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Flue Gas Recycle Fan: Introduction

The Flue Gas Recycle Fan is part of the COGA unit. The fan increases the efficiency of the COGA unit by recycling a proportion of the incinerated gases from the COGA stack. The fan is critical in sustaining high rates of operation on the plant, catastrophic failure of this fan would result in a COGA unit shut down. This would increase the emissions to the atmosphere and heavy fines could be imposed by the Environment Agency.

Flue Gas Online Vibrartion Points

The above Photo illustrates the position of the fixed online vibration sensors that are fitted to the fan and motor (i.e. MNV = Motor Non Drive End Bearing Vertical).

Flue Gas Fan Vibration Frequencies

The above diagram shows the configuration of the flue gas fan. The above configurations, speeds, bearing details etc have being entered into the online system to assist in fault diagnostics.

In Mid May 2002 the Flue gas fan sensor (Fan Non Drive End Fan Horizl) entered into an alarm condition, the system automatically started rapid data collection. Two parameters were initially in alarm PK-PK Waveform, (Peak to Peak Value of time waveform measured in G’s) and a Bearing energy band also measured in G’s. Below is the Online watch screen showing the status of monitored plant.

Flue Gas Online Watch Screen

Flue Gas Fan Trend Display Waveform

The above online trend is taken off the Fan Non Drive End Sensor;  note how quick the fault is deteriorating. Planning windows are rare on the COGA unit due to the environmental consequences if the plant is shut down.

The next step is to analyse the data to pinpoint why the vibration levels were increasing. Spectrum and Time Waveform analysis was used for this. Below is a spectrum taken from the online system. (Fan Non Drive end horizontal Bearing.)

Flue Gas Fan Bearing Vertical

The filtered spectrum above indicates a problem with the cage and rollers on the NDE fan bearing, a clear match is made with the cage ( 0.4 orders ). 2X Roller spin freq is also present due to defects on the rollers impacting the inner and outer races as they rotate. Cage defects are well known to deteriorate quickly.

Flue Gas Fan Bearing Vertical 2

The time waveform shows impacting to 78 G’s, severe bearing damage.

After discussions with production and maintenance, the reliability team decided to plan for the fan bearings to be changed at the earliest opportunity. New bearings were ordered and a scaffold erected ready for a quick bearing change. The opportunity came on the 21st May when the Dryer Plant shut down on an overload issue. The COGA was still running at this point, so a plan was formulated to shut the flue gas fan down in controlled manner so that the COGA unit could still be run, but at reduced rates, this was only possible because of the Dryer plant shutting down.

Flue Gas Fan Trend Display Waveform PK PK

Flue Gas Fan Bearing

Upon inspection of the bearing it was found that the cage had disintegrated and the bearing had entered the final failure mode. The fan would have failed catastrophically later that day, this would have caused major shaft and fan damage. The bearings were replaced and the fan was running within 6 Hours.

The cleaned up NDE cooper fan bearing showing remains of the cage and the damaged rollers.

Flue Gas Fan Bearing 2

Estimated Cost Savings

(Using Best Practice)

Actual Costs (Action Taken)

Parts : New Bearings  Coo 01400 x 2 = £ 500

Labour : 2 men , 6 hours @ £ 30/ hour = £ 360

Production Losses: None, job planned in with Boil Out

Total Cost = £  860

Costs (No Action Taken)

40% of ERV (Estimated replacement value)

0.40 x £ 55000 (Cost of New Fan) = £ 22,000

Labour : 2 men, 48 hours @ £30 /hour = £3500

Environmental Effect (Fines)

3 Days to remove/repair/replace flue gas fan

If no credits/ Fines Potential £ 2 Million a /day

Production Loss / running on lower rates.

3 Days on lower rates £ 26012

Total Cost  = £ 47978

Estimated Avoided Cost = £ 51512

Final Note

This case study highlights the fact that cage defects can rapidly deteriorate; in this case it only took 5 Days. This type of fault is often missed using conveniently walk round programs; continuous monitoring is sometimes the only way to pick these faults up.

FAQs

The fan is critical in sustaining high rates of operation on the plant, catastrophic failure of this fan would result in a COGA unit shut down. This would increase the emissions to the atmosphere and heavy fines could be imposed by the Environment Agency.

This case study highlights the fact that cage defects can rapidly deteriorate; in this case it only took 5 Days. This type of fault is often missed using conveniently walk round programs; continuous monitoring is sometimes the only way to pick these faults up.

