Vibration Analysis

Case Studies

Asset Management Conference 2006

31 July 2006

Mark Arrowsmith
Condition Monitoring Engineer
SKF Reliability Systems

2006-07-27 SKF Slide 2 [Code]

SKF [Organisation]
Personal Introduction

2006-07-27 SKF Slide 3 [Code]

SKF [Organisation]
Fan Looseness - Application

Continuous manufacturing operation 24hrs / 7days

Fan used to cool the product
Critical plant, line stops if plant
A motor failure resulted in two days downtime
SKF performs monthly vibration surveys

2006-07-27 SKF Slide 4 [Code]

Fan Looseness - Vibration

Overall vibration velocity trend at the fan NDE vertical

Acceleration waveform shows cyclic impacting at the fan NDE vertical

2006-07-27 SKF Slide 5 [Code]

Fan Looseness Vibration Spectra

Good condition vibration velocity spectra at the fan NDE vertical

Moderate running speed harmonics, this vibration velocity spectra at the fan NDE vertical

2006-07-27 SKF Slide 6 [Code]

Fan Looseness Action Taken

The looseness in the fan barrel was an issue, but

action was not required immediately
The client prepared and scheduled the maintenance
and performed other maintenance on the line at the
same time
The bearing housing had flogged out causing
excessive clearance and the looseness

2006-07-27 SKF Slide 7 [Code]

Fan Looseness
- Advantages of Early Detection

Minimised downtime during repair due to planing and

scheduling of the change-out
No consequential damage occurred due to a
unexpected catastrophic failure

2006-07-27 SKF Slide 8 [Code]

EGR Gearbox Fault - Application

This EGR site manufactured sheet acrylic. The Stober

gearbox was part of the main drive
SKF was asked to take vibration measurements and give
an opinion as to the source of the audible knocking

2006-07-27 SKF Slide 9 [Code]

EGR Gearbox - Schematic

2006-07-27 SKF Slide 10 [Code]

EGR Gearbox Vibration

Acceleration time history, this at the gearbox output shaft

Figure 2 Velocity spectra at the gearbox input shows tooth-mesh energy at 425Hz

2006-07-27 SKF Slide 11 [Code]

EGR Gearbox - Identification of Energy

Initially the fault was thought to be a fault on the input shaft because the
running speed matched the impact frequency. Back calculating with the
knowledge of the gear-teeth numbers showed that running speed was
26.5Hz ie. differs by half a percent from the impact frequency at 26.4Hz.
SKF went to considerable effort to discover the exact gear ratio and then to
calculate the actual gear-teeth numbers by writing a Visual Basic program.

The frequency at 425Hz was an anomaly and was determined to be gear-

mesh energy.

2006-07-27 SKF Slide 12 [Code]

EGR Gearbox - Action

The fault was confirmed not to be on the input shaft as

initially suspected
SKF advised that the fault was likely to be on the
intermediary shaft bearings, which was later confirmed by
inspection
EGR was able obtain the correct bearings from overseas
before the gearbox was removed from service and thus
minimised downtime

2006-07-27 SKF Slide 13 [Code]

Qld Mine Vent Fan Howden Vent Fan

Howdens are a supplier of large industrial fans.

This application was for a ventilation fan in the Bowen Basin
The vibration trend recorded a large increase after
recommissioning of the two fan units
The mine was concerned about the increase as was
Howdens
Howdens asked SKF to take vibration readings and to give
an opinion of the source and severity

2006-07-27 SKF Slide 14 [Code]

Qld Mine Vent Fan Vibration Trend

2006-07-27 SKF Slide 15 [Code]

Qld Mine Vent Fan Vibration Spectra

Vibration velocity spectra of Ventilation Fan #1, Fan drive-side bearing, Axial measurement

2006-07-27 SKF Slide 16 [Code]

Qld Mine Vent Fan - Diagnosis

SKF advised that the bearings should be inspected as

soon as possible
SKF advised that the high velocity levels were consistent
with damage caused by false brinelling which may have
occurred during transport, fan shaft assembly was off site

2006-07-27 SKF Slide 17 [Code]

Qld Mine Vent Fan - Inspection

2006-07-27 SKF Slide 18 [Code]

Qld Mine Vent Fan
- Advantages of Detection

No consequential damage occurred due to a

unexpected catastrophic failure of the fans

NOTE :
HOWDEN DID NOT DESIGN, SUPPLY OR FIT THE
TEMPERATURE SENSORS

2006-07-27 SKF Slide 19 [Code]

 The End

Thank you for listening!

Now :-

Any Questions ?
Any Concerns ?

2006-07-27 SKF Slide 20 [Code]