GUJARAT CEMENT WORKS

CASE STUDIES ON
VIBRATION

Mr. ANANT SATHE

Mr. ANIL LAKHLAN

Ms MONIKA SHEKHAR

Mr. SANDIP HIVAREKAR

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 INDEX

VIBRATION CASE STUDIES

Case Study No. Case Study Title Page

No.
Case Study - 1 Balancing of Jet Pulse Filter fan of Cement mIll-2 (Z2P45), Motor Rating – 3-4
45 KW
Case Study - 2 Resonance and rotational looseness problem in ID fan of Kiln-1 Bag House, 5-6
Eqpt. Code : J1P30, Motor rating : 1640 KW
Case Study - 3 Resolving high vibration and overload tripping problem of Raw Mill-2 7-8
Reclaimer Chain Drive Motor , Eqpt. Code A6L05M1 : , Motor rating : 110
KW
Case Study - 4 Bearing failure detection on 1490 RPM motor installed in Aumund Feeder 9-13
in Raw Mill 1 area., Eqpt. Code :R1J02 , Motor rating : 45 KW
Case Study - 5 Coupling Disc failure analysis for 1490 RPM motor installed at reversible 14-18
DPC U3J02 , Motor rating : 45 KW

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Case Study -1 : Balancing of Jet Pulse Filter fan of Cement mIll-2 (Z2P45), Motor rating : 45 KW

Date: 09/04/2014

Equipment: Cement Mill II JPF Z2P45

Equipment History:

JPF Fan Z2P45 was running at very high vibration from Mar-2013. After looking at the trends, it was assumed that
fan might have tendency of running within such high vibration. But considering its high vibration and machine
reliability, coating cleaning was carried out in the month of Nov-Dec’13, but no significant change observed in the
vibration.

In month of January ’14, equipment was running at the vibration of 83.6 mm/sec. With subsequent cleaning of
coating, vibration came down to 67.8 mm/sec.

We have taken the vibration readings of JPF Z2P45 on 07/04/2014. Following were the observations and
recommendations:

Observation:

While analyzing, observed the following points:

1) Overall vibration is extremely high ( max. upto 75 mm/sec) at Fan DE & NDE side in all directions.
2) Spectrum indicating 1X component.
3) Vibration amplitude pattern in all directions & spectrum analysis clearly indicated the symptoms of
unbalance.

Recommendations:

1) Impeller coating to be cleaned.

2) After coating cleaning, dynamic balancing to be carried out.
Initial Spectrum (before balancing, max. value at 1xRPM , 75 mm/sec)

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Job carried out:

1) Impeller coating cleaned.

2) Dynamic balancing carried out.

Results:

1) Again vibration readings taken on 09.04.2014 & found equipment vibration level within limit.
2) Unbalance component (1X) reduced from 75.1 mm/s to 3.6 mm/s.
3) Please refer below table for comparison of vibration levels & spectrum after balancing:

Fan DE Fan NDE

Date H V A H V A Remarks

42.2 6.6 24.5 75.1 22.1 30.2 Before

07.04.2014 balancing

4.2 4.3 4.7 7.3 5 4.4 After

09.04.2014 balancing

Vibration Table

Note: All above readings are in mm/s

Spectrum after Balancing

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 Case Study -2 : Resonance and rotational looseness problem in ID fan of Kiln-1 Bag House,
Eqpt. Code : J1P30, Motor rating : 1640 KW

Date: 20/11/2014

Taken the vibration readings on 13/08/2014. Following were the observation and recommendations:

Equipment: ID fan of Kiln-1 Bag House

Observation:

While analyzing, observed the following points:

1) When the fan is running at 540 rpm, high rubbing & hitting sound observed & also vibration in axial (9.2
mm/s) as well as radial direction (5.5 mm/s)observed. This sound indicates that something within the
system is loose or rubbing. Normally vibration range of this fan is 1-2 mm/sec.
2) When we run the fan above or below 540 rpm ie. 550-650 rpm and 530 rpm respectively, there is sudden
decrease in vibration as mentioned in the above table. The sound also gets vanished.
3) Vibration spectrum was showing symptoms of rotational looseness in both bearings of fan
Above phenomenon was occurring due to resonance condition (exiting frequency coinciding with natural
frequency of the system) & rotational looseness.