John Stubbs, Geoff Copeland, Stuart Walker, Chris Bennet, Dean Whittle, David Shevels

 

stuart walker bio rms 2020

 Stuart Walker 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 20 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.

Dynamic Vibration Absorber

BONUS: This is the 6th and final (free) case study in the series on Enhanced System Reliability.

In this sixth case study from his book “Enhancing System Reliability Through Vibration Technology”, James Sylvester from JPS Reliability and an Reliability Training Institute Trainer, shows how the use of Dynamic Vibration Absorbers can effectively reduce vibration levels. This case study covers a 2-year project period from initial root cause diagnosis to designing, trialing, and implementing an innovative cost-effective solution.

The other case studies in this series can be viewed on our Blog.

james sylvester

 James Sylvester is an RMS Trainer at the Reliability Training Institute.

RMS has been a key Mobius Training partner since 2004 and James’ addition to the team will help us in delivery of the growing number of course offerings available. James will support in the delivery of our Accredited training courses conforming with ISO 18436, that offer either MiBoc or BINDT certification options.

Being a time-served engineer and having 20 years’ experience in the implementation of Condition-Based Maintenance and Reliability-Based Maintenance programs, with practical experience and qualifications make him an ideal candidate for the role as an RMS Trainer.

Starting as an apprentice fitter turner (millwright) and after 10 years in the Mechanical Engineering and Maintenance he made the move into Condition Monitoring and Reliability Engineering. He has spent the last 20 years working with many of the Blue-Chip companies in the UK and Australia.

James is also the Author of “Enhanced System Reliability Through Vibration Technology” ISBN 978-1-5272-5386-5.

Book Content

ISBN: 978-1-5272-5386-5

Chapter 1 – Condition Monitoring
Chapter 2 – Mechanics of Failure
Chapter 3 – Condition Monitoring Technologies

Chapter 4 – Setting up and Reporting
Chapter 5 – Practical Application
Chapter 6 – ISO Standards

Chapter 7 – Vibration Units
Chapter 8 – Accelerometer Selection and Mounting
Chapter 9 – Signal Processing
Chapter 10 – Bearing Condition Units
Chapter 11 – System Dynamics
Chapter 12 – Resonance & Natural Frequencies
Chapter 13 – Operating Deflection Shape Analysis
Chapter 14 – Motion Amplification
Chapter 15 – Modal Analysis Chapter 16 – Orbit Plot
Chapter 17 – Bode Plots

Chapter 18 – General Vibration Analysis
Chapter 19 – Rolling Element Bearings
Chapter 20 – Fluid Film Bearings
Chapter 21 – Gears
Chapter 22 – Paper Machines
Chapter 23 – Jaw Crushers
Chapter 24 – Vibrating Screens
Chapter 25 – DC Drives
Chapter 26 – AC Drives
Chapter 27 – Electrical Discharge Machining (EDM)
Chapter 28 – Pumps
Chapter 29 – Compressors
Chapter 30 – Reciprocating Engine Vibration
Chapter 31 – Turbo Machinery Notes

Chapter 32 – Balancing

Chapter 33 – Case Studies

Ordering

Throughout May you can purchase the book at a reduced price of £44.50 (RRP £75) +p&p.

  • Postage to the UK is £4.45
  • Postage to the EU is £9.45
  • Postage to the Rest of the World is £13.45

On completion of the form, James will send the invoice and Paypal link.

4 + 2 = ?

James has also created a series of five technical case studies, each of which is full of insights. The case studies are free to review and are created in an easy-to-follow video format. The case studies can be found here.

23RPM Defect on a 4 Point Contact Bearing

This was to be the final of the five case studies on Enhanced System Reliability by James Sylvester. But, following on from feedback we will have one more case study next week, this will be an extra long project case study!

In this fifth case study from his book “Enhancing System Reliability Through Vibration Technology”, James Sylvester from JPS Reliability and an Reliability Training Institute Trainer, demonstrates vibration analysis of a slow rotational 4 Point Contact Bearing, with a 23RPM Defect. This is to remind us that correct database set up, and Time Waveform Analysis is so important in slow rotational bearings.

The other case studies in this series can be viewed on our Blog.

james sylvester

 James Sylvester is an RMS Trainer at the Reliability Training Institute.

