RITEC

Research, Industrial, Training

and Engineering services
Company, SAE

Introduction

Based on the contract between RITEC and Kandil Industries (KI), RITEC is responsible of
presenting a monthly report including measurements list, analysis, conclusions, and
recommendations based on the measurements conducted on the Rolling, Pickling, Skin Pass, Coating
and Galvanizing Lines.

This report contains the analysis of the measurements conducted to the New Galvanizing Line
Blowers during May 2009. The following table contains a list of the measured machines:

No. M/C Name Remarks

1 Hot Air Generator
2 Jet Cooler 1
3 Jet Cooler 2
4 Spencer Blower

Road 286, New Maadi, Cairo 11435, Egypt ,13

Tel. +20-(0)2-2516-6736 / 2753-7447 - Fax. 2516-6918
e-mail: ritec@ritec-eg.com
 RITEC
Research, Industrial, Training
and Engineering services
Company, SAE

Hot Air Generator

Location Pos Direction Data Type Units Value % Chg Date/Time
MNDE Brg-A 1 Axial Magnitude mm/sec 7.59 12.11 05/05/2009
MNDE Brg-H 1 Horizontal Magnitude mm/sec 7.59 10.81- 05/05/2009
MNDE Brg-V 1 Vertical Magnitude mm/sec 7.24 50.24- 05/05/2009
MDE Brg-A 2 Axial Magnitude mm/sec 5.78 76.70- 05/05/2009
MDE Brg-H 2 Horizontal Magnitude mm/sec 7.41 14.53- 05/05/2009
MDE Brg-V 2 Vertical Magnitude mm/sec 6.29 68.57- 05/05/2009
FDE Brg-A 3 Axial Magnitude mm/sec 32.51 30.41 05/05/2009
FDE Brg-H 3 Horizontal Magnitude mm/sec 20.94 29.82 05/05/2009
FDE Brg-V 3 Vertical Magnitude mm/sec 18.95 142.95 05/05/2009
FNDE Brg. 4 Axial Magnitude mm/sec 71.51 91.61 05/05/2009
FNDE Brg-H 4 Horizontal Magnitude mm/sec 36.28 151.77 05/05/2009
FNDE Brg-V 4 Vertical Magnitude mm/sec 37.89 239.52 05/05/2009

Analysis
 The machine exhibits unacceptable vibration levels. The levels are very high.
 Motor Vibration levels are showing significant increasegeneral decrease, while fan vibration
levels are showing general decreasesignificant increase compared to previous measurements.
 Main vibration in the spectra of motor bearings is at the high amplitude motor operating speed
49.5130.63 Hz with low amplitude harmonics indicate looseness problem.
 In addition, the fan running speed component (51.2330.85 Hz) appears in the spectra with
several harmonics, which indicates looseness problem.
 The magnification of the fan running speed component in the spectra of fan bearings indicate
unbalance problem. the levels are increased
 The presence of high moderate amplitude 100 Hz component at the motor bearings spectra
indicates electrical problem (may be soft foot problem). The levels have increaseddecreased.
 The presence of low amplitude sub harmonic component at 11.3819.2 Hz with its harmonics
represents belt frequency specially the 4th harmonic indicate belt problem.
 Main vibration in the spe4ctra of fan bearings is at the fan running speed (51.230.85 Hz) and its
several harmonics which indicates looseness/wear problem.
 The presence of high amplitude non harmonic component 243.5 Hz (BPFO) in the fan bearings
spectra indicates serious bearing fault.

Road 286, New Maadi, Cairo 11435, Egypt ,13

Tel. +20-(0)2-2516-6736 / 2753-7447 - Fax. 2516-6918
e-mail: ritec@ritec-eg.com
 RITEC
Research, Industrial, Training
and Engineering services
Company, SAE

 The presence of relatively high amplitude non harmonic component 371.56 Hz (BPFI) with
harmonics in the fan bearings spectra modulated with side bands at the fan running speed
component indicates bearing fault.
 The presence of moderate amplitude broad band spikes in the spectra of fan bearings indicates
improper lubrication and confirm bearing fault.
 Time wave form analysis of the motor bearings showed modulation pattern which is due to
beating behavior between the both motor and fan speeds.
Conclusions
 The motor has uneven air gap problem.
 Motor has looseness problem.
 The machine has belt problem.
 The fan bearings are faulty.
 The machine has unbalance problem.
 Fan bearings have serious looseness problem.

Recommendations
 Replace fan bearings. The levels are very high.
 Check fan bearing's housings for excessive clearances problem.
 Check motor for uneven air gap problem (soft foot test is required).
 Check motor for looseness problem.
 Check machine balance.

