VA 2017-May - Nestle KBF - Report

Tribology Motor Online
Diagnostics Condition Portable

Monitoring Vibration
Ultrasonic
Balancing Borescope
Vibration Analysis Survey Report

For
Nestle Pakistan Ltd. Kabirwala
May 2017
Corporate Head Quarter:
Sumico Technologies (Pvt) Limited,

185/J-1, M.A. Johar Town, Lahore.
Ph: +92-42-35315541-43, Fax: +92-42-35315540,
Email: info@sumico.com.pk, Web: www.sumico.com.pk
Attn:
Nestle Pakistan Ltd. Kabirwala
Subject: Vibration Analysis Report for May 2017.
Dear Sir,
We are pleased to submit you Vibration Analysis Report for the month of May 2017.
We hope you will find this report complete in all respects.
However, if you feel any discrepancy please feel free to contact us.
Thanks and best regards,
Yours truly,
For SUMICO Technologies Pvt. Ltd.
Dr. Anees Ur Rehman,

B.Sc, M.Sc, PhD (Condition Monitoring), CEng, MIMecE
General Manager (Operations)
Sumico Technologies (Pvt) Limited.
C: +92-321-4974215
E: anees.rehman@sumico.com.pk
VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 2 | 33


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Table of contents
Executive Summary.........................................................................................................................4
1. Inspection Area - UTILITIES..................................................................................................5
1.1. Overview............................................................................................................................5
1.2. Critical Maintenance Review.............................................................................................9
1.3. Abbreviated Measurement Summary..............................................................................11
1.4. Detailed Spectra (UTILITIES area)..................................................................................12
2. Inspection Area - EGRON-1.................................................................................................13
2.1. Overview..........................................................................................................................13
2.2. Critical Maintenance Review...........................................................................................14
2.4. Detailed Spectra (EGRON-1 area)..................................................................................16
3. Inspection Area - EGRON-2.................................................................................................17
3.1. Overview..........................................................................................................................17
3.4. Detailed Spectra (EGRON-2 area)..................................................................................20
4. Inspection Area - STD PLANT.............................................................................................21
4.1. Overview..........................................................................................................................21
4.4. Detailed Spectra (STD PLANT area)...............................................................................25
5. Inspection Area - UHT PLANT.............................................................................................26
5.1. Overview..........................................................................................................................26
5.4. Detailed Spectra (UHT PLANT area)..............................................................................29
6. Inspection Area - NOODLE PLANT.....................................................................................30
6.1. Overview..........................................................................................................................30
6.4. Detailed Spectra (NOODLE PLANT area).......................................................................33


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Executive Summary
This report consists of the vibration analysis of your machine. The survey and data collection of
your equipment was carried out in May 2017. So we are in position to determine mechanical
condition of machines.
This inspection report includes an explanation of all measurement and review conducted. The
mechanical and dynamic behavior of each machine and its components are analyzed and
recommended actions are also detailed for each component of machine.
This report consists of some spectra and waveforms of machine vibration.

In the report points are mentioned as
M1H =Motor Outboard Horizontal

M2A = Motor Inboard Axial
P2V =Pump Outboard Vertical
G1H = Gearbox Inboard horizontal
F2H = Fan Outboard horizontal
Where
Outboard = Non driving end
Inboard = Driving End (Coupling Side)
These abbreviations are used by the software and will be shown as such in the reports. Overall
values of all the points for all machines have been attached with the report. The soft copy of the
report is attached with this for your convenience.


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1. Inspection Area - UTILITIES