RMS has been a key Mobius Training partner since 2004 and James’ addition to the team will help us in delivery of the growing number of course offerings available. James will support in the delivery of our Accredited training courses conforming with ISO 18436, that offer either MiBoc or BINDT certification options.

Being a time-served engineer and having 20 years’ experience in the implementation of Condition-Based Maintenance and Reliability-Based Maintenance programs, with practical experience and qualifications make him an ideal candidate for the role as an RMS Trainer.

Starting as an apprentice fitter turner (millwright) and after 10 years in the Mechanical Engineering and Maintenance he made the move into Condition Monitoring and Reliability Engineering. He has spent the last 20 years working with many of the Blue-Chip companies in the UK and Australia.

James is also the Author of “Enhanced System Reliability Through Vibration Technology” ISBN 978-1-5272-5386-5.

Book Content

ISBN: 978-1-5272-5386-5

Chapter 1 – Condition Monitoring
Chapter 2 – Mechanics of Failure
Chapter 3 – Condition Monitoring Technologies

Chapter 4 – Setting up and Reporting
Chapter 5 – Practical Application
Chapter 6 – ISO Standards

Chapter 7 – Vibration Units
Chapter 8 – Accelerometer Selection and Mounting
Chapter 9 – Signal Processing
Chapter 10 – Bearing Condition Units
Chapter 11 – System Dynamics
Chapter 12 – Resonance & Natural Frequencies
Chapter 13 – Operating Deflection Shape Analysis
Chapter 14 – Motion Amplification
Chapter 15 – Modal Analysis Chapter 16 – Orbit Plot
Chapter 17 – Bode Plots

Chapter 18 – General Vibration Analysis
Chapter 19 – Rolling Element Bearings
Chapter 20 – Fluid Film Bearings
Chapter 21 – Gears
Chapter 22 – Paper Machines
Chapter 23 – Jaw Crushers
Chapter 24 – Vibrating Screens
Chapter 25 – DC Drives
Chapter 26 – AC Drives
Chapter 27 – Electrical Discharge Machining (EDM)
Chapter 28 – Pumps
Chapter 29 – Compressors
Chapter 30 – Reciprocating Engine Vibration
Chapter 31 – Turbo Machinery Notes

Chapter 32 – Balancing

Chapter 33 – Case Studies

Ordering

Throughout May and June you can purchase the book at a reduced price of £44.50 (RRP £75) +p&p.

  • Postage to the UK is £4.45
  • Postage to the EU is £9.45
  • Postage to the Rest of the World is £13.45

On completion of the form, James will send the invoice and Paypal link.

1 + 1 = ?

James has also created a series of five technical case studies, each of which is full of insights. The case studies are free to review and are created in an easy-to-follow video format. The case studies can be found here.

Vibrating Screen Gearbox Bearing Defect

This is the fourth of five video case studies on Enhanced System Reliability by James Sylvester.

In this fourth case study from his book “Enhancing System Reliability Through Vibration Technology”, James Sylvester from JPS Reliability and an Reliability Training Institute Trainer, shows how it’s possible to diagnose faults on a vibrating screen. We demonstrate that by measuring the correct vibration parameters you can resolve defects in harsh applications, even an inner raceway defect on a vibrating screen.

The other case studies in this series can be viewed on our Blog.

james sylvester

 James Sylvester is an RMS Trainer at the Reliability Training Institute.

RMS has been a key Mobius Training partner since 2004 and James’ addition to the team will help us in delivery of the growing number of course offerings available. James will support in the delivery of our Accredited training courses conforming with ISO 18436, that offer either MiBoc or BINDT certification options.

Being a time-served engineer and having 20 years’ experience in the implementation of Condition-Based Maintenance and Reliability-Based Maintenance programs, with practical experience and qualifications make him an ideal candidate for the role as an RMS Trainer.

Starting as an apprentice fitter turner (millwright) and after 10 years in the Mechanical Engineering and Maintenance he made the move into Condition Monitoring and Reliability Engineering. He has spent the last 20 years working with many of the Blue-Chip companies in the UK and Australia.

James is also the Author of “Enhanced System Reliability Through Vibration Technology” ISBN 978-1-5272-5386-5.

