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    Vibration Case Histories

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    anupraja
    This document contains 4 vibration case histories from a company's predictive maintenance program: 1) Excessive motor vibration caused by a gear fault in a gearbox driving a vacuum pump. Replacing the faulty gearbox resolved the issue. 2) Unusual motor and gearbox vibration on an agitator system caused by broken rotor bars in the motor and design of a 4-yoke gear in the gearbox. 3) Repeated failures of a fan bearing due to misalignment issues resolved by installing a new fan base and more tolerant bearing type. 4) High vibration on a critical pump indicated cage wear in an outboard bearing, resolved by replacing the defective bearing.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Vibration Case Histories

    Uploaded by

    anupraja
    196 views56 pages
    This document contains 4 vibration case histories from a company's predictive maintenance program: 1) Excessive motor vibration caused by a gear fault in a gearbox driving a vacuum pump. Replacing the faulty gearbox resolved the issue. 2) Unusual motor and gearbox vibration on an agitator system caused by broken rotor bars in the motor and design of a 4-yoke gear in the gearbox. 3) Repeated failures of a fan bearing due to misalignment issues resolved by installing a new fan base and more tolerant bearing type. 4) High vibration on a critical pump indicated cage wear in an outboard bearing, resolved by replacing the defective bearing.

    Original Description:

    Vibration Presentation

    Original Title

    VI Presentation, 091203

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    This document contains 4 vibration case histories from a company's predictive maintenance program: 1) Excessive motor vibration caused by a gear fault in a gearbox driving a vacuum pump. Replacing the faulty gearbox resolved the issue. 2) Unusual motor and gearbox vibration on an agitator system caused by broken rotor bars in the motor and design of a 4-yoke gear in the gearbox. 3) Repeated failures of a fan bearing due to misalignment issues resolved by installing a new fan base and more tolerant bearing type. 4) High vibration on a critical pump indicated cage wear in an outboard bearing, resolved by replacing the defective bearing.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    196 views56 pages

    Vibration Case Histories

    Uploaded by

    anupraja
    This document contains 4 vibration case histories from a company's predictive maintenance program: 1) Excessive motor vibration caused by a gear fault in a gearbox driving a vacuum pump. Replacing the faulty gearbox resolved the issue. 2) Unusual motor and gearbox vibration on an agitator system caused by broken rotor bars in the motor and design of a 4-yoke gear in the gearbox. 3) Repeated failures of a fan bearing due to misalignment issues resolved by installing a new fan base and more tolerant bearing type. 4) High vibration on a critical pump indicated cage wear in an outboard bearing, resolved by replacing the defective bearing.

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    Vibration Case Histories

    Barry T. Cease
    MeadWestvaco

    1
    9/19/2006

    Introduction
    Case History#1 Excessive
    Vibration Of Motor
    Case History#2 Strange Motor &
    Gearbox Vibration
    Case History#3 Repeat Fan
    Bearing Failures
    Case History#4 Pump Bearing
    Cage Failure

    2
    9/19/2006

    Case History#1,
    Excessive Vibration Of Motor
    EQUIPMENT: Nash 9000 series
    vacuum pump driven by a single
    reduction, parallel gearbox and a
    700 HP synchronous motor.
    The vacuum pump is one of many
    used to pull water out of the paper
    (dry it) as it moves thru the
    process.

    3
    9/19/2006

    CH#1 Equipment Layout

    4
    9/19/2006

    CH#1 - Problem
    Excessive & noisy vibration at
    motor.
    This problem could be heard & felt
    clearly at the motor.
    It sounded like something was
    rubbing and/or loose.

    5
    9/19/2006

    CH#1 Test Data & Observations


    (Motor)
    Motor speed was exactly 400 rpm.
    Pump speed was 267 rpm.
    Pump vibration data showed no
    abnormal patterns or levels.
    Motor spectra showed many
    harmonics of running speed and of
    133 cpm (1/3 x rpm).
    Motor waveform showed impacting
    at 400 & 133 cpm.

    6
    9/19/2006

    CH#1 - Motor Spectra

    7
    9/19/2006

    CH#1 Motor Spectra Zoom

    8
    9/19/2006

    CH#1 Motor Waveform

    9
    9/19/2006

    CH#1 Test Data & Observations


    (Gearbox)

    Gearbox input speed was 400 rpm.


