. Under severe misalignment conditions, the load on the teeth will be concentrated to the end of the gear tooth flank. Mis-alignment can also cause lubrication problems, resulting in metal to metal contact and therefore greatly increased wear.
Misalignment can increase the wear on gear couplings
If you eliminate misalignment, the machine will provide greater service. Bearings, shafts, seals and couplings will last longer. Unexpected breakdowns cause secondary damage to machines, and the downtime and repair can cost a small fortune.
CONTINUED ON PAGE 12
When a bearing fails, production may stop and there can be secondary damage, i.e. damage to other parts of the machine due to the bearing failure. The downtime, parts, and labor are very expensive - and avoidable.
Seal damage
Seals are high cost items, often costing up to a third of the total pump cost. Misalignment also causes seals to fail prematurely due to the increased load. Seals do not tolerate misalignment: face rubbing, elevated temperatures, and ingress of contami-nants quickly damage expensive components. The life of the seal can be reduced to 30-50% of design life.
Seals will fail prematurely due to misalignment
The result is lubricant leakage and other lubrication problems, and in many cases, total seal failure with little or no warning. When the seal fails, production may stop. The seal and bearing will have to be replaced. The total cost of parts, labor and downtime can make this a very expensive failure.
Coupling damage
The impact of misalignment on couplings varies greatly according to the type of coupling used. The forces and friction are detrimental to all couplings, however the signs of damage, and the nature of the damage can vary.
VIBRATION MATTERS - FEBRUARY 2019 THE VIBRATION ANALYST’S NEWSLETTER 9
FEATURED LESSON continued
Vibration
The rotational forces that result from misalignment generate vibration. We have seen how these forces can damage the coupling, seals, shaft and bearing, but the vibration can damage other components - even machines located within close proximity.
Misalignment generates vibration
Have you ever heard of a standby machine that was started, only to quickly fail? This can be due to “brinelling”. The bearings in the standby machine are subjected to the vibration of local machines, and that vibration either creates localized wear, or it results in “plastic deformation” of the bearing surface.
Brinelling – bearings are subject to vibration from surrounding machines
Energy consumption
Misaligned machines can also consume more energy. Although studies have produced varying results, it is generally considered that a misaligned machine will consume up to 15% more energy. Large studies have documented savings of between 3% and 8%.
Consider the following equations. If we can reduce the con-sumption of a 30 HP (22 kW) 460 Volt motor from 36 amps to 32 amps, and we are paying 0.06 per kW Hour then the savings are approximately $1,500.
kW = (Volts x Amps x pf x 1.732)/1000
Annual savings = 8400 x kW x kWH cost
Example kW = (460 x 4 x 0.92 x 1.732)/1000 = 2.931
Example savings = 8400 x 2.931 x 0.06 = $1477
Product quality
Misalignment can also result in reduced product quality in many industries. By reducing vibration levels, and aligning rolls and other items, product quality can be maximized.
Downtime and production capacity
The biggest issue of all is production capacity. If you can increase the reliability of rotating machinery, downtime will be reduced. If you increase the uptime, your plant can increase production which has a major impact on the bottom line. It is therefore in everyone’s best interest to correctly align machines. The extra time and effort required will increase profitability - and job security.
In our coming issues, we will look at how to best detect mis-alignment, and take a closer look at various types of misalign-ment and acceptable tolerances.
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FEATURED LESSON continued
THE VIBRATION ANALYST’S NEWSLETTER 10
THE VIBRATION ANALYST’S NEWSLETTER 11
FEATURED LESSON
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11 VIBRATION MATTERS - MAY 2017
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THINK RELIABILITY
ASSET CRITICALITY RANKINGLots of decisions have to be made when implementing an asset reliabil-ity program. Decisions can be prioritized when you understand which assets are most critical to your process. Criticality ranking helps you to determine many things, including repair priorities, spares inventory, condition monitoring justification, qualified for online monitoring, performing acceptance testing, and more.
It’s easy to jump to conclusions of criticality rankings, but your most critical machines may not be your most expensive machines. It is always best to follow a structured process for determi-nation. Criticality is determined by equipment performance and its likelihood of failure. But also you must think about the consequences of failure and not just the likelihood of failure. Consider if an asset’s failure creates risk for your plant or causes quality problems with your products or customers, these have high consequences, and should cause the ranking of criticality to be much higher.
So having established proper and consistent asset criticality ranking process, it will help you justify projects and prioritize your actions. You should use a structured process to determine rankings and involve all relevant stakeholders so that the criticality rankings have broad support. And keep in mind, that rankings should be re-evaluated from time to time because circumstances may change!