Book Content

ISBN: 978-1-5272-5386-5

Chapter 1 – Condition Monitoring
Chapter 2 – Mechanics of Failure
Chapter 3 – Condition Monitoring Technologies

Chapter 4 – Setting up and Reporting
Chapter 5 – Practical Application
Chapter 6 – ISO Standards

Chapter 7 – Vibration Units
Chapter 8 – Accelerometer Selection and Mounting
Chapter 9 – Signal Processing
Chapter 10 – Bearing Condition Units
Chapter 11 – System Dynamics
Chapter 12 – Resonance & Natural Frequencies
Chapter 13 – Operating Deflection Shape Analysis
Chapter 14 – Motion Amplification
Chapter 15 – Modal Analysis Chapter 16 – Orbit Plot
Chapter 17 – Bode Plots

Chapter 18 – General Vibration Analysis
Chapter 19 – Rolling Element Bearings
Chapter 20 – Fluid Film Bearings
Chapter 21 – Gears
Chapter 22 – Paper Machines
Chapter 23 – Jaw Crushers
Chapter 24 – Vibrating Screens
Chapter 25 – DC Drives
Chapter 26 – AC Drives
Chapter 27 – Electrical Discharge Machining (EDM)
Chapter 28 – Pumps
Chapter 29 – Compressors
Chapter 30 – Reciprocating Engine Vibration
Chapter 31 – Turbo Machinery Notes

Chapter 32 – Balancing

Chapter 33 – Case Studies

Ordering

Throughout May and June you can purchase the book at a reduced price of £44.50 (RRP £75) +p&p.

  • Postage to the UK is £4.45
  • Postage to the EU is £9.45
  • Postage to the Rest of the World is £13.45

On completion of the form, James will send the invoice and Paypal link.

0 + 7 = ?

James has also created a series of five technical case studies, each of which is full of insights. The case studies are free to review and are created in an easy-to-follow video format. The case studies can be found here.

Variable Frequency Drive Deterioration

This is the third of five video case studies on Enhanced System Reliability by James Sylvester.

In this third case study from his book “Enhancing System Reliability Through Vibration Technology”, James Sylvester from JPS Reliability and an Reliability Training Institute Trainer, shows how analyzing vibration and thermal data can diagnose electrical drive faults.

The other case studies in this series can be viewed on our Blog.

james sylvester

 James Sylvester is an RMS Trainer at the Reliability Training Institute.

RMS has been a key Mobius Training partner since 2004 and James’ addition to the team will help us in delivery of the growing number of course offerings available. James will support in the delivery of our Accredited training courses conforming with ISO 18436, that offer either MiBoc or BINDT certification options.

Being a time-served engineer and having 20 years’ experience in the implementation of Condition-Based Maintenance and Reliability-Based Maintenance programs, with practical experience and qualifications make him an ideal candidate for the role as an RMS Trainer.

Starting as an apprentice fitter turner (millwright) and after 10 years in the Mechanical Engineering and Maintenance he made the move into Condition Monitoring and Reliability Engineering. He has spent the last 20 years working with many of the Blue-Chip companies in the UK and Australia.

James is also the Author of “Enhanced System Reliability Through Vibration Technology” ISBN 978-1-5272-5386-5.

Book Content

ISBN: 978-1-5272-5386-5

Chapter 1 – Condition Monitoring
Chapter 2 – Mechanics of Failure
Chapter 3 – Condition Monitoring Technologies

Chapter 4 – Setting up and Reporting
Chapter 5 – Practical Application
Chapter 6 – ISO Standards

Chapter 7 – Vibration Units
Chapter 8 – Accelerometer Selection and Mounting
Chapter 9 – Signal Processing
Chapter 10 – Bearing Condition Units
Chapter 11 – System Dynamics
Chapter 12 – Resonance & Natural Frequencies
Chapter 13 – Operating Deflection Shape Analysis
Chapter 14 – Motion Amplification
Chapter 15 – Modal Analysis Chapter 16 – Orbit Plot
Chapter 17 – Bode Plots

Chapter 18 – General Vibration Analysis
Chapter 19 – Rolling Element Bearings
Chapter 20 – Fluid Film Bearings
Chapter 21 – Gears
Chapter 22 – Paper Machines
Chapter 23 – Jaw Crushers
Chapter 24 – Vibrating Screens
Chapter 25 – DC Drives
Chapter 26 – AC Drives
Chapter 27 – Electrical Discharge Machining (EDM)
Chapter 28 – Pumps
Chapter 29 – Compressors
Chapter 30 – Reciprocating Engine Vibration
Chapter 31 – Turbo Machinery Notes

Chapter 32 – Balancing

Chapter 33 – Case Studies

Ordering

Throughout May and June you can purchase the book at a reduced price of £44.50 (RRP £75) +p&p.

