sample vibration analysis report

Sample Predictive Maintenance Report

Vibration Analysis

12857 E. Independence Blvd., Suite F Matthews, North Carolina 28105

800-532-0415 www.ISIservesYOU.com

© All rights reserved. Written permission should first be obtained through Instrumentation Services, Inc., prior to any reproduction or transmission of this document in any form by any

means, electronic, mechanical, photocopying or otherwise.

Vibration Analysis Priority Criteria

Repair Priority Causal Events or Scenarios

PRIORITY 1

Serious or advanced anomaly noted; i.e., broken gear tooth or advanced bearing defect, or Rapid upward vibration trend indicative of increased degradation; failure may be imminent, or Any defect noted on an extremely critical or safety-related piece of equipment, or Vibration levels far above industry norm for a particular component. Recommended repairs to be instituted in a timely fashion or at next earliest opportunity. If equipment should be immediately secured, customer will be informed prior to departure from site.

PRIORITY 2

Any Priority 3 anomalies which have begun to gradually trend upwards, or Initial detection of most bearing defects with no prior machine history, or Any defect noted which, left unattended, will result in further cumulative damage to a machine; i.e., coupling misalignment resulting in bearing damage. Recommended repairs to be completed during the next available outage period, if not sooner. Continued operation as a Priority 2 may result in the machine degrading to Priority 1 condition.

PRIORITY 3

Initial detection of a minor anomaly, or Initial data collection following corrective maintenance (status update), or Any Priority 2 faults which have been re-evaluated as not trending upwards and not a long-term reliability threat. Recommended repairs to be performed at a convenient time, unless otherwise specified.

Note: ISI Vibration Analysts reserve the right to deviate from the above guidelines based on analyst’s experience, statistical data, or industry “best-practices.”

Equipment Problem Description Priority 08-07 07-07 06-07 RemarksChill Water Pump (E) Tested OKChill Water Pump (W) Tested OKChill Water Pump (M) OOS Tested OK

C.T. Pump (NE) Tested OKC.T. Pump (NW) OOS OOS OOS OOS Out of serviceC.T. Pump (NM) Tested OKC.T. Pump (SE) Tested OKC.T. Pump (SW) Tested OK

C.T. Fan (NE) OOS Out of serviceC.T. Fan (NW) Tested OKC.T. Fan (SE) Tested OKC.T. Fan (SW) Possible loose motor shaft component. 3 slight trendDA Pump (N) OOS Tested OKDA Pump (S) OOS OOS Tested OK

Electric Chiller Drive (E) Tested OKK-1 Vacuum Pump OOS OOS Tested OKK-2 Vacuum Pump Tested OKK-3 Vacuum Pump OOS Out of service

K-1 Agitator Process issue. 1 1 OOS spikeK-2 Agitator OOS access 2 Out of serviceK-3 Agitator 2 Trend improvedT-1 Mixer Structural damage. 2 OOS

Base Absorber Pump (N) Defective motor. 1 1 2 upward trendBase Absorber Pump (S) Tested OK

ABS Heat Exchanger Pump Tested OKMethanol Pump (N) Tested OKMethanol Pump (S) OOS OOS OOS OOS Out of service

HCHO Transfer Pump OOS OOS OOS OOS Out of serviceHCHO Charge Pump #1 OOS OOS OOS OOS Out of serviceHCHO Charge Pump #2 OOS OOS OOS OOS Out of service

Resin Oxidizer Fan Tested OKHCHO Oxidizer Fan Tested OK

Blower 150 A OOS Tested OKBlower 150 B OOS Out of serviceBlower 300 A Tested OKBlower 300 B Tested OKBlower 700 A Tested OKBlower 700 B Tested OK

HCHO Agitator #1 2 Trend improvedHCHO Agitator #2 OOS Tested OKHCHO Agitator #3 OOS Tested OKHCHO Agitator #4 OOS Tested OKHCHO Agitator #5 Possible gear wear. 2 erratic trendHCHO Agitator #6 OOS Tested OKHCHO Agitator #7 Defective gearbox component 2 2 2 2 erratic trendHCHO Agitator #8 OOS Tested OKHCHO Agitator #9 Tested OK

HCHO Agitator #10 Gearbox bearing lube. 2 OOS erratic trend

Executive Summary for Vibration AnalysisSeptember 25, 2007

Copyright 2007 Instrumentation Services, Inc.

Vibration AnalysisABC Company123 StreetAnywhere, USAPhoneFax

Equipment Name Base Absorber Pump (N)

Primary Problem:

Defective motor.

Detailed Problem Description:

Prior analysis had identified loose bolts on the pump that resulted in a jump in vibration levels. Feedback indicates these bolts have been tightened and the pump has been aligned, resulting in a drop in pump vibration levels. However, overall vibration readings are continuing to increase on the motor and are indicative of a defect with the motor, possibly electrical. Current readings are above alarm levels.