1.1. Overview
Sr. Equip. Equipment
Status Remarks
# ID Description
1 1015. PA FAN-1 1015 Normal
Lubricate fan both bearings properly, Keep
2 1025 PA FAN-2 1025 Moderate monitoring temperature. Retake fan data after
lubrication.
3 1035 PA FAN 3 1035 Minor Lubricate motor and fan bearings.
FORCED FAN MOTOR
4 1.1 Normal
1.1 (A.H-1)
FORCED FAN MOTOR Monitor bearing tempetraure. Retake data in case of
5 2.1 Moderate
2.1 (A.H-2) temperature rise/ abnormal sound.
FORCED FAN MOTOR
6 3.1 Normal
3.1 (A.H-3)
Lubricate motor both bearings, keep under
7 0612 PA FAN-4 0612 Minor
observation.
0612- PA FAN-4 0612(OLD
8 N/A
OLD MOTOR)
FORCED FAN MOTOR 4
9 FFM-4 Normal
(A.H-4)
FORCE FAN MOTOR Monitor motor temperature. Increase monitoring
10 FFM-1 Moderate
1(BOL-1) frequency.
OIL BURNER MOTOR Tighten motor mounting bolts and retake data after
11 OBM-1 Moderate
1(BOL-1) bolt tightening.
Lubricate motor bearing if applicable. Monitor motor
FORCE FAN MOTOR
12 FFM-2 Moderate bearing temperature. Also increase monitoring
2(BOL-2)
frequency.
OIL BURNER MOTOR
13 OBM-2
2(BOL-2)
FORCE FAN MOTOR
14 FFM-3 Normal
3(BOL-3)
OIL BURNER MOTOR Nonsyncronous vibration found in motor DE, Monitor
15 OBM-3 Minor
3(BOL-3) temperature, under observation.
FEED WATER PMP 1
16 3781 Normal
3781(BOL-1)
FEED WATER PMP 2
17 3782 Normal
3782(BOL-1)
FEED WATER PMP 3
18 3783 Normal
3783(BOL-2)
FEED WATER PMP 4
19 3784 Normal
3784(BOL-2)
FEED WATER PMP 5
20 FWP-5 N/A
(BOL-3)
FEED WATER PMP 6
21 FWP-6 N/A
(BOL-3)
FEED WATER PMP 1
22 D001 Normal
D001(W.H.B)


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Status Remarks
# ID Description
FEED WATER PMP 1
23 D002 Normal
D002(W.H.B)
FEED WATER PMP
24 FWP-7
7(BOL-3 S.BY)
WCP- WATER CIRCULATION
25
WHB PMP(W.H.B)
CH.W COOLING CIRCL
26 1120 Minor Check oil level in pump, Monitor temperature.
PMP 1120
CH.W COOLING CIRCL
27 1140 Minor Lubricate motor both bearings.
PMP 1140
CH.W COOLING CIRCL
28 1160 Normal
PMP 1160
CH.W COOLING CIRCL
29 1190 Minor Lubricate motor DE bearing.
PMP 1190
CH.W COOLING CIRCL
30 1100 Minor Check oil level in pump.
PMP 1100
CH.W COOLING CIRCL Inspect motor DE bearing for any looseness.
31 1180 Moderate
PMP 1180 Replace if needed.
COOLING W.FEED PMP-
32 6021 N/A
01 6021
COOLING W.FEED PMP-
33 C W P-02 N/A
02
HFO B.P HFO BOOSTER PUMP
34
1 1(6.7MW)
HFO B.P HFO BOOSTER PUMP
35
2 2(6.7MW)
LUBE OIL SEP
36 1E1 Normal
1E1(6.7MW)
START AIR COMP 1
37 B003 Normal
B003(6.7MW)
START AIR COMP 2
38 B004 Normal
B004(6.7MW)
39 H.W.C.P H.W.C PMP 6.7 MW Normal
PBB HFO CENTRIFUG SEP 1
40 Normal
901/1 PBB901/1
PBB HFO CENTRIFUG SEP 2
41 Minor Lubricate motor DE bearing.
901/2 PBB901/2
HFO FP- HFO FEEDER UNIT
42 Normal
2 PMP-2
I-A INSTRUMENT AIR
43 N/A
COMP COMP 6.7 MW
HFO FP- HFO FEEDER UNIT
44 Normal
1 PMP-1
HFO T.P- HFO TRANSFER PMP
45 N/A
1 1(6.7MW)
HFO T.P- HFO TRANSFER PMP
46 N/A
2 2(6.7 MW)
DRINKING WTER TRB-1
47 2201 Normal
2201


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Status Remarks
# ID Description
DRINKING WTER TRB-2
48 2205 Normal
2205
49 2239 DRINKING W.PMP 2239 Minor Monitor pump bearing temperature.
Lubricate motor DE bearing properly, Monitor
50 2250 DRINKING W.PMP 2250 Moderate
temperature and vibration frequently.
51 1214 COOLING T.D PMP 1214 Moderate Lubricate motor both bearings, Monitor temperature..
52 1224 COOLING T.D PMP 1224 Normal