  • Postage to the UK is £4.45
  • Postage to the EU is £9.45
  • Postage to the Rest of the World is £13.45

On completion of the form, James will send the invoice and Paypal link.

2 + 2 = ?

James has also created a series of five technical case studies, each of which is full of insights. The case studies are free to review and are created in an easy-to-follow video format. The case studies can be found here.

Standby Fan Motor Bearing Defect

This is the second of five video case studies on Enhanced System Reliability by James Sylvester.

In this case study from his book “Enhancing System Reliability Through Vibration Technology”, James Sylvester from JPS Reliability and an Reliability Training Institute Trainer, shows how analyzing bearing damage can lead to the root cause of the problem.

The other case studies in this series can be viewed on our Blog.

james sylvester

 James Sylvester is an RMS Trainer at the Reliability Training Institute.

RMS has been a key Mobius Training partner since 2004 and James’ addition to the team will help us in delivery of the growing number of course offerings available. James will support in the delivery of our Accredited training courses conforming with ISO 18436, that offer either MiBoc or BINDT certification options.

Being a time-served engineer and having 20 years’ experience in the implementation of Condition-Based Maintenance and Reliability-Based Maintenance programs, with practical experience and qualifications make him an ideal candidate for the role as an RMS Trainer.

Starting as an apprentice fitter turner (millwright) and after 10 years in the Mechanical Engineering and Maintenance he made the move into Condition Monitoring and Reliability Engineering. He has spent the last 20 years working with many of the Blue-Chip companies in the UK and Australia.

James is also the Author of “Enhanced System Reliability Through Vibration Technology” ISBN 978-1-5272-5386-5.

Book Content

ISBN: 978-1-5272-5386-5

Chapter 1 – Condition Monitoring
Chapter 2 – Mechanics of Failure
Chapter 3 – Condition Monitoring Technologies

Chapter 4 – Setting up and Reporting
Chapter 5 – Practical Application
Chapter 6 – ISO Standards

Chapter 7 – Vibration Units
Chapter 8 – Accelerometer Selection and Mounting
Chapter 9 – Signal Processing
Chapter 10 – Bearing Condition Units
Chapter 11 – System Dynamics
Chapter 12 – Resonance & Natural Frequencies
Chapter 13 – Operating Deflection Shape Analysis
Chapter 14 – Motion Amplification
Chapter 15 – Modal Analysis Chapter 16 – Orbit Plot
Chapter 17 – Bode Plots

Chapter 18 – General Vibration Analysis
Chapter 19 – Rolling Element Bearings
Chapter 20 – Fluid Film Bearings
Chapter 21 – Gears
Chapter 22 – Paper Machines
Chapter 23 – Jaw Crushers
Chapter 24 – Vibrating Screens
Chapter 25 – DC Drives
Chapter 26 – AC Drives
Chapter 27 – Electrical Discharge Machining (EDM)
Chapter 28 – Pumps
Chapter 29 – Compressors
Chapter 30 – Reciprocating Engine Vibration
Chapter 31 – Turbo Machinery Notes

Chapter 32 – Balancing

Chapter 33 – Case Studies

Ordering

Throughout May and June you can purchase the book at a reduced price of £44.50 (RRP £75) +p&p.

  • Postage to the UK is £4.45
  • Postage to the EU is £9.45
  • Postage to the Rest of the World is £13.45

On completion of the form, James will send the invoice and Paypal link.

5 + 2 = ?

James has also created a series of five technical case studies, each of which is full of insights. The case studies are free to review and are created in an easy-to-follow video format. The case studies can be found here.

Electrical Vibration Problem

This is the first of five video case studies on Enhanced System Reliability by James Sylvester.

In this first case study James shows how vibration analysis can be used to diagnose electrical vibration problems. In this case a VFD driven Motor. Over the next few weeks James is going to share a selection of interesting vibration analysis case studies. Enjoy, and please share if you found it useful – thanks.

The other case studies in this series can be viewed on our Blog.

james sylvester

 James Sylvester is an RMS Trainer at the Reliability Training Institute.

RMS has been a key Mobius Training partner since 2004 and James’ addition to the team will help us in delivery of the growing number of course offerings available. James will support in the delivery of our Accredited training courses conforming with ISO 18436, that offer either MiBoc or BINDT certification options.

