CASE STUDY Equipment & Location: Pump for Wash Column Ejector Instruments used: Vibration Data Collector/Analyser, Model Easy-Viber Abstract of Case: This pump had been showing increase in the vibration levels due to Misalignment, and

also it was making abnormal sound in operations. The flexible membranes of coupling were found in the damaged condition. Also the alignment was checked and corrected, resulting in to decreasing the vibration levels.

Equipment Specifications: Pump – Make Pompe Gabbioneta, Model R 200/38 GM1, Max Condition Flow Rate 29

M3/Hour, Head Max 51 Meter, Suction Min/Max Press 1.92/1.9 bar, Discharge Press 5.82 bar, Design Pressure 30.4 bar, Design Temp 200 Degree C, Impellers Diameter 195 mm, Impellers Material A 351 CF3M, Diameter of Suction 3 inch, Diameter of Discharge Line 2 inch, Seal Type Mechanical, Coupling Flexible Membrane Type. Driver Electrical Motor, Speed 2,900 rpm,

Vibration Data: The measurement unit of vibration readings is in mm/sec rms.

Point Direction 13-Feb-2006 19-Feb-2006 23-Feb-2006 Vertical 0.4324 1.774 0.5895

Horizontal 0.7037 0.6828 0.7942 Motor Free End Bearing Axial 0.499 3.090 1.658

Vertical 0.8400 0.3229 0.9139 Horizontal 1.184 1.230 1.535 Motor Coupling

End Bearing Axial 0.4507 1.593 0.8470 Vertical 0.5393 2.689 0.5356

Horizontal 0.3761 0.6289 0.5799 Pump Coupling End Bearing Axial 0.5615 0.6756 0.6231

Vertical 0.3270 0.4991 0.4423 Horizontal 0.3784 0.4515 0.4333 Pump Free

End Bearing Axial 0.4344 1.104 1.086 Maximum Vibration 1.184 3.090 1.658

Vibration Analysis: Vibration level had increased from 1.184 to 3.09 mm/sec rms. Checking of the coupling

and alignment was suggested on 20th February 2006 due to rise in the vibrations particularly in the axial direction at the motor bearings. Accordingly, checking of the coupling and alignment was asked on priority. The actions were taken on 22nd February 2006 and re-alignment was carried. Observed decrease in vibrations to 1.658 mm/sec after re-alignment. The bearing fault frequency (BPFO) was excited at motor bearings though its level is low. The spare bearings were asked to be kept readily available in stock for replacing, in future, if required.

Action/Observations: Checking of the coupling and alignment was asked on 20th February 2006 due to rise

in vibrations particularly in the axial direction at the motor bearings. Checks of coupling and alignment were done on 22nd February 2006 and re-alignment was carried out due to existing misalignment in the motor and pump. Also the membranes of the coupling were found in damaged condition.

Conclusion: Alignment problems can very well be identified by the Vibration Analysis through study

of the Signs and Symptoms in the early / initial stages and they also can be rectified in time in enhancing the Reliable and Operable Life of a Machine.

TREND REPORT (23rd Feb 2006) Motor Bearing # 1-Vertical

TREND REPORT (23rd Feb 2006) Motor Bearing # 1-Horizontal

TREND REPORT (23rd Feb 2006) Motor Bearing # 1-Axial

TREND REPORT (23rd Feb 2006) Motor Bearing # 2-Vertical

TREND REPORT (23rd Feb 2006) Motor Bearing # 2-Horizontal

TREND REPORT (23rd Feb 2006) Motor Bearing # 2-Axial

TREND REPORT (23rd Feb 2006) Pump Bearing # 3-Vertical

TREND REPORT (23rd Feb 2006) Pump Bearing # 3-Horizontal

TREND REPORT (23rd Feb 2006) Pump Bearing # 3-Axial

TREND REPORT (23rd Feb 2006) Pump Bearing # 4-Vertical

TREND REPORT (23rd Feb 2006) Pump Bearing # 4-Horizontal

TREND REPORT (23rd Feb 2006) Pump Bearing # 4-Axial

SPECTRA REPORT (19th Feb 2006) Motor Bearing # 1-Axial

SPECTRA REPORT (23rd Feb 2006) Motor Bearing # 1-Axial

SPECTRA REPORT (19th Feb 2006) Motor Bearing # 2-Axial

SPECTRA REPORT (23rd Feb 2006) Motor Bearing # 2-Axial

SPECTRA REPORT (19th Feb 2006) Pump Bearing # 3-Axial

SPECTRA REPORT (23rd Feb 2006) Pump Bearing # 3-Axial

SPECTRA REPORT (19th Feb 2006) Pump Bearing # 4-Axial

SPECTRA REPORT (23rd Feb 2006) Pump Bearing # 4-Axial