Failure Analysis Case Studies by using Vibration Analysis Technique 1- Bearing Premature Fatigue Problem Initiation and definition :

The problem was initiated by the operator. He noticed that high vibration level was sensed by human sense. Vibration measurements were carried out by condition monitoring engineer as he received the order.

Measuring procedures and used instrumentations :

The condition monitoring engineer select the measuring point which is near to the expected fault. An axial vibration data ware collected using piezoelectric accelerometer mounted with magnet. The accelerometer have the following characteristics ( natural frequency F= 200 order 0f the machine rotational speed, the accelerometer sensitivity = 100 mV/g) The accelerometer signal was sent to the CSI model 2120 equipped condition monitoring and diagnosis programs.

Analysis:
Bearing outer race defect was detected in the 4th mode as indicated from the time signal and FFT plot where BPFO was presented at 12.21 order according the bearing type and it needs to be changed As Soon As possible. This defect resulted from excessive axial load causes edge loading and overstressing of the raceway and result in premature fatigue. This is easily recognized as the damage is clearly restricted to one side..

Follow Up:
After changing the bearing and revising the assembly . the problem was disappeared where vibration measurements identical to that described in Measuring procedures and used instrumentations were carried out.

18 16 PK Velocity in mm/Sec 14 12 10 8 6 4 2 0 0 20 15 10 Acceleration in G-s 5 0 -5 -10 -15 -20 -25 0

SPIN - FINISHING HOLDER HOLDER#16 -IHA INNER BRG.HOLDER AXIAL(HIGH FRQ) E E E E E E E ROUTE SPECTRUM 15-Jul-99 10:03:42 OVRALL= 36.75 V-DG PK = 36.51 LOAD = 100.0 RPM = 507. RPS = 8.44 >SKF 61836M A E=BPFO : 102.5

100

200

300

400 500 Frequency in Hz CF ALARM

600

700

800

PK ALARM PK ALARM

WAVEFORM DISPLAY 15-Jul-99 10:03:42 RM S = 4.89 PK(+) = 14.75 PK(-) = 18.71 CRESTF= 3.83

CF ALARM

100

200

300 Tim e in m Secs

400

500

600

Label: Before changing the bearing

SPIN - FINISHING HOLDER HOLDER#16 -IHA INNER BRG.HOLDER AXIAL(HIGH FRQ)

Freq: 103.13 Ordr: 12.21 Spec: 3.648

PK Velocity in mm/Sec

18 16 14 12 10 8 6 4 2 0 0 2.0 1.5 100

ROUTE SPECTRUM 22-Jul-99 08:49:03 OVRALL= 6.73 V-DG PK = 6.70 LOAD = 100.0 RPM = 430. RPS = 7.16

200

300 Frequency in Hz PK ALARM CF ALARM

400

500

600

Acceleration in G-s

1.0 0.5 0 -0.5 -1.0 -1.5 -2.0 0 100 200

WAVEFORM DISPLAY 22-Jul-99 08:49:03 RMS = .3284 PK(+) = 1.39 PK(-) = 1.16 CRESTF= 4.23

CF ALARM PK ALARM 300 400 Time in mSecs 500 600 700 Freq: Ordr: Spec: 7.125 .995 5.086

Label: After changing the bearing

2- Bearing Fatigue Problem Initiation and definition :

The problem was initiated by the PM Craw. They noticed that high vibration level was sensed by human sense. Vibration measurements were carried out by condition monitoring engineer as he received the order.

Measuring procedures and used instrumentations :

The condition monitoring engineer select the measuring point which is near to the expected fault. An axial vibration data ware collected using piezoelectric accelerometer mounted with magnet. The accelerometer have the following characteristics ( natural frequency F= 200 order 0f the machine rotational speed, the accelerometer sensitivity = 100 mV/g) The accelerometer signal was sent to the CSI model 2120 equipped condition monitoring and diagnosis programs.

Analysis:
Bearing outer race defect was detected in the 4th mode as indicated from the time signal and FFT plot where BPFO was presented at 12.1order according the bearing type and it needs to be changed As Soon As possible. This defect resulted from excessive axial load due to severe looseness causes general outer race annular damage. ..

Follow Up:
After changing the bearing and revising the assembly . the problem was disappeared where vibration measurements identical to that described in Measuring procedures and used instrumentations were carried out.

18 16 PK Velocity in mm/Sec 14 12 10 8 6 4 2 0 0 20 15 10 Acceleration in G-s 5 0 -5 -10 -15 -20 -25 0

SPIN - FINISHING HOLDER HOLDER#16 -IHA INNER BRG.HOLDER AXIAL(HIGH FRQ) E E E E E E E ROUTE SPECTRUM 15-Jul-99 10:03:42 OVRALL= 36.75 V-DG PK = 36.51 LOAD = 100.0 RPM = 507. RPS = 8.44 >SKF 61836M A E=BPFO : 102.5

100

200

300

400 500 Frequency in Hz CF ALARM

600

700

800

PK ALARM PK ALARM

WAVEFORM DISPLAY 15-Jul-99 10:03:42 RM S = 4.89 PK(+) = 14.75 PK(-) = 18.71 CRESTF= 3.83

CF ALARM

100

200

300 Tim e in m Secs

400

500

600

Label: Before changing the bearing

Freq: 103.13 Ordr: 12.21 Spec: 3.648

Spin - FINSHING HOLDER HOLDER#17 -UOA UPPER BRG.HOLDER AXIAL(HIGH FRQ) 30 27 24 21 18 15 12 9 6 3 0 0 E E E E E E E ROUTE SPECTRUM 29-Jun-02 11:51:45 OV RALL= 38.49 V-DG PK = 38.38 LOAD = 100.0 RPM = 626. RPS = 10.44 >SKF 61836M A E=BPFO : 126.6