Being a time-served engineer and having 20 years’ experience in the implementation of Condition-Based Maintenance and Reliability-Based Maintenance programs, with practical experience and qualifications make him an ideal candidate for the role as an RMS Trainer.

Starting as an apprentice fitter turner (millwright) and after 10 years in the Mechanical Engineering and Maintenance he made the move into Condition Monitoring and Reliability Engineering. He has spent the last 20 years working with many of the Blue-Chip companies in the UK and Australia.

James is also the Author of “Enhanced System Reliability Through Vibration Technology” ISBN 978-1-5272-5386-5.

Book Content

ISBN: 978-1-5272-5386-5

Chapter 1 – Condition Monitoring
Chapter 2 – Mechanics of Failure
Chapter 3 – Condition Monitoring Technologies

Chapter 4 – Setting up and Reporting
Chapter 5 – Practical Application
Chapter 6 – ISO Standards

Chapter 7 – Vibration Units
Chapter 8 – Accelerometer Selection and Mounting
Chapter 9 – Signal Processing
Chapter 10 – Bearing Condition Units
Chapter 11 – System Dynamics
Chapter 12 – Resonance & Natural Frequencies
Chapter 13 – Operating Deflection Shape Analysis
Chapter 14 – Motion Amplification
Chapter 15 – Modal Analysis Chapter 16 – Orbit Plot
Chapter 17 – Bode Plots

Chapter 18 – General Vibration Analysis
Chapter 19 – Rolling Element Bearings
Chapter 20 – Fluid Film Bearings
Chapter 21 – Gears
Chapter 22 – Paper Machines
Chapter 23 – Jaw Crushers
Chapter 24 – Vibrating Screens
Chapter 25 – DC Drives
Chapter 26 – AC Drives
Chapter 27 – Electrical Discharge Machining (EDM)
Chapter 28 – Pumps
Chapter 29 – Compressors
Chapter 30 – Reciprocating Engine Vibration
Chapter 31 – Turbo Machinery Notes

Chapter 32 – Balancing

Chapter 33 – Case Studies

Ordering

Throughout May and June you can purchase the book at a reduced price of £44.50 (RRP £75) +p&p.

  • Postage to the UK is £4.45
  • Postage to the EU is £9.45
  • Postage to the Rest of the World is £13.45

On completion of the form, James will send the invoice and Paypal link.

0 + 7 = ?

James has also created a series of five technical case studies, each of which is full of insights. The case studies are free to review and are created in an easy-to-follow video format. The case studies can be found here.

4th May 2020

Company News

james sylvester

RMS Reliability Training Institute are pleased to announce and welcome James Sylvester as a partner into the RMS Training Team.

RMS has been a key Mobius Institute training partner since 2004 and James’ addition to the team will help us in delivery of the growing number of course offerings available. James will support in the delivery of our Accredited training courses conforming with ISO 18436, that offer either MiBoc or BINDT certification options.

Being a time-served engineer and having 20 years’ experience in the implementation of Condition-Based Maintenance and Reliability-Based Maintenance programs, with practical experience and qualifications make him an ideal candidate for the role as an RMS Trainer.

Starting as an apprentice fitter turner (millwright) and after 10 years in the Mechanical Engineering and Maintenance he made the move into Condition Monitoring and Reliability Engineering. He has spent the last 20 years working with many of the Blue-Chip companies in the UK and Australia.

James is also the Author of “Enhanced System Reliability Through Vibration Technology” ISBN 978-1-5272-5386-5. Take a look at his first video case study, it’s a great way to meet him!

Welcome to the RMS Training Team, James.

Dean & Wendy Whittle, Stuart Walker
RMS Ltd, Company Directors

8th April 2020

Service announcement

Apologies for the yet another coronavirus post, our intention is to ensure you are kept informed of our capabilities to support and serve you in these challenging times.

Things are changing very quickly with the coronavirus (COVID-19) situation. We’ve been closely monitoring and making changes along the way in accordance with the government guidelines, as we take very seriously our responsibility to help care for our customers and staff.

We would like to inform you that we will continue providing critical system support for upper and lower Tier-1 sites as per the COMAH directives, as well as for customer sites with critical assets. We are making every effort to support customers, including remote data asset health analysis, so that the training, products, services and consultancy you depend upon remains available.