Recommended Action:

Recommend replacing the motor and performing a laser alignment and softfoot check. Provide feedback to ISI.

Horsepower 20

Voltage 480

RPM 1755

Vibration Analysis History:

Location

Description Horizontal induction motor direct coupled to an overhung centrifugal pump

Date Priority Description

Equipment ID Base Absorber Pump (N)

Priority

1

8/29/2007 1 Loose pump bolts.

7/24/2007 2 Motor electrical fault.

2/21/2007 3 Vibration level reduction.

Analyzed By: Frank Vereb Tuesday, September 25, 2007Page 1


Ro

ute

Sp

ectr

um

25-

Sep

-07

13:

15:5

9O

VE

RA

LL

= .4

603

V-A

N P

K =

.45

55 L

OA

D =

100

.0 R

PM

= 1

757.

(29

.28

Hz)

050

010

0015

0020

00

00.1

0.2

0.3

0.4

0.5

Fre

qu

ency

in H

z

PK Velocity in In/Sec

Ro

ute

Wav

efo

rm 2

5-S

ep-0

7 1

3:15

:59

RM

S =

.45

09 P

K(+

/-)

= 1.

80/1

.78

CR

ES

TF

= 3.

99

03

69

12

-2.0

-1.5

-1.0

-0.500.5

1.0

1.5

Rev

olu

tio

n N

um

ber

Acceleration in G-sR

ES

- B

ase

Ab

sorb

er P

um

p (

No

rth

)B

AS

E-N

OR

TH

-MIA

M

oto

r In

bo

ard

Axi

alT

ren

d D

isp

lay

Ove

rall

Val

ue

030

060

090

012

00

00.1

0.2

0.3

0.4

0.5

0.6

Day

s: 2

0-Ju

l-04

To

25-

Sep

-07


F

AU

LT

Dat

e:T

ime:

Am

pl:

25-

Sep

-07

13:

15:5

6

.460

Cop

yrig

ht 2

007

Inst

rum

enta

tion

Ser

vice

s, In

c.


Equipment Name K1 Agitator

Primary Problem:

Process problem.


Vibration levels have decreased since the last service call, but remain well above alarm levels. Although no feedback has been received on this matter, ISI assumes that there is still a process problem that is affecting the operation of the agitator.

Recommended Action:

Correct the problem with the process ASAP to alleviate the excessive vibration levels. Provide feedback to ISI.

Horsepower 50

Voltage 480

RPM 1765


Location Covered Process

Description Vertical induction motor direct coupled to a planetary gearbox


Equipment ID K1 Agitator

Priority

1

8/29/2007 1 Process problem.



Ro

ute

Sp

ectr

um

25-

Sep

-07

11:

26:5

7O

VE

RA

LL

= .7

417

V-A

N P

K =

1.2

6 L

OA

D =

100

.0 R

PM

= 1

765.

(29

.42

Hz)

050

010

0015

0020

00

00.3

0.6

0.9

1.2

1.5

Fre

qu

ency

in H

z


Ro

ute

Wav

efo

rm 2

5-S

ep-0

7 1

1:26

:57

RM

S =

.13

59 P

K(+

/-)

= .4

760/

.453

6 C

RE

ST

F=

3.50

03

69

12

-0.6

-0.300.3

0.6

Rev

olu

tio

n N

um

ber


ES

- K

-1 A

git

ato

rK

1-A

GIT

AT

R-M

IH

Mo

tor

Inb

oar

d H

ori

zon

tal

Tre

nd

Dis

pla

yO

vera

ll V

alu

e

020

040

060

080

010

00

00.5

1.0

1.5

2.0

2.5

Day

s: 1

5-F

eb-0

5 T

o 2

5-S

ep-0

7


F

AU

LT

Dat

e:T

ime:

Am

pl:

25-

Sep

-07

11:

26:5

7

.742

Cop

yrig

ht 2

007

Inst

rum

enta

tion

Ser

vice

s, In

c.


Equipment Name HCHO Agitator #10

Primary Problem:

Gearbox bearing lube issue.


Feedback from the field indicates this gearbox sounds as if it is running a little dry on lubrication. A review of trend data shows an erratic increase in the amount of friction occurring on the output shaft bearing. Suspect either a lack of oil in the gearbox or the output shaft bearing needs greased.

Recommended Action:

Recommend checking the lube in the gearbox and grease the output shaft bearing. Provide feedback to ISI.

Horsepower 1.5

Voltage 480

RPM 1750



Description Horizontal induction motor direct coupled to a angle gearbox


Equipment ID F-10

Priority

2

10/19/2005 3 Vibration decrease.

9/23/2005 1 Drive defect worsening.

8/18/2005 2 Possible gearbox defect.