PK Velocity in mm/Sec

200

400

600 Fre que ncy in Hz CF ALARM

800

1000

20 15 Acceleration in G-s 10 5 0 -5 -10 -15 -20 -25 0 50 100 150

PK ALARM PK ALARM

WAV EFORM DISPLAY 29-Jun-02 11:51:45 RM S = 7.27 PK(+) = 19.50 PK(-) = 20.49 CRESTF= 2.82

CF ALARM 200 250 Tim e in m Se cs Labe l: BEFORE CHANGING THE BEARING 300 350 400 Fre q: 126.25 Ordr : 12.10 Spe c: 4.069

Spin - FINSHING HOLDER HOLDER#17 -UOA UPPER BRG.HOLDER AXIAL(HIGH FRQ) PK Velocity in mm/Sec 27 BBBBBBBBBBBB 24 21 18 15 12 9 6 3 0 0 8 6 Acceleration in G-s 4 2 0 -2 -4 -6 -8 0 100 200 300 Tim e in m Secs 400 500 600 Freq: Ordr: Spec: 9.375 .995 5.998 CF ALARM PK ALARM PK ALARM CF ALARM 100 200 300 400 500 Frequency in Hz 600 700 800 ROUTE SPECTRUM 30-Jun-02 16:13:32 OVRALL= 20.01 V-DG PK = 19.92 LOAD = 100.0 RPM = 565. RPS = 9.42 B=1X HARM ONIC : 9.42

WAVEFORM DISPLAY 30-Jun-02 16:13:32 RMS = 1.11 PK(+) = 6.42 PK(-) = 6.42 CRESTF= 5.77

Label: AFTER CHANGING THE BEARING

3- Coupling Fatigue Problem Initiation and definition :

The problem was initiated by the maintenance groupe. They noticed that high vibration level was sensed by human sense. Vibration measurements were carried out by condition monitoring engineer as he received the order.

Measuring procedures and used instrumentations :

The condition monitoring engineer select the measuring point which is near to the expected fault. An axial vibration data ware collected using piezoelectric accelerometer mounted with magnet. The accelerometer have the following characteristics ( natural frequency F= 200 order 0f the machine rotational speed, the accelerometer sensitivity = 100 mV/g) The accelerometer signal was sent to the CSI model 2120 equipped condition monitoring and diagnosis programs.

Analysis:
Coupling defect was detected in the 4th mode as indicated from the time signal and FFT plot where it was presented at 8order and 1 order in the axial direction in the radial direction according the coupling type where the coupling have 8 jaws and it needs to be changed As Soon As possible. This defect can be attributed to misalignment of coupling jaws causes edge loading and overstressing of the coupling jaws and result in premature fatigue. Coupling defect frequency exists with rotating speed modulation due to coupling excessive wear. Action must be taken is to adjust the alignment and change the coupling.

Follow Up:
After adjusting the alignment and changing the coupling . the problem was disappeared .

8 L 7 L

VWP - VERTICAL WATER PUMP PUMP#B -P1V INPUT SHAFT INB.BRG.VER. L L L L Route Spectrum 29-Jan-03 14:17:35 OVRALL= 12.70 V-DG PK = 12.65 LOAD = 100.0 RPM = 1488. RPS = 24.79 L=Coupling frq : 198.3

6 PK Velocity in mm/Sec

0 0 400 800 1200 Frequency in Hz 1600 2000 Freq: 198.36 Ordr: 8.000 Spec: 6.221

Label: Before changing the coupling

8 L 7 L

VWP - VERTICAL WATER PUMP PUMP#B -P1V INPUT SHAFT INB.BRG.VER. L L L L Route Spectrum 05-Feb-03 11:45:27 OVRALL= 5.80 V-DG PK = 5.80 LOAD = 100.0 RPM = 1493. RPS = 24.89 L=Coupling frq : 199.1

PK Velocity in mm/Sec

0 0 400 800 1200 Frequency in Hz 1600 2000 Freq: 199.11 Ordr: 8.000 Spec: .275

Label: After changing the coupling

4- Impeller Wear Problem Initiation and definition :

The problem was initiated by the operator and from the pump performance. They noticed that high vibration level was sensed by human sense. Vibration measurements were carried out by condition monitoring engineer as he received the order.

Measuring procedures and used instrumentations :

The condition monitoring engineer select the measuring point which is near to the expected fault. An radial vibration data ware collected using piezoelectric accelerometer mounted with magnet. The accelerometer have the following characteristics ( natural frequency F= 200 order 0f the machine rotational speed, the accelerometer sensitivity = 100 mV/g) The accelerometer signal was sent to the CSI model 2120 equipped condition monitoring and diagnosis programs. .

Analysis:
The defect was detected in the 4th mode as indicated from the time signal and FFT plot . It was presented at 1order in the radial direction and it needs to be changed As Soon As possible. This defect can be attributed to Severe pitting on the pump impeller due to corrosion erosion and chemical water effect. Action must be taken is to adjust the alignment and change the coupling. Sub-synchronous vibrations due to impeller wear which exits structure resonance. Change the pump impeller and recoat it with the ceramic coating.

Follow Up:
The lifetime of the impeller was extended and the Sub-synchronous vibration was disappeared after changing the impeller.

12

VWP - VERTICAL WATER PUM P PUMP#A -MOH AC M OTOR OUTB.BRG.HOR. Route Spectrum 18-Oct-01 12:08:35 OVRALL= 15.59 V-DG PK = 15.56 LOAD = 100.0 RPM = 1493. RPS = 24.88

10

8 PK Velocity in mm/Sec

0 0 50 100 150 200 250 Frequency in Hz 300 350 400 Freq: Ordr: Spec: 25.00 1.005 8.558

Label: Before changing the im pe ller