Check oil level and oil condition, increase monitoring
53 1235 COOLING T.D PMP 1235 Moderate
frequency.
54 1245 COOLING T.D PMP 1245 Moderate Check oil level and increase monitoring frequency.
AIR COMPRESSOR GA-
55 GA-110
110(N2)
Replace stage 1 male rotor NDE bearing in next
56 ZR 500 AIR COMPRESSOR 500 Moderate
stoppage. Monitor motor bearing temperature..
57 ZR 450 AIR COMPRESSOR 450 N/A
CH.W CIRCULTION PMP
58 0907
0907
CH.W CIRCULATION
59 0986 Minor Lubricate motor bearings.
PMP 0986
CH.W CIRCULATION
60 0918 Minor Lubricate motor bearings, under observation.
PMP 0918
HOT.W CIRCULATION
61 9339 Minor Monitor Pump temperature frequently.
PMP 9339
HOT.W CIRCULATION
62 9340 Minor
PMP 9340
HOT.W CIRCULATION
63 9341
PMP 9341
Lubricate motor bearings properly ,aslo inspect
CH.W DISTRIBUTION
64 9335 Moderate coupling elemtent and realigh equipment. Keep
PMP 9335
monitoring motor bearing temperature.
CH.W DISTRIBUTION
65 1029 N/A
PMP 1029
CH.W DISTRIBUTION
66 1007 Normal
PMP 1007
CH.W DISTRIBUTION
67 1018 Minor Monitor motor bearing temperature.
PMP 1018
AMMONIA
68 AM.C-1 Normal
COMPRESSOR-1
AMMONIA
69 AM.C-2 Minor Lubricate motor bearings, under observation.
COMPRESSOR-2
GEA AMMONIA
70 GAC Minor Lubruicate motor bearings, Monitor temperature.
COMPRESSOR
ICE.W DISTRIBUTION
71 1515 Normal
PMP 1515
ICE.W DISTRIBUTION
72 1520 Normal
PMP 1520


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Status Remarks
# ID Description
ICE.W CIRCULATION Lubricate motor NDE bearing. Monitor motor
73 1516 Moderate
PMP 1516 temperature frently.
ICE.W CIRCULATION
74 1519 Normal
PMP 1519


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1.2. Critical Maintenance Review

Area UTILITIES (Page 1 of 2)
Observations & Analysis
1025 - PA FAN-2 1025
BPFO fault frequencies found in fan DE and NDE bearings. High g's value also found in peakvue spectra.
2.1 - FORCED FAN MOTOR 2.1 (A.H-2)
Bearing fault frequencies found in motor DE bearing.
FFM-1 - FORCE FAN MOTOR 1(BOL-1)
Non syncrounous vibration found in spectra indicating motor bearing initial wear also rotor bar faul
frequencies found in spectra indicating rotor bar initail wear.
OBM-1 - OIL BURNER MOTOR 1(BOL-1)
High 1xT vibration found in vertical direction indicating structural loosenss.
Bearing fault frequencies found in motor NDE bearing.
1120 - CH.W COOLING CIRCL PMP 1120
BPFI fault frequencies found in pump DE bearing.
2xLF found indicating rotor/stator air gap problem. Also loosness symptoms found in motor DE bearing.
2239 - DRINKING W.PMP 2239
Recommendations
1025 - PA FAN-2 1025
Lubricate fan both bearings properly, Keep monitoring temperature. Retake fan data after lubrication.
2.1 - FORCED FAN MOTOR 2.1 (A.H-2)
Monitor bearing tempetraure. Retake data in case of temperature rise/ abnormal sound.
Monitor motor temperature. Increase monitoring frequency.
OBM-1 - OIL BURNER MOTOR 1(BOL-1)
Tighten motor mounting bolts and retake data after bolt tightening.
Lubricate motor bearing if applicable. Monitor motor bearing temperature. Also increase monitoring frequency.
Check oil level in pump, Monitor temperature.
Inspect motor DE bearing for any looseness. Replace if needed.
Prepared By Review by Approved By

Technical Service Engineer Sr. Technical Service Engineer G.M (Operations)



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Area UTILITIES (Page 2 of 2)

BPFO and BPFI fault frequencies found in motor DE bearing indicating stage 3 bearing fault.
1214 - COOLING T.D PMP 1214
Bearing fault frequencies found in motor both bearing.
Bearing fault frequencies found in pump both bearings.
Bearing fault frequencies found in pump both bearings.
ZR 500 - AIR COMPRESSOR 500
Bearing fault frequencies found with High g's value in stage 1 male rotor NDE bearing peakvue spectra
indicating male rotor NDE bearing fault.
9335 - CH.W DISTRIBUTION PMP 9335
Non syncronuous vibration found in motor bearings indicating initial bearing wear, Also high 1xT with
harmonics found in pump radial and axial direction indicating misalignment due to couplin elemnt wear.
GAC - GEA AMMONIA COMPRESSOR
Bearing fault frequencies found in spectra.
1516 - ICE.W CIRCULATION PMP 1516
Rotor bar fault frequencies found in spectra with 2xLF side bands indicating rotor bar wear/damage. Also g's
value trend increased in motor NDE bearing.
Recommendations
Lubricate motor DE bearing properly, Monitor temperature and vibration frequently.
Lubricate motor both bearings, Monitor temperature..
Check oil level and oil condition, increase monitoring frequency.
Check oil level and increase monitoring frequency.
ZR 500 - AIR COMPRESSOR 500
Replace stage 1 male rotor NDE bearing in next stoppage. Monitor motor bearing temperature..
9335 - CH.W DISTRIBUTION PMP 9335
Lubricate motor bearings properly ,aslo inspect coupling elemtent and realigh equipment. Keep monitoring
motor bearing temperature.
GAC - GEA AMMONIA COMPRESSOR
Lubruicate motor bearings, Monitor temperature.
1516 - ICE.W CIRCULATION PMP 1516
Lubricate motor NDE bearing. Monitor motor temperature frently.