FEATURED VIDEO
Related Video
FEATURED VIDEO
THE VIBRATION ANALYST’S NEWSLETTER 12
Rough Alignment Mac MacCormack of Vibralign demonstrates
the four steps to perform a preliminary/rough
shaft alignment that will make your follow-on
precision alignment much easier.
Simulator Spotlight: iTeachAlignment Watch as Jason Tranter demonstrates the iTeachAlignment simulator. This interactive simulator demonstrates phase measurements and how dynamics and sensor type affect phase readings, and is included as part of the iLearnReliability [Condition Monitoring] e-learning product.
Related Video
VIBRATION MATTERS - FEBRUARY 2019
We offer public and on-site training courses in 55 countries worldwide. See our website for a complete course list. CAT - I CAT - II CAT - III CAT - IV OTHER
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VIBRATION MATTERS - FEBRUARY 2019 THE VIBRATION ANALYST’S NEWSLETTER 13
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VIBRATION MATTERS - FEBRUARY 2019 THE VIBRATION ANALYST’S NEWSLETTER 14
VIBRATION MATTERS - FEBRUARY 2019
Tarun MotwaniCAT IVCertificate: M-8135-01Exp: 11 December 2019Location: Smithfield, NSW AU
Pipatpong KuesirikulCAT IVCertificate: M-125310-01Exp: 9 August 2021Location: Chonburi, TH
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Thomas FischerCAT IVCertificate: M-125829-01Exp: 20 September 2021Location: Essen, NRW DE
Luca Barraco CAT IVCertificate: M-126430-01Exp: 24 February 2022Location: Milano, IT
Dries Van LoonCAT IVCertificate: M-127765-01Exp: 27 April 2022Location: San Diego, CA US
Jacobus Johannes BotesCAT IVCertificate: M-127767-01Exp: 27 April 2022Location: Kyalami ZA
ISO Category IV Vibration Analysts are an elite group of specialists that carry the highest regard in the field of Condition Monitoring, at Mobius Institute we recognize them VIBRATION SUPERHEROES.
VIBRATION SUPERHEROES are qualified to lead condition monitoring teams and have a deep understanding of machine dynamics and failure modes. Their knowledge and qualifications allow them to design tests to solve difficult problems and identify underlying issues to prevent re-occurrence. There are no rotating machines problems too difficult to solve.
Mobius Institute would like congratulate all of our Vibration Superheroes and take the opportunity to recognize several of you in each issue of Vibration Matters.
You can become a VIBRATION SUPERHERO TOO! To learn more about CAT-IV blended training at www.mobiusinstitute.com/CAT4
THE VIBRATION ANALYST’S NEWSLETTER 15VIBRATION MATTERS - FEBRUARY 2019
VIBRATION HALL OF FAME
Mobius Institute is represented well all around the world. We have107 Authorized Training Centers (ATC) that offer Genuine Mobius Institute Training in more than 55 countries.
Mobius Institute Authorized Training Centers (ATC) provide high quality training and certification. Centrally managed through Mobius Institute and Mobius Institute Board of Certification, students from around the world receive the same quality of training and accredited certifi-cation according to ISO 18436-1 and ISO 18436-2.
To learn more about ATOs in your region of the world, visit our website and select “Locations & Schedules”.
We would like to recognize several of our ATOs in each issue of Vibration Matters, please see this month’s listing to the right.
Process Management Limitedhttp://www.pml.co.tt/Duane, Zaheer Lall, [email protected] Couva, Trinidad and Tobago+8686362170
AMPs AShttp://www.amps.no/Tommy Glesnes, [email protected], Bergen, Norway+47 915 23 878
PRUFTECHNIK S.E.A. PTE LTDhttp://www.pruftechnik.com.sg/Sven Fleischer, [email protected]+(65) 638 20662
Kistal Equipment Supplies Ltd.http://www.kistalng.com/Ibrahim Adegbite, [email protected], Lagos, Nigeria +234 803 363 8055
SKF LATIN TRADE S.A.Shttp://www.skf.com.co/Liliana Gordillo, [email protected], Cundinamarca, Colombia+57 3157918468
Samir Odeh Engineering Grouphttp://www.samirodeh.com/Riyadh Bsiso, [email protected], United Arab Emirates+971 4 2821762
Mobius Institute North Americawww.mobiusinstitute.comLorne McMurray, [email protected] Island, Washington, USA(+1) 877 550 3400
VIBRATION MATTERS - FEBRUARY 2019 THE VIBRATION ANALYST’S NEWSLETTER 16
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