Vibration Analysis Case Studies By Eng/ Akram Abdelhamid

Case Study - 1 Cooling Tower Fan

!Machine(Data:(

Power:!110!kW!Current: 164!A!

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Shaft Speed Bearing type

Motor 1490 6316 C3 (SKF) 6317 C3 (SKF)

G.B Input 1490 32313-B (FAG) G.B

Intermediate 472.44 32315 BJ2/QCL7C (SKF) 32315-A (FAG)

G.B Output 123.24

NJ 222 ECJ/C3 (SKF) SL 182932 (FAG) = NCF 2932 CV (SKF) 81220-72/W1114

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Machine(Layout(

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Initial reading

Final reading

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M/C$ Br.No$ A$ V$ H$ G1H$

Motor$ M1# 1.8$ 1.6$ 2.2$ 1.9$

All!measurements!in!mm/s! ! ! !

M/C$ Br.No$ A$ V$ H$ G1H$

Motor$ M1# 1.7$ 1.4$ 1.9$ 2.25$

All!measurements!in!mm/s! ! ! !

Motor G.Box

Initial Reading on Gearbox!

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!!!!!" !UREA!COOLING!TOWER!FAN388K001!C!"G1

Analyze!ACorr(Wf)!!!!!!!22"Mar"12!!07:44:18!!

!!RMS!=!!.0954!!!!LOAD!=!!!!.0!!!!!RPM!=!60.!(1.00!Hz)!!

!!PK(+)!=!.7282!!!!!!!PK(" )!=!.3719!!!!!!!CRESTF=!7.63!!!!!!

0 100 200 300 400 500 600 700

"1.0

"0.5

0!

0.5

1.0

Time!in!mSecs

Correlation!Factor

!!!!!" !UREA!COOLING!TOWER!FAN

388K001!C!"G1

Analyze!ACorr(Wf)!!!!!

!!22"Mar"12!!07:56:20!!

!!RMS!=!!.0947!!

!!LOAD!=!!!!.0!!!

!!RPM!=!1450.!(24.16!Hz)!!

!!PK(+)!=!.7482!!!!!

!!PK(" )!=!.3773!!!!!

!!CRESTF=!7.90!!!!!!

0 30 60 90 120 150 180

"1.0

"0.5

0!

0.5

1.0

Time!in!mSecs

Correlation!Factor

Final Reading after change broken gear!

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!!!!!" !UREA!COOLING!TOWER!FAN388K001!C!"G1H

Analyze!ACorr(Wf)!!!!!!!23"Oct"13!!10:09:07!!

!!RMS!=!!.1897!!!!LOAD!=!!!!.0!!!!!RPM!=!1423.!(23.72!Hz)!!

!!PK(+)!=!.5688!!!!!!!PK(" )!=!.4347!!!!!!!CRESTF=!3.00!!!!!!

0 30 60 90 120 150 180

"1.0

"0.5

0!

0.5

1.0

Time!in!mSecs

Correlation!Factor

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Comparison between initial spectrum and after change broken gear

Initial reading.

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After Repair

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Comparison between initial Time wave form and after change broken gear

Initial reading.

After Repair

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!!!!!" !UREA!COOLING!TOWER!FAN388K001!C!"G1

Analyze!ACorr(Wf)!!!!!!!22"Mar"12!!07:44:18!!

!!RMS!=!!.0954!!!!LOAD!=!!!!.0!!!!!RPM!=!60.!(1.00!Hz)!!

!!PK(+)!=!.7282!!!!!!!PK(" )!=!.3719!!!!!!!CRESTF=!7.63!!!!!!

0 100 200 300 400 500 600 700

"1.0

"0.5

0!

0.5

1.0

Time!in!mSecs

Correlation!Factor

!!!!!" !UREA!COOLING!TOWER!FAN388K001!C!"G1H

Analyze!ACorr(Wf)!!!!!!!23"Oct"13!!10:09:07!!

!!RMS!=!!.1897!!!!LOAD!=!!!!.0!!!!!RPM!=!1423.!(23.72!Hz)!!

!!PK(+)!=!.5688!!!!!!!PK(" )!=!.4347!!!!!!!CRESTF=!3.00!!!!!!

0 30 60 90 120 150 180

"1.0

"0.5

0!

0.5

1.0

Time!in!mSecs

Correlation!Factor

Machine photos:

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Case Study – 1 Diagnosis

Gearbox teeth Defect

Case Study - 2

Sprayer Air Fan !

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((((((((Machine(Data:(Speed: 2990!rpm!Power 1100!kW!Design!volume!flow!rate:45!Km3/h!Current: 85!A!Flap Opening 100!%!Motor Br. No 6022C3!(SKF)!Motor Br. No NU 1022 M!(SKF)!

Initial reading

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Final reading

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M/C$ Br.No$ A$ V$ H$

Motor$ M1# 2.7$ 7.6$ 4$

M/C$ Br.No$ A$ V$ H$

Motor$ M1# 0.98$ 1.4$ 0.7$

BASE#FRAM#

Motor#Blower#

M#B1#B2#

Initial Reading at 28-9-2014

Final Reading After Change Motor Bearings at 2-10-2015

!!!!!" !DEDUSTING!FAN335K002!!!"M1A

Analyze!Spectrum!!!!!!!!02"Oct"14!!15:04:23!!

!!RMS!=!!.9801!!!!LOAD!=!!!!.0!!!!!RPM!=!2993.!(49.88!Hz)!!

0 1000 2000 3000 4000 5000

0!

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

Frequency!in!Hz

RMS!Velocity!in!mm/Sec

23.26

47.5049.88

224.79

226.42

229.41

479.12

499.08

501.47

2395.0

2495.1

2595.2

Bearings#Defect#Frequency#

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Case Study – 2 Diagnosis

Motor Bearing defect

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Case Study - 3 !

Boiler Combustion Air Fan

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Machine(Data:(Speed: 1494!rpm!Power 560!kW!Current: 50.9!A!Flap Opening 36.5!%!Br.1 No 22226!EC3(SKF)!Br.2 No 22226!EC3(SKF)!

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Machine(Layout(

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Initial reading

M/C$ Br.No$ A$ V$ H$

Motor$ M1# 2.9$ 2.3$ 3.6$

Fan$B1# 1.8$ 5$ 1.4$

B2# 4$ 2.5$ 3.5$!

Final reading

M/C$ Br.No$ A$ V$ H$

Motor$ M1# 1.1$ 2$ 1.4$

Fan$B1# 1.9$ 1.4$ 1.5$

B2# 1.7$ 1.2$ 1.4$All!measurements!in!mm/s! ! !

Motor Fan

M1 B1 B2

Initial Reading at 7-7-2014

At 23-8-2014 After adjust alignment

Comparison between initial spectrum and after Alignment correction Initial reading.

After Alignment

At 24-8-2014

After washed blower blades.

At 24-8-2014

After balance blower blades.

Spectrum comparison before and after balancing process

After washed blower blades.

After balance blower blades.

Balance Sheet

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Case 3 Diagnosis

Misalignment and unbalance for !