Road 286, New Maadi, Cairo 11435, Egypt ,13

Tel. +20-(0)2-2516-6736 / 2753-7447 - Fax. 2516-6918
e-mail: ritec@ritec-eg.com
 RITEC
Research, Industrial, Training
and Engineering services
Company, SAE

Jet Cooler (1)

Location Pos Direction Data Type Units Value Date/Time
MNDE Brg-A 1 Axial Magnitude mm/sec 1.39 05/05/2009
MNDE Brg-H 1 Horizontal Magnitude mm/sec 1.05 05/05/2009
MNDE Brg-V 1 Vertical Magnitude mm/sec 1.57 05/05/2009
MDE Brg-A 2 Axial Magnitude mm/sec 2 05/05/2009
MDE Brg-H 2 Horizontal Magnitude mm/sec 1.25 05/05/2009
MDE Brg-V 2 Vertical Magnitude mm/sec 2.22 05/05/2009
FDE Brg-A 3 Axial Magnitude mm/sec 4.77 05/05/2009
FDE Brg-H 3 Horizontal Magnitude mm/sec 5.03 05/05/2009
FDE Brg-V 3 Vertical Magnitude mm/sec 2.58 05/05/2009
FNDE Brg. 4 Axial Magnitude mm/sec 8.77 05/05/2009
FNDE Brg-H 4 Horizontal Magnitude mm/sec 4.23 05/05/2009
FNDE Brg-V 4 Vertical Magnitude mm/sec 2.47 05/05/2009

Analysis
 The machine exhibits unacceptable vibration levels.
 Main vibration in the spectra of motor and fan bearings is at the relatively high amplitude
motor operating speed 49.88 Hz with low amplitude harmonics modulated with family of side
bands at the operating speed (1X) indicate looseness problem.
 The presence of relatively high amplitude sub harmonic component at 9.57 Hz and it is
dominant in some spectra with its several harmonics represents belt frequency specially the 5th
harmonic indicate belt problem.
 The presence of low amplitude non harmonic components 20.8, 24.4 and 128.46 Hz and other
non harmonic components in the spectra of motor and fan bearings especially the FDE bearing
which indicate early bearing fault.
 In addition, the presence of low amplitude non harmonic component 21.2 Hz with its
harmonics in the demodulation spectra of FDE which may be the FTF and this confirm the FDE
faulty.
Conclusions
 Motor has looseness problem.
 The machine has belt problem.
 The FDE are faulty.

Recommendations
 Check motor for looseness problem.
Road 286, New Maadi, Cairo 11435, Egypt ,13
Tel. +20-(0)2-2516-6736 / 2753-7447 - Fax. 2516-6918
e-mail: ritec@ritec-eg.com
 RITEC
Research, Industrial, Training
and Engineering services
Company, SAE

 Check the belt and replace if necessary.

 Check motor bearing for early fault.
 Check FDE bearing for faults.

Road 286, New Maadi, Cairo 11435, Egypt ,13

Tel. +20-(0)2-2516-6736 / 2753-7447 - Fax. 2516-6918
e-mail: ritec@ritec-eg.com
 RITEC
Research, Industrial, Training
and Engineering services
Company, SAE

Jet Cooler (2)

Location Pos Direction Data Type Units Value Date/Time
MNDE Brg-A 1 Axial Magnitude mm/sec 0.63 05/05/2009
MNDE Brg-H 1 Horizontal Magnitude mm/sec 1.04 05/05/2009
MNDE Brg-V 1 Vertical Magnitude mm/sec 0.99 05/05/2009
MDE Brg-A 2 Axial Magnitude mm/sec 0.62 05/05/2009
MDE Brg-H 2 Horizontal Magnitude mm/sec 1 05/05/2009
MDE Brg-V 2 Vertical Magnitude mm/sec 1.29 05/05/2009
FDE Brg-A 3 Axial Magnitude mm/sec 1.56 05/05/2009
FDE Brg-H 3 Horizontal Magnitude mm/sec 1.64 05/05/2009
FDE Brg-V 3 Vertical Magnitude mm/sec 0.9 05/05/2009
FNDE Brg. 4 Axial Magnitude mm/sec 1.4 05/05/2009
FNDE Brg-H 4 Horizontal Magnitude mm/sec 1.52 05/05/2009
FNDE Brg-V 4 Vertical Magnitude mm/sec 1.02 05/05/2009

Analysis
 The machine exhibits acceptable vibration levels.
 Main vibration in the spectra of motor and fan bearings is at the relatively high amplitude
motor operating speed 49.88 Hz with low amplitude harmonics modulated with family of side
bands at the operating speed (1X) indicate looseness problem.
 The presence of relatively high amplitude sub harmonic component at 9.57 Hz and it is
dominant in some spectra with its several harmonics represents belt frequency specially the 5 th
harmonic indicate belt problem.
 The presence of low amplitude non harmonic components 20.8, 24.4 and 128.46 Hz and other
non harmonic components in the spectra of motor and fan bearings especially the FDE bearing
which indicate early bearing fault.
 In addition, the presence of low amplitude non harmonic component 21.2 Hz with its
harmonics in the demodulation spectra of FDE which may be the FTF and this confirm the FDE
faulty.
Conclusions
 Motor has looseness problem.
 The machine has belt problem.
 The FDE are faulty.