    Gearbox output speed was 267 rpm
    (1.5:1 ratio and 56T/84T).
    Gearbox spectra showed many
    harmonics of both input & output speed
    and 133 cpm (1/2 x output).
    Gearbox spectra didnt show high
    gearmesh frequency at 22,400 cpm.
    Gearbox waveform showed heavy
    impacting at 400 cpm.
    Gearbox Peakvue data showed many
    harmonics of 400 cpm.
    10
    9/19/2006

    CH#1 Gearbox Spectra

    11
    9/19/2006

    CH#1 Gearbox Spectra Zoom

    12
    9/19/2006

    CH#1 Gearbox Waveform

    13
    9/19/2006

    CH#1 Peakvue Spectra

    14
    9/19/2006

    CH#1 Peakvue Waveform

    15
    9/19/2006

    CH#1 Maintenance History


    The motor was changed out in
    7/02 and the gearbox was changed
    in 8/02.
    After motor change in 7/02, motor
    vibration levels initially dropped,
    but eventually resumed previous
    levels.
    The gearbox installed in 8/02 had
    been used before, but was the only
    16
    spare available at the time.
    9/19/2006

    CH#1 Conclusions &


    Recommendations

    It was recommended that the gearbox


    be changed out when possible due to a
    probable gear fault.
    The gearbox was changed in 5/03.
    An inspection of the gearbox showed
    many gear teeth broken off on the
    pinion gear with significant wear on
    both gears.
    Follow-up data on both machines after
    the gearbox change showed much lower
    vibration levels the problem vanished.
    17
    9/19/2006

    CH#1 Gearbox Inspection

    18
    9/19/2006

    CH#1 Motor Data, B & A

    19
    9/19/2006

    CH#1 Gearbox Spectra, B & A

    20
    9/19/2006

    CH#1 Gearbox Wave, B & A

    21
    9/19/2006

    Case History#2, Strange Motor &


    Gearbox Vibration
    EQUIPMENT: Agitator driven thru
    single reduction, parallel gearbox
    by an induction motor.
    This agitator helps maintain the
    consistency of the stock in our
    hydrapulper tank.

    22
    9/19/2006

    CH#2 - Problem

    Strange pulsing noise coming


    from motor & gearbox.

    23
    9/19/2006

    CH#2 Test Data & Observations


    (Motor)

    Motor speed was exactly 1192 rpm.


    Agitator speed was 236 rpm (5:1 ratio).
    Motor spectra showed many harmonics
    of running speed & closer inspection
    showed 48 cpm sidebands around each
    harmonic.
    Motor waveform showed pulsations or
    modulation at a period of approx. 1.25
    sec or 48 cpm.
    24
    9/19/2006

    CH#2 Motor Data

    25
    9/19/2006

    CH#2 Motor Zoom

    26
    9/19/2006

    CH#2 Test Data & Observations


    (Gearbox), Part 1

    Gearbox speed was 1192 rpm input &


    236 rpm output (single reduction @ 5:1
    ratio).
    Gearbox spectra showed high gearmesh
    frequency (26,200 cpm) with sidebands
    at 945 cpm.
    Gearmesh sidebands usually relate to
    one of the gear speeds, but 945 cpm
    didnt correlate to either speed (1192 or
    236 rpm).
    27
    9/19/2006

    CH#2 Test Data & Observations


    (Gearbox), Part 2
    Gearbox waveform showed
    impacting or modulation at 945
    cpm.
    Agitator data showed nothing
    abnormal.

    28
    9/19/2006

    CH#2 Gearbox Data

    29
    9/19/2006

    CH#2 Gearbox Zoom

    30
    9/19/2006

    CH#2 Conclusions &


    Recommendations (Motor), P1

    It was concluded that the strange


    vibration data on the motor was the
    result of broken rotor bars.
    The 48 cpm sidebands around the
    motor harmonics related directly to its
    pole pass frequency.
    The classic spectral pattern of broken
    rotor bars is running speed harmonics
    with sidebands at pole pass frequency.
    The classic waveform pattern of broken
    rotor bars is pulsations at pole pass
    frequency.
    31
    9/19/2006

    CH#2 Conclusions &


    Recommendations (Motor), P2
    Pole Pass Frequency =
    (Theoretical RPM True RPM) * #Poles.
    PPF = (1200 1192) * 6 = 48 cpm.
    The recommendation was made to
    changeout the motor at the next outage.
    Later inspection by a motor repair shop
    showed many broken rotor bars.

    32
    9/19/2006

    CH#2 Conclusions &


    Recommendations (Gearbox)
    After consultation with the gearbox
    vendor, it was concluded the the
    strange data from the gearbox was
    likely due to the 4-yoke design of
    the bull gear.
    The 4-yokes in the gear hub result
    in minor deviations from the gear
    pitch circle causing modulation
    each time these teeth move in and
    out of the mesh.
    4 * 236 rpm = 945 cpm.

    33
    9/19/2006

    CH#2 - 4-Yoke Gear

    34
    9/19/2006

    CH#2 Conclusions &


    Recommendations (Gearbox),
    Part 2

    The vendor indicated it shouldnt


    be a problem, but recommended
    an annual gear inspection &
    continued vibration monitoring
    looking for any change in
    condition.

    35
    9/19/2006

    Case History #3, Repeat Fan


    Bearing Failures
    EQUIPMENT: Overhung,
    centrifugal fan belt-driven by a 60
    HP induction motor.
    This is a critical fan necessary to
    the process of winding the paper
    into customer-specified sizes.

    36
    9/19/2006

    CH#3 Equipment Layout

    37
    9/19/2006

    CH#3 - Problem

    Repeat fan bearing failures.