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1.3. Abbreviated Measurement Summary


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1.4. Detailed Spectra (UTILITIES area)


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2. Inspection Area - EGRON-1

2.1. Overview
Status Remarks
# ID Description
FINE POW SEP EXHST
1 2919
FAN 2919
2 2924 ADF FAN 2nd SEC 2924
3 3106 ACF FAN 3106
4 2630 BBS BLOW 2630
5 2640 BBS BLOW 2640
6 4420 FPS BLOW 4420
7 3215 PP BLOW 3215
SECONDARY AIR FAN-1
8 3301
3301
TOWER EXT AIR FAN-1
9 2130
2130
TOWER EXT AIR FAN-2
10 2131
2131
SECONDARY AIR FAN-2
11 3320
3320
NOZZLE COOLING FAN
12 1601
1601
BP AIR BLOW 1051(EG-1
13 1051
ROOF)
AIR BLOWER SUGER
14 1072
1072(TIPP)
VITAMIN PREMIX AIR
15 1080
BLOW 1080


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Area EGRON-1

Recommendations




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2.4. Detailed Spectra (EGRON-1 area)


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3. Inspection Area - EGRON-2

3.1. Overview
Status Remarks
# ID Description
SECONDARY AIR FAN
1 2110
2110
SECONDARY AIR FAN
2 2120
2120
3 5202 ADF FAN 1ST SEC 5202
4 5302 ADF FAN 2ST SEC 5302

5 5402 ADF FAN 5402
6 0102 W.R BLOWER 0102
7 4216 BBS BLOW 4216
8 4406 BBS BLOW 4406
9 4416 BBS BLOW 4416
10 4206 BBS BLOW 4206
11 6206 FFS BLOW 6206
12 6406 FFS BLOW 6406
13 3001 BPA BLOW 3001
14 7001 C.H AIR BLOW 7001
15 6115 FCE AIR FAN 6115
16 6315 FCE AIR FAN 6315
17 6001 SUGAR GRINDER 6001
TOWER EXHST AIR FAN
18 4115
4115
TOWER EXHST AIR FAN
19 4315
4315
NOZZLE COOLING FAN
20 1401
1401
SECONDARY AIR FAN
21 2203
2203
22 5001 TIPPING AIR BLOW 5001


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Area EGRON-2

Recommendations




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3.4. Detailed Spectra (EGRON-2 area)


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4. Inspection Area - STD PLANT

4.1. Overview
Status Remarks
# ID Description
1 7101 WARM SKIMMER 7101
UHT FEED LINE PMP
2 2624
2624
W.SKIMER SHEAR MIXR
3 7336
PMP 7336
W.SKIMMER BOOSTER
4 7335
PMP 7335
W.SKIMMER B.TANK
5 7303
PMP 7303
W.SKIMMER SLURY
6 6902
DOS PMP 6902
7 3801 C.SKIMMER 1 3801
8 3901 C.SKIMMER 2 3901
C.SKIMMER-2 B.TANK
9 2804
PMP 2804
10 7601 BUTTER OIL SEP 1 7601

HOMOGENIZER B.OIL
13 7704
7704
CREAM PASTURIZR BO
14 5607
PMP 5607
15 6131 SCANIMA MIXER 1 6131
SHEAR MIXER PMP
18 3605
EVAP L1 3605
SHEAR MIXER PMP
19 3610
EVAP L2 3610
SLURRY DOSING PMP
20 7002
TO EV 7002
THERMIZER B.TANK
21 0103
PMP 0103
THERMIZER B.TANK
22 0203
PMP 0203
Acid Circulation Pump
23 2.23
2.23
Caustic Circulation Pump
24 3.23
3.23
Caustic Circulation Pump
25 4.23
2 4.23