Recommendations:

After observing all above conditions, we recommended to avoid the operation of fan between 540 to 550 rpm till
below checks/recommendations are implemented in next opportunity :

1) Check for any looseness within fan bearing housing & their assembly.
2) Check for rubbing of cooling disc on cooling disc guards.
3) Check coupling for any looseness like pin bush, bolts, etc.

Initial Spectrum on fan bearing (drive end side) : (spectrum showing rotational looseness coupled with resonance)

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Physical Observations and Job carried out:

Fan both bearings are inspected & found:

1) DE bearing found loose in housing.

2) Heavy pitting found in bottom cover of housing of NDE bearing.
3) Both Fan bearings along with their housing replaced with new one.

DE Bearing NDE Bearing bottom Housing

Results:

1) Again vibration readings taken on 20.11.2014 & found equipment vibration level in limit.
2) Please refer below table for comparison of vibration levels:

Fan DE Fan NDE

Date H V A H V A Remarks

13.08.2014 5.9 5.8 9.2 4.9 6.4 6.6 Before above

Job carried out

20.11.2014 1.9 0.9 3.3 2.1 0.9 2.5 After above

Job carried out

Note: All above readings are in mm/s

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 Case Study -3 : Resolving high vibration and overload tripping problem of Raw Mill-2
Reclaimer Chain Drive Motor , Eqpt. Code A6L05M1 : , Motor rating : 110 KW

Date: 07/08/2015

As reported on 28/07/2015, the problem of overload tripping of Reclaimer Chain Drive of Phase II, we have taken
the vibration readings on 28/07/2015 & 29/07/2015. Following are the observation and recommendation:

Equipment: Phase II Reclaimer Chain Drive

Observation:

1) Overall vibration of motor increased from 13 mm/s to 20 mm/s & overall vibration of Gearbox also
increased from 10 mm/s to 17 mm/s.
2) Motor Bearings envelop reading increased from 4.4 gE to 18 gE & also rubbing sound observed from
motor bearings
3) Head Sprocket bearings sound & temperature were normal.
4) Spectrum analysis & time waveform analysis carried out & we observed:
a) Symptoms of rotational looseness & misalignment between motor & Gearbox.
b) Harmonics of line frequency observed in motor.
5) To confirm the problem Phase analysis carried out & we get 190⁰ phase shift across the motor & gearbox
in axial direction.
Recommendations:

1) Motor to be replaced.
2) Coupling bushes to be inspected & to be replaced.
3) Proper alignment to be done between motor & gearbox. (Use Laser alignment kit)

Initial Spectrum (before rectification of problem) : Motor NDE side bearing

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Job carried out:

1) Coupling - all bushes inspected & found wear/damaged condition. All bushes replaced with new one.
2) Motor replaced with other spare motor.
3) Alignment carried out with Laser Alignment kit.
4) Reclaimer chain bucket spikes were cut to reduce the load (These spikes were added in shutdown to
increase material carrying capacity).

Damaged coupling bushes

Results:

1) Please refer below table for comparison of vibration levels:

Motor NDE Motor DE

Date H V A H V A Remarks

29.07.15 21.4 13.9 NA 13.2 10.9 14 Before above Job carried out

04.08.15 8.6 6.4 NA 6.8 5.2 5 After above Job carried out

05.08.15 Motor decouple trail before

(10:30AM) 1.1 1.8 3.2 0.8 2.4 bearing replacement

05.08.15 Motor decouple trail after

(07:15PM) 1.3 1.5 1 0.7 0.3 bearing replacement

Note: All above readings are in mm/s

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 Case Study -4 : Bearing failure detection on 1490 RPM motor installed in Aumund Feeder in
Raw Mill 1 area., Eqpt. Code :R1J02 , Motor rating : 45 KW

Date : 30-Aug-2015

The machine was running smoothly but the useful life of Sealed bearing in motor was over. Motor was
replaced in annual shutdown of Aug-2015., Here is the spectrum before the shut down with earlier
motor. The 1 X peak is dominant in the Motor NDE side which has very little amplitude (Less than 3
mm/sec rms value).

1 X peak observed 2.77 mm/sec , RMs

value 2.77 mmsec

Spectrum Of Motor NDE BRG Horizontal Initially.