    In one instance, vibration detected
    bearing faults on this fan less than a
    month after changeout.
    Predictive maintenance was able to
    detect these failures early enough to
    schedule repairs during outages, but
    after three fan bearing changeouts in 12
    months, we knew something had to be
    done differently.
    38
    9/19/2006

    CH#3 Test Data & Observations,


    Part 1

    Motor speed was 1786 rpm


    Fan speed was 1985 rpm
    Motor spectra showed running speed &
    harmonics, fan speed & harmonics, belt
    frequencies & little else.
    Fan spectra was similar to motor data,
    but also showed fan bearing defect
    frequencies (BPFO & harmonics).

    39
    9/19/2006

    CH#3 Fan Spectra

    40
    9/19/2006

    CH#3 Test Data & Observations,


    Part 2
    Fan trend data showed initial drop
    when bearings were changed, but
    soon jumped up to previous high
    levels days or weeks after
    changeout.
    One of the mechanics involved in
    the bearing change told us, it took
    us over an hour to get the bearings
    aligned to where the shaft would
    even turn.

    41
    9/19/2006

    CH#3 Fan Trend Data

    42
    9/19/2006

    CH#3 Test Data & Observations,


    Part 3
    The fan bearings were standard
    pillow block style housings with
    tapered roller bearings inside.
    We assumed these were selfaligning bearings as most pillow
    blocks are, but this assumption
    turned out to be false.

    43
    9/19/2006

    CH#3 Conclusion &


    Recommendations, Part 1

    The relatively tight alignment tolerances


    of the existing tapered roller bearings
    combined with the poor condition of the
    fan base made for short bearing life.
    We asked our bearing supplier for a
    replacement bearing type that would
    carry the same load, but be more
    forgiving for misalignment.
    We also had our machine shop fabricate
    a new fan base that was machined flat
    & line bored to perfectly fit the new
    pillow block bolt pattern.
    44
    9/19/2006

    CH#3 Conclusions &


    Recommendations, Part 2

    After installation of the new type


    bearings & new fan base we have not
    had another bearing failure.
    Our bearing life has went from an
    average of 4-months to 26 months and
    counting.
    Further inspection of maintenance
    history showed a fan speed increase
    which corresponded quite well to our
    increased rate of failure.
    45
    9/19/2006

    CH#3 Conclusions &


    Recommendations, Part 3

    This case history is a good example of


    both predictive & proactive
    maintenance.
    Predictive maintenance allowed us to
    avoid catastrophic fan bearing failures
    and perform repairs during scheduled
    outages.
    Proactive maintenance extended the life
    & reliability of the fan bearings.
    46
    9/19/2006

    Case History#4, Pump Outboard


    Bearing Cage Failure
    Equipment: Double-suction, centrifugal
    pump driven by a 1250 HP synchronous
    motor turning at 514 rpm.
    This is the most critical pump in the
    process directly providing the product
    (stock) used to make paper on the paper
    machine.

    47
    9/19/2006

    CH#4 - Problem

    Increasing HFD vibration levels at pump


    outboard. Current levels had exceeded
    maximum of long term trend.

    48
    9/19/2006

    CH#4 Test Data & Observations,


    Part 1
    Since the bearing was oil lubricated, an
    analysis of the outboard bearing oil was
    requested.
    Oil analysis results showed very high
    copper levels indicating cage wear.
    Vibration data showed very high HFD
    levels on outboard bearing.

    49
    9/19/2006

    CH#4 HFD Trend

    50
    9/19/2006

    CH#4 Test Data & Observations,


    Part 2
    Peakvue spectra showed harmonics of
    fundamental train frequency (cage).
    An 10/01 paper by J. Robinson & J. Berry
    recommends a Peakvue fault level of 4.0
    gs pk-to-pk for a 500 rpm machine.
    Peakvue waveform on outboard bearing
    showed levels at 11.3 gs pk-to-pk!!!
    Maintenance history showed a continuing
    problem of a leaking pump outboard seal.

    51
    9/19/2006

    CH#4 Peakvue Spectra, P1

    52
    9/19/2006

    CH#4 Peakvue Spectra, P2

    53
    9/19/2006

    CH#4 Peakvue Waveform

    54
    9/19/2006

    CH#4 Conclusion &


    Recommendations, Part 1
    The recommendation was made to
    changeout the pump outboard bearing.
    Later inspection of the bearing showed the
    cage worn badly particularly in the area
    separating the rolling elements from one
    another.
    During the bearing change, shims were
    found under the bearing making up the fit
    with the housing.

    55
    9/19/2006

    CH#4 Conclusion &


    Recommendations, Part 2

    Failure analysis of the bearing found lube


    contamination and skidding as the primary
    causes of failure. Corrective actions were as
    follows:
    1) Replace the outboard bearing housing,
    2) Repair or replace the pump outboard packing
    gland,
    3) Replace the pump rotor which was causing
    thrust loading, and
    4) Upgrade the lube from an ISO 68 to an ISO
    150 weight oil (temporarily use grease until
    packing gland repaired).
    56
    9/19/2006

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