Recommendations
 Check motor for looseness problem.
Road 286, New Maadi, Cairo 11435, Egypt ,13
Tel. +20-(0)2-2516-6736 / 2753-7447 - Fax. 2516-6918
e-mail: ritec@ritec-eg.com
 RITEC
Research, Industrial, Training
and Engineering services
Company, SAE

 Check the belt and replace if necessary.

 Check motor bearing for early fault.
 Check FDE bearing for faults.

Road 286, New Maadi, Cairo 11435, Egypt ,13

Tel. +20-(0)2-2516-6736 / 2753-7447 - Fax. 2516-6918
e-mail: ritec@ritec-eg.com
 RITEC
Research, Industrial, Training
and Engineering services
Company, SAE

Spencer Blower
Location Pos Direction Data Type Units Value % Change Date
MNDE Brg-A 1 Axial Magnitude mm/sec 7.79 15.58 05/05/2009
MNDE Brg-H 1 Horizontal Magnitude mm/sec 6.52 46.85 05/05/2009
MNDE Brg-V 1 Vertical Magnitude mm/sec 10.11 108.88 05/05/2009
MDE Brg-A 2 Axial Magnitude mm/sec 7.48 6.97- 05/05/2009
MDE Brg-H 2 Horizontal Magnitude mm/sec 6.95 4.83 05/05/2009
MDE Brg-V 2 Vertical Magnitude mm/sec 4.11 18.79 05/05/2009
FDE Brg-A 3 Axial Magnitude mm/sec 7.08 39.64 05/05/2009
FDE Brg-H 3 Horizontal Magnitude mm/sec 5.02 0.40 05/05/2009
FDE Brg-V 3 Vertical Magnitude mm/sec 9.57 0.84 05/05/2009
FNDE Brg.-A 4 Axial Magnitude mm/sec 9.85 52.71 05/05/2009
FNDE Brg-H 4 Horizontal Magnitude mm/sec 7.33 33.03 05/05/2009
FNDE Brg-V 4 Vertical Magnitude mm/sec 8.98 10.32 05/05/2009

Analysis
 The machine exhibits unacceptable vibration levels.
 Motor vibration levels are showing general decrease increase especially the red bolded points
which show significant increase compared to the previous measurements.
 Main vibration in the spectra of both motor and fan bearings is at the operating speed
component (1X: 49.77 Hz) with several harmonics, especially in the fan bearings which are
showing high amplitude harmonics of the fan operating speed. This indicates looseness and/or
excessive bearing clearances problem in the fan bearings.
 The magnification of 1X component in the motor spectra may indicate structural and/or
resonance problem.
 The magnification of the 1X component in the spectra of fan bearing may indicate unbalance
problem.
 The presence of the 100 Hz component in relatively highmoderate magnitude in the motor
bearings spectra , especially in the horizontal direction of the motor non drive end bearing,
indicates an electrical problem in the motor, possibly air-gap variation problem.
 The presence of non harmonic component 239.8 Hz and its harmonics in the demodulation
spectra of FDE bearing indicates early bearing fault.
 In addition, the presence of moderate amplitude non harmonic component 309 Hz along with
other low amplitude non harmonic components in the spectra of fan bearings indicates possible
fan bearing fault.

Road 286, New Maadi, Cairo 11435, Egypt ,13

Tel. +20-(0)2-2516-6736 / 2753-7447 - Fax. 2516-6918
e-mail: ritec@ritec-eg.com
 RITEC
Research, Industrial, Training
and Engineering services
Company, SAE

 The presence of non defined component 159.4 Hz in the FDE bearing spectra modulated with
side bands at 9.77 Hz need to be investigated.
 The presence of low amplitude broad band spikes in the spectra of fan bearings indicates
improper lubrication problem.

Conclusions
 The motor has a possible structural and/or resonance problem.
 The machine has misalignment and/or unbalance problem.
 Motor bearings may have early faults.
 Fan bearings have severe looseness and/or excessive bearing clearances problem.
 Fan bearings have improper lubrication problem.

Recommendations
 Check machine alignment.
 Eliminating fan bearings, bearing housings’ clearances and looseness problems is strongly
recommended.
 Check the motor for weak support problem.
 Lubricate fan bearings.

Road 286, New Maadi, Cairo 11435, Egypt ,13

Tel. +20-(0)2-2516-6736 / 2753-7447 - Fax. 2516-6918
e-mail: ritec@ritec-eg.com