Regarding training, all public and onsite courses have been initially postponed through April and May. On a more positive note, we are now able to offer community-based and instructor-led Mobius Institute certified distance-learning courses for Vibration Analysis and Asset Reliability Practitioner (ARP) with optional mentoring support. Students can now continue learning and gain certification while following the safety guidance to stay at home. Details of the new online course options can be found in the Training Brochure and on the Training section of our website.

Our team remains vigilant of the situation and is responding rapidly as conditions evolve. We will provide ongoing updates via Social Media and our Website to ensure you have clarity of our capabilities to support you. We hope, as does everyone, that the situation improves as soon as possible. In between, please stay safe and follow the advice from government authorities.

2nd June 2020

Service announcement

We are hopeful that Public courses may become an option at the beginning of July. Our team continues to remain vigilant of the situation and is responding rapidly as conditions evolve. We will provide ongoing updates via Social Media and our Website to ensure you have clarity of our capabilities to support you. We are continuing to follow the UK Government’s health guidelines.

Dean & Wendy Whittle, Stuart Walker
RMS Ltd, Company Directors

As part of the Innovate UK fund, over the past 2 years RMS have been involved in an ‘Intelligent Wireless Vibration System’ collaboration between the Building Research Establishment (BRE), Cybula, Griffiths Associates and Skanska. The project called REAM (Enabling remote built environment asset management using embedded intelligence) is tasked with enabling low-cost embedded intelligence within the Facilities Management (FM) market.

st barts hospital rms ai condition monitoring wireless vibrationThis is done by optimising Artificial Intelligence (A.I) technologies for use in detecting the pre-cursors of fault conditions arising on rotating plant. The landmark achievement of the project was during the pilot studies run at St. Barts Hospital and British Sugar where the system was capable of learning the behavior of the plant and successfully detecting anomalies in their condition. All completed on single board computing systems with no cloud server for computing power. Interestingly the system is capable of communicating over long distances with Wifi and other radio technologies but can take care of all its computing on the CPUs next to the machines.

rms ai british sugar factorywissington w256h182

The natural progression for this technology is certainly for use in the built environment enabling low cost condition monitoring using a variety of technologies. With that in mind the Innovate UK fund encourages projects such as this to seek commercial viability and opportunities, as such the pre-production prototype versions of the commercial system are now being trialed as manufacturing preparations are made.

The condition monitoring analytics, which have been developed in high integrity applications (such as nuclear, transport, and energy) for rapid and easily configurable abnormality detection of failure modes can also be run on more highly critical machines utilising more traditional data collection types. Firstly though, Skanska feel the future of Facilities Management (FM) is the use of multiple data sources through intelligent condition monitoring to enable more effective and efficient asset management.

The future of the project looks bright as it becomes a commercial product capable of increasing asset life, maximising efficiency, reducing risk of unexpected failures and reducing energy usage. The REAM project was nominated as a finalist for the “Best Asset Management Innovation” at the Building Innovation Awards.

Interested to know more about this exciting technology? Contact us to schedule a call on +44 (0)1206 791917 or via email to: info (at) rms-reliability.com.

Arlanxeo Performance Elastomers, Belgium, win a BEMAS Asset Performance Award; from all at RMS Reliability, many congratulations on this well-deserved achievement.

In the category ‘Best Improvement in Maintenance & Asset Management’, Christophe Van de Maele and Kristof Van Den Berghe of Arlanxeo were allowed to take the trophy home. The four case examples in which they used their new motion amplification camera received great acclaim.

Best Improvement in Maintenance & Asset Management
Arlanxeo received the award for improving reliability in the 16 extruders in the finishing department. When an extruder comes to a standstill, the repair often takes 7 days. This results in a loss of € 1 million. There were 4 failures per year to the extruders, the cause of which was unknown in half of the cases. By means of vibration measurements, it is not always possible to find the correct cause. In addition to the standard solutions available. Improving the alignment, reinforcing structures, adapting the material of the anchor bolts, there were still problems. Thanks to a combination of further root cause analysis and the motion amplification camera, which magnifies minimal vibrations, the malfunctions could be tackled more successfully. Christophe Van de Maele and Kristof Van Den Berghe received the award for Arlanxeo.

Arlanxeo have a well developed Condition Monitoring and Reliability Team at their plant in Belgium. They invested in an IRIS M Motion Amplification System from RMS Ltd late 2018 with certified training carried out onsite early 2019.

For more information on this amazing technology feel free to contact us at info[at]motionamplification.co.uk