Ro

ute

Sp

ectr

um

25-

Sep

-07

13:

58:5

7(P

kVu

e-H

P 1

000

Hz)

OV

ER

AL

L=

1.98

A-A

N R

MS

= 1

.22

LO

AD

= 1

00.0

RP

M =

59.

(.9

9 H

z)

020

4060

8010

0

00.2

0.4

0.6

0.8

1.0

Fre

qu

ency

in H

z

RMS Acc in G-s

Ro

ute

Wav

efo

rm 2

5-S

ep-0

7 1

3:58

:57

(PkV

ue-

HP

100

0 H

z) R

MS

= 3

.31

PK

(+)

= 10

.54

CR

ES

TF

= 3.

18 D

Co

ff =

0.0

04

812

16

036912

Rev

olu

tio

n N

um

ber

Acceleration in G-s

RE

S -

HC

HO

Ag

itat

or

#10

HC

HO

-10

-G

3P

Lo

w S

pee

d In

bo

ard

Ho

rz P

eakv

ue

Tre

nd

Dis

pla

yP

K-P

K W

AV

EF

OR

M

040

080

012

0016

00

036912

Day

s: 0

8-Ju

n-0

4 T

o 2

5-S

ep-0

7

Pk-Pk Waveform in G-s

F

AU

LT

Dat

e:T

ime:

Am

pl:

25-

Sep

-07

13:

59:0

3

10.5

6

Cop

yrig

ht 2

007

Inst

rum

enta

tion

Ser

vice

s, In

c.



Primary Problem:

Defective gearbox internals.


As previously reported, levels of impacting on the gearbox and motor are erratic and continuing to trend up. Suspect the cause may be due to damaged gearbox internals. Levels are well above alarm levels.

Recommended Action:

Recommend drawing a hot 3 ounce oil sample from the gearbox to verify damage is occurring and standby to replace the gearbox. Provide feedback to ISI.

Horsepower 1.5

Voltage 480

RPM 1750





Equipment ID F-7

Priority

2

8/29/2007 2 Defective gearbox internals.





Ro

ute

Sp

ectr

um

25-

Sep

-07

13:

46:4

8O

VE

RA

LL

= .1

043

V-A

N P

K =

.07

66 L

OA

D =

100

.0 R

PM

= 1

766.

(29

.43

Hz)

050

010

0015

0020

00

0

0.00

8

0.01

6

0.02

4

0.03

2

Fre

qu

ency

in H

z


Ro

ute

Wav

efo

rm 2

5-S

ep-0

7 1

3:46

:48

RM

S =

2.1

3 P

K(+

/-)

= 8.

89/7

.70

CR

ES

TF

= 4.

17

03

69

12

-10-50510

Rev

olu

tio

n N

um

ber

Acceleration in G-s

RE

S -

HC

HO

Ag

itat

or

#7H

CH

O-7

-

G2V

H

igh

Sp

eed

Ou

tbo

ard

Ver

tica

lT

ren

d D

isp

lay

PK

-PK

WA

VE

FO

RM

040

080

012

0016

00

05101520

Day

s: 0

8-Ju

n-0

4 T

o 2

5-S

ep-0

7

Pk-Pk Waveform in G-s

F

AU

LT

Dat

e:T

ime:

Am

pl:

25-

Sep

-07

13:

46:3

8

16.5

0

Cop

yrig

ht 2

007

Inst

rum

enta

tion

Ser

vice

s, In

c.



Primary Problem:

Possible gear wear.


Feedback from the field indicates this gearbox sounds slightly rougher than the others. A review of trend data indicates an erratic increase on some of the gearbox test points that appears to be consistent with gear wear.

Recommended Action:

Recommend drawing a hot oil sample from the gearbox to confirm the fault and the severity. Standby to replace this gearbox should the trend continue.

Horsepower 1.5

Voltage 480

RPM 1750





Equipment ID F-5

Priority

2

10/19/2005 3 Vibration level decrease.

12/21/2004 2 Motor and gearbox lube.

8/25/2004 2 Motor and reducer defects.



Ro

ute

Sp

ectr

um

25-

Sep

-07

13:

38:4

9(S

ST

-Co

rrec

ted

)O

VE

RA

LL

= .1

746

V-A

N P

K =

.20

38 L

OA

D =

100

.0 R

PM

= 5

9. (

.98

Hz)

020

4060

8010

0

0

0.03

0.06

0.09

0.12

0.15

Fre

qu

ency

in H

z


Ro

ute

Wav

efo

rm 2

5-S

ep-0

7 1

3:38

:49

RM

S =

.08

35 P

K(+

/-)

= .3

228/

.284

7 C

RE

ST

F=

3.87

04

812

16

-0.4

-0.3

-0.2

-0.1

0.0

0.1

0.2

0.3

Rev

olu

tio

n N

um

ber


ES

- H

CH

O A

git

ato

r #5

HC

HO

-5

-G

3H

Lo

w S

pee

d In

bo

ard

Ho

rizo

nta

lT

ren

d D

isp

lay

Ove

rall

Val

ue

040

080

012

0016

00

0

0.05

0.10

0.15

0.20

Day

s: 0

8-Ju

n-0

4 T

o 2

5-S

ep-0

7


F

AU

LT

Dat

e:T

ime:

Am

pl:

25-

Sep

-07

13:

38:4

7

.175

Cop

yrig

ht 2

007

Inst

rum

enta

tion

Ser

vice

s, In

c.