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Status Remarks
# ID Description
26 1004 CIP FEED PMP L-1 1004
27 1010 CIP FEED PMP L-2 1010
28 1015 CIP FEED PMP L-3 1015
29 1020 CIP FEED PMP L-4 1020
30 1027 CIP FEED PMP L-5 1027
31 1032 CIP FEED PMP L-6 1032
32 1037 CIP FEED PMP L-7 1037

AIR BLOWER 0150(WET
33 0150
TIPPING)


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Area STD PLANT

Recommendations




Ph: +92-42-35315541-43, Fax: +92-42-35315540,


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4.4. Detailed Spectra (STD PLANT area)


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5. Inspection Area - UHT PLANT

5.1. Overview
Status Remarks
# ID Description
1 M6 HOMO MOYOR VTIS M6
2 0101 FEED PMP 0101
3 0111 BOOSTER PMP 0111
4 M2 FEED PMP M2
FLASH VESSEL OUTLET
5 M5
PMP M5
6 M8 WATER CIRCL PMP M8
HOT WATER CIRCL PMP
7 0125
0125
HOT WATER CIRCL PMP
8 0124
0124
HOMOGENIZER UHT
9 0126
0126
0124- HOT.W CIRCL PMP
10
0125 0124-0125(S)


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Area UHT PLANT

Recommendations




Ph: +92-42-35315541-43, Fax: +92-42-35315540,


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5.4. Detailed Spectra (UHT PLANT area)


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6. Inspection Area - NOODLE PLANT

6.1. Overview
Status Remarks
# ID Description
1 B1 Blower
2 B2 Blower1
3 B3 Blower2
4 B4 Blower3
5 B5 Blower4
6 B6 Blower5
7 P1 pump 1
8 P2 pump 2
9 P3 pump 3
10 P4 pump 4
11 P5 pump 5
12 g1 Gear Box
13 g2 Gear Box1
14 g3 Gear Box2
15 g4 Gear Box3


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Area NOODLE PLANT

Recommendations




Ph: +92-42-35315541-43, Fax: +92-42-35315540,


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6.4. Detailed Spectra (NOODLE PLANT area)

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Tribology Motor Online

Diagnostics Condition Portable

Vibration Analysis Survey Report

Sumico Technologies (Pvt) Limited,

Subject: Vibration Analysis Report for May 2017.

We hope you will find this report complete in all respects.

Thanks and best regards,

For SUMICO Technologies Pvt. Ltd.

Dr. Anees Ur Rehman,

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 2 | 33

Sumico Technologies (Pvt) Limited,

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 3 | 33

Sumico Technologies (Pvt) Limited,

This report consists of some spectra and waveforms of machine vibration.

M1H =Motor Outboard Horizontal

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 4 | 33

Sumico Technologies (Pvt) Limited,

1. Inspection Area - UTILITIES

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 5 | 33

Sumico Technologies (Pvt) Limited,

Sr. Equip. Equipment

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 6 | 33

Sumico Technologies (Pvt) Limited,

Sr. Equip. Equipment

52 1224 COOLING T.D PMP 1224 Normal

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 7 | 33

Sumico Technologies (Pvt) Limited,

Sr. Equip. Equipment

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 8 | 33

Sumico Technologies (Pvt) Limited,

1.2. Critical Maintenance Review

Prepared By Review by Approved By

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 9 | 33

Sumico Technologies (Pvt) Limited,

Area UTILITIES (Page 2 of 2)

Prepared By Review by Approved By

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 10 | 33

Sumico Technologies (Pvt) Limited,

1.3. Abbreviated Measurement Summary

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 11 | 33

Sumico Technologies (Pvt) Limited,

1.4. Detailed Spectra (UTILITIES area)

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 12 | 33

Sumico Technologies (Pvt) Limited,

2. Inspection Area - EGRON-1

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 13 | 33

Sumico Technologies (Pvt) Limited,

2.2. Critical Maintenance Review

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 14 | 33

Sumico Technologies (Pvt) Limited,

2.3. Abbreviated Measurement Summary

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 15 | 33

Sumico Technologies (Pvt) Limited,

2.4. Detailed Spectra (EGRON-1 area)

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 16 | 33

Sumico Technologies (Pvt) Limited,

3. Inspection Area - EGRON-2

4 5302 ADF FAN 2ST SEC 5302

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 17 | 33

Sumico Technologies (Pvt) Limited,

3.2. Critical Maintenance Review

VA Report – Nestle Pakistan Ltd. Kabirwala – for May 2017 P a g e 18 | 33

Sumico Technologies (Pvt) Limited,

3.3. Abbreviated Measurement Summary