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 Acceleration envelope of the motor NDE BRG initially

But nevertheless the motor was replaced as part of annual motor replacement programme.
Spare motor was installed in shutdown.

After two running days at site condition, abnormal sound and vibration was reported by the
site personnel. Vibration readings were taken , the spectrum was analyzed. Both motor
DE(4.2 mm/sec rms) & NDE(18 mm/sec rms) bearings were having high vibrations with non
integral peaks in the spectrum.

The highest peak was observed at 7.32 X . This non Integral Multiple represent the fault in
Bearing outer race , which might have developed due to false brinnelling or fretting in
bearing race ways during the storage time. Fault was aggravated during the running of
machine.

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 Peak at 7.3 X , 17 mm/sec, rms
value

Spectrum Of Motor NDE BRG Horizontal with motor fitted in shutdown

Acceleration envelope of the motor NDE BRG with motor fitted in shutdown

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The vibration levels at NDE side were much higher than DE side as it is a horizontal flange
Mounted Motor. Since NDE end was free to move, resulting in higher level of Vibration. But
the Fault frequencies were observed in DE brg as well with peaks in high frequency range.

Peak observed at 7.3X, 4.3

mm/sec, rms value

The presence of high frequency peaks indicate

DE Brg failure

Spectrum Of Motor DE BRG Horizontal with motor fitted in shutdown

Acceleration envelope of the motor DE BRG with motor fitted in shutdown

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The recommendation were given to replace the motor bearings. Below spectrum are after
the bearing replacement, the Vibration level were below 1 mm/sec, rms in Motor DE as well
as motor NDE Bearing.

1 X peak with
0.9mm/sec, rms

Spectrum Of Motor NDE BRG Horizontal after BRG replacement

1x Vibration 0.74 mm/sec

value

Spectrum Of Motor DE BRG Horizontal after BRG replacement

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Case Study -5 : Coupling Disc failure analysis for 1490 RPM motor installed at reversible DPC
U3J02 , Motor rating : 45 KW

Date : 15-Sep-2015

DPC (Deep Pan Conveyor) Drive is installed on a steel Platform on a clinker Silo ( Peter Silo) and has
inherently structure looseness problem.

Motor Coupling Disc failed on 5/9/2015 and spare coupling disk fitted back and machine was realigned
with the help of laser alignment kit.

After starting of drive on no load, High Vibrations found in Horizontal direction of motor DE & NDE side
(Up to 70 mm/sec.)

Here is the Vibration Trend :

Dt. 06-09-2015,readings just after coupling disc replacement and subsequent readings are
after strengthening of base frame in stages

Motor NDE - Horizontal

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 Motor NDE – Vertical

Dt. 06-09-2015,readings just after coupling disc replacement and subsequent readings are
after strengthening of base frame in stages

Motor DE Horizontal

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 Motor DE Vertical

Dt. 06-09-2015,readings just after coupling disc replacement and subsequent readings are after
strengthening of base frame in stages

The Vibration readings were taken and spectrum was analysed , The 1 X component in Horizontal
direction was very High indicating directional Vibration . This was caused due to Resonance.

1 X – Peak Present only (75 mm/sec)

Motor NDE Horizontal Spectrum

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 Horizontal Vibrations were higher than the vertical Vibration

Motor NDE Vertical Spectrum

The Site Team was advised to improve the structural rigidity. The rigidity was improved step by step and
vibration readings were taken after each step. Vibration in first step reduced to 20 mm/sec, then to 7
mm/sec in second step and finally reached to 4 mm/sec in horizontal Direction. Because of
stregnthening, the zone of Resonating frequency changed.

Resonance occurs at natural frequency, which is dependent on Stifness & Mass of system and can be
calculated by mathemetical formula.

Whre fn is the natural frequency, k is the stifeeness of component & m is mass of the system.

The Stregnthening design was conceived by Mr Jai Kumar Jain, FLE- DPC .

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 Strengthened Structure

The Root cause of the problem was analyzed and it was found that cleaning of area was done and heavy
coating was removed (which was attached to the structure). This has impacted adversely in terms of
rigidity of motor structure

Above studies Contributed By :

Mr. Anil Lakhlan (Engineer, MID)

Mr. Ankit Pareek (Engineer, MID)

Ms. Monika Shekhar (Engineer, MID)

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