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20091119 Report No: 19 November 2009 Report Date:

ALIGNMENT and VIBRATION REPORT


Cooling Tower Fan
Tom & Jerry Compressor Engineering cc
P.O. Box 10810
Cannibal Valley
Tree 7
jerry@tom.co.za E-Mail:
080 0800 0800 Cell:
Mr. Jerry Attention:
6 Vibration Fault Report:
3 Priority Explanation:
2 Laser Alignment Report:
1 Cover Page:
Page Contents
031 914 0237 Contact Number - Office:
083 268 4794 Contact Number - Cell:
Robbie Venter Name:
If there are any enquiries regarding the content of this report,
please contact the author.
Alignment Report
Motor Gearbox
265 190 285 270
190
100
Comments:
The unit was aligned to the required specifications.
0.34 mm 0.20 mm Horizontal:
0.38 mm 0.21 mm Vertical:
Back Foot Front Foot
Foot Results
0.046 mm - 0.059 mm Horizontal:
0.021 mm - 0.072 mm Vertical:
Offset ( II ) Angularity ( I/ )
Coupling Results
1500 RPM Speed:
19 November 2009 Date:
Cooling Tower Fan Machine Description:
PRIORITY DESCRIPTION
5 No Action Required
4 Await Trend Developments
3 Repair At Next Outage
2 Repair During Operation
1 Immediate Attention
Priority Number Priority Description
POINT DESCRIPTION EXPLANATION
Motor Gearbox
1H 2H 3H 4H 5H 6A
Axial. A
Vertical. V
Horizontal. H
Gearbox output shaft drive side bearing. 6A
Gearbox output shaft 5H
Gearbox input shaft non-drive side bearing. 4H
Gearbox input shaft drive side bearing. 3H
Motor drive side bearing. 2H
Motor non-drive side bearing. 1H
Point Explanation Point Description
1
1
2
3
1
3
2
3
1
2
2
3
1
2
3
4
5
6
7
8
9
1
0
1
1
1
2
1
3
1
4 1
5
1
2
3
4
5
6
7
8
9
1
0
1
1
1
2
1
3
1
4
1
5
1
2
3
4 5
6
7
8
9
1
0
1
1
1
2
1
3
1
4
1
5
12 t 45 t
15 Output Shaft Factor
4 Input Shaft Factor
3 Common Prime Factor
3.750 Gear Ration
6.65 Hz 300 RPM Gearbox Output Speed
24.93 Hz 1496 RPM Gearbox Input Speed
Frequency in Hz
1.66 99.73 299.20 6.65 24.93
Tooth Repetition Assembly Phase Gear Mesh Speed Out Speed In
Frequency in CPM
100 5984 17952 399 1496
Tooth Repetition Assembly Phase Gear Mesh Speed Out Speed In
Frequency in Orders
0.07 4.00 12.00 0.27 1.00
Tooth Repetition Assembly Phase Gear Mesh Speed Out Speed In
Gear assembly phase problems are a gear wear pattern induced fault that outcomes in the
generation of fractional sub-harmonics of gear mesh frequency in the vibration spectrum.
Manufacturing problems in the gears, damage to the gears from contamination travelling through
the mesh or from reorienting the gear during overhaul operations can cause this fault. What
usually results from this type of problem is accelerated wear.
For any gear, the assemble phase factor (NA) defines the groups of gear teeth that will come in
contact during meshing. The product of the common prime factors of the tooth counts in the
meshing gears is NA.
For example:
TPINION = 12 Prime factors: 4
TGEAR = 45 Prime factors: 15
NA = product of Common prime factors, 3
The gear seat will have three unique groups or phases of teeth that will mesh. The spectral
frequency produced is the gear assembly phase frequency will be equal to (GMF/NA). An
example for a spectrum is shown below.
G1 = 1x RPM Output Shaft Speed
P1 = 1x RPM Input Shaft Speed
P2 = 2x RPM Input Shaft Speed
1x GAPF = 1x Gear Assembly Phase Frequency
2x GAPF = 2x Gear Assembly Phase Frequency
1x GMF = 1x Gear Mesh Frequency
If No, what is the plan of action:
No Yes Problem Solved: Date: Artisan:
Feedback:
Ensure the gearbox has adequate lubrication and that the oil is free of water. Take
oil sample for analysis to monitor wear rate. Continue to monitor vibration to ensure
the gears are wearing in and not out. Balance the fan impeller.
Action:
Multiple harmonics at gear mesh frequency, gear assembly phase frequency with
running speed sidebands of the input and output shaft-running speed present on the
gearbox. (See pages 4 and 5 for explanation) Vibration levels
in the high frequency band (1-5 kHz) increased when the doors were closed. High
1x at fan speed in the radial plane indicates imbalance.
Findings:
Gear assembly phase problems and imbalance. Problem:
Gearbox Component:
001 Cooling Tower Fan Machine:
Immediate Attention NCP Station:
1
WP Analyst: 19 November 2009 Date:
Priority:
SPECIFIC MACHINE FAULT REPORT