Vibration AnalysisABC Company

123 Street Anywhere, USA Phone Fax

Equipment Name T1 Mixer

Primary Problem:

Structural damage.


Feedback from the field indicates cracks are appearing in the center post that meets the top cross member between the motor and mixer shafts. There also appears to be a large horizontal vibration that may be a contributing factor to the damage.

Recommended Action:

Investigate the structural damage and make repairs as necessary. Also, determine the reason for the excessive rocking of the structure and provide feedback to ISI.

Horsepower 300

Voltage 480

RPM 1185



Description Vertical induction motor belt-coupled to a vertical mixer shaft


Equipment ID T1 Mixer

Priority

2

6/13/2006 2 Possible mixer imbalance.



Ro

ute

Sp

ectr

um

25-

Sep

-07

14:

04:0

9O

VE

RA

LL

= .3

898

V-A

N P

K =

.25

41 L

OA

D =

100

.0 R

PM

= 1

199.

(19

.99

Hz)

030

060

090

012

0015

00

0

0.06

0.12

0.18

0.24

0.30

Fre

qu

ency

in H

z


Ro

ute

Wav

efo

rm 2

5-S

ep-0

7 1

4:04

:09

RM

S =

.16

83 P

K(+

/-)

= .5

898/

.604

0 C

RE

ST

F=

3.59

04

812

16

-0.8

-0.400.4

0.8

Rev

olu

tio

n N

um

ber


ES

- T

-1 A

git

ato

rT

1-A

GIT

AT

R-M

OH

M

oto

r O

utb

oar

d H

ori

zon

tal

Tre

nd

Dis

pla

yO

vera

ll V

alu

e

680

720

760

800

840

880

920

960

1000

0.21

0.24

0.27

0.30

0.33

0.36

0.39

Day

s: 1

1-Ja

n-0

5 T

o 2

5-S

ep-0

7


F

AU

LT

Dat

e:T

ime:

Am

pl:

25-

Sep

-07

14:

04:0

6

.390

Cop

yrig

ht 2

007

Inst

rum

enta

tion

Ser

vice

s, In

c.


Equipment Name Cooling Tower Fan (SW)

Primary Problem:

Possible loose motor shaft component.


Feedback from the field indicates this motor sounds "rough." A review of trend data indicates a slight upward trend and the possibility of a loose motor shaft component. This would be consistent with the noise being heard from the motor.

Recommended Action:

Recommend checking the motor shaft for excessive endplay using a dial indicator and inspect for loose or worn shaft components.

Horsepower 100

Voltage 480

RPM 1770


Location

Description Horizontal induction motor direct coupled to a reducer


Equipment ID Cooling Tower Fan (SW)

Priority

3

11/28/2006 3 Vibration level reduction.

10/27/2006 1 Defective reducer.

9/27/2006 1 Defective reducer.



Ro

ute

Sp

ectr

um

25-

Sep

-07

12:

23:5

5O

VE

RA

LL

= .2

028

V-A

N P

K =

.18

29 L

OA

D =

100

.0 R

PM

= 1

800.

(29

.99

Hz)

050

010

0015

0020

00

0

0.02

0.04

0.06

0.08

0.10

Fre

qu

ency

in H

z


Ro

ute

Wav

efo

rm 2

5-S

ep-0

7 1

2:23

:55

RM

S =

.84

87 P

K(+

/-)

= 3.

33/3

.53

CR

ES

TF

= 4.

15

03

69

12

-4-3-2-10123

Rev

olu

tio

n N

um

ber

Acceleration in G-s

RE

S -

So

uth

wes

t C

T F

anC

TF

AN

-SW

-M

IH

Mo

tor

Inb

oar

d H

ori

zon

tal

Tre

nd

Dis

pla

yO

vera

ll V

alu

e

800

880

960

1040

1120

1200

1280

0.08

0.12

0.16

0.20

0.24

0.28

0.32

Day

s: 0

8-Ju

n-0

4 T

o 2

5-S

ep-0

7


F

AU

LT

Dat

e:T

ime:

Am

pl:

25-

Sep

-07

12:

23:5

4

.203

Cop

yrig

ht 2

007

Inst

rum

enta

tion

Ser

vice

s, In

c.

sample vibration analysis report

Documents