Gearbox rb ox Vibra Vibr ation ti on An A n aly al y s i s
Contents Case No.1 Case No.2 Case No.3 Case No.4 Case No.5 Case No.6 Case No.7 Case No.8 Case No.9
- Gearwear - Chipped Tooth - Gearwear - Chipped Tooth - Misaligned Gears - Gearwear - Misaligned Gears - Bearing defect - Bearing defect
1.83 rpm 42 rpm 8052 rpm 1239 rpm 146 rpm 97 rpm 5 rpm 9 rpm 231 rpm
Cases highlighted in red show the possibilities of vibration provided the information on the machine is correct and a good set-up is used. Selecting the correct sensor is also important.
Phone: +44 (0)1206 791917
Email:
[email protected]
Web: rms-reliability.com
Vibration Analys is - Gearbo x Exampl es Case No.1 Slow Speed Pulp Press Gearbox Localised Gearwear ( 1.83 rpm Output )
Gearbox measured similar to one above. Prs - PULP PRESS 3 STORD 980 PULPPRESS3-5RP GBX SHAFT 5 RIGHTFRONT AXIAL PKV
0.025 s G n i n o i t a r e l e c c A K P
M
0.020
M
M
0.015 0.010
ANA LYZE SPECTRUM 01-Dec-00 16:44:20 (PkVue- HP 500 Hz) OUTPUT GEARMESH WITH HARMONICS & SIDEBANDS PK = .1391 LOAD = 100.0 RPM = 2. RPS = .03
0.005
M=4TH RED WHEEL : 58.00
0 0
100
200
300
400
500
600
700
Frequency in Orders 2.0 s G n i n o i t a r e l e c c A
WAVEFORM DISPLAY 01-Dec-00 16:44:20 (PkVue- HP 500 Hz) PK = .1410 PK(+) = 1.86 PK(-) = .1044 CRESTF= 18.64
1.5 1.0 0.5 0 1 REV
-0.5 0
10
1 REV 20
30
40
50
Time in Seconds Localised damage to output gear
60
70
80
Ordr: 58.00 Freq: 1.770 Spec: .01370
Set-up: Slow speed sensor, Fmax 1200 cpm, 1600 Lines, Acceleration, Magnet mount, PkVue 500 Hz filter, Normal low freq readings taken also.
Chipped Tooth ( 42 rpm second shaft )
Case No.2 Slow Speed Pulp Press Gearbox
s G n i
n o i t a r e l e c c A S M R
PULP - PULP PRESS NO2 37PRSS0002-L2S GBOX 1st SET LEFT (320L MAG) STD
0.005 E
0.004
E
E
E
E
0.003 0.002
ROUTE SPECTRUM 19-Jan-01 10:21:18 HARMONICS OF GEARMESH WITH SIDEBANDS @42CPM (SST-Corrected) OVERALL= .0133 A-DG RMS = .0133 LOAD = 100.0 RPM = 41. RPS = .69
E
E
E
E
E
0.001 E=GMF 17T : 704.8 0 0
4000
8000
12000
16000
Frequency in CPM 0.12 0.09 s G n i n o i t a r e l e c c A
WAVEFORM DISPLAY 19-Jan-01 10:21:18 RMS = .0135 PK(+) = .0827 PK(-) = .1050 CRESTF= 7.75
ONCE PER REV IMPACT (CHIPPED TOOTH)
0.06 0.03 0.00 -0.03 -0.06 -0.09 -0.12 0
1
2
3
4
5
6
7
Time in Seconds
Freq: 704.80 Ordr: 17.00 Spec: .00010
Set-up: Slow speed sensor, Fmax 14000 cpm, 6400 Lines Res, Acceleration, Magnet mount, SST Enabled. PkVue also taken. Case No.3 High Speed 13MW Steam Turbine Gearbox Input Gearwear ( 8052 rpm Input )
c e S /
m m n i y t i c o l e V S M R
Turb
7 6 5
43 - Steam Turbin e 13MW -2V Turbine DE Vertical
25 Tooth input gear with fault sidebands at 8052 cpm
4
ANAL YZE SPECTRUM 17-Jan-01 13:54:14 RMS = 13.25 LOAD = 55.0 RPM = 8052. RPS = 134.20
0 0 . 5 2
3
1xrpm 2 0 0 .
1 1 0 0
4
8
12
16
20
24
28
32
36
40
Frequency in Orders WAVEFORM DISPLAY 17-Jan-01 13:54:14 PK = 19.32 PK(+) = 33.69 PK(-) = 42.78 CRESTF= 3.13
30 s G n i n o i t a r e l e c c A
20 10 0 -10 -20 -30 -40
HIGH G LEVELS IN WAVEFORM
-50 0
40
80
120
160
200
240
280
320
Time in mSecs Label: HIGH GEARMESH WITH SIDEBA NDS
Set-up: Fixed sensor, Fmax 650000 cpm, 6400 Lines Res, Acceleration.. PkVue also taken.
Ordr: 25.00 Freq: 3354.7 Spec: 4.539
Case No.4 Reduction Gearbox Chipped Tooth ( 1239 rpm )
c e S /
m m n i y t i c o l e V S M R
Fts - Gearbox ( CHIPPED TEETH ) Gearbo x -GIV GEARBOX INPUT VERTICAL DE
2.7 2.4
J
ROUTE SPECTRUM 10-MAY-99 15:31:33 OVRALL = 4.80 V-DG RMS = 4.76 LOAD = 100.0 MPM = 794. RPM = 1239.
J
2.1 1.8 1.5
Low level sidebands surr ound gearmesh
1.2 0.9
J=GMF
: 33.46K
0.6 0.3 0 0
20000
40000
60000
80000
100000
Frequency in CPM
s G n i n o i t a r e l e c c A
ROUTE WAVEFORM 10-MAY-99 15:31:33 RMS = 1.97 PK(+) = 13.16 PK(-) = 14.53 CRESTF= 7.39
12 9 6 3 0 -3 -6 -9 -12 -15
Once per rev impacting ( Waveform Key t o analysis)
-18 0
60
120
180
240
300
Time in mSecs
Freq: 1238.8 Ordr: 1.000 Spec: 1.052
Set-up: Standard Magnet sensor, Fmax 90000 cpm, 6400 Lines Res, Vel, Acceleration.
s G n i
n o i t a r e l e c c A S M R
Fts - Gearbox ( CHIPPED TEETH ) Gearbo x -GIV GEARBOX INPUT VERTICAL DE
6
ANAL YZE SPECTRUM 10-MAY-99 09:46:16 (PkVue-HP 1000 Hz) RMS = 8.51 LOAD = 100.0 MPM = 875. RPM = 1365.
5 4
Typical Faulty Gear Spectrum ( PkVue )
3 2 1 0 0
20000
40000
60000
Frequency in CPM 80 s G n i n o i t a r e l e c c A
ANAL YZE WAVEFORM 10-MAY-99 09:46:16 (PkVue-HP 1000 Hz) RMS = 9.06 PK(+) = 75.36 PK(-) = 6.16 CRESTF= 8.32
60 40 20 0 Waveform once per rev impact
-20 0
100
200
300
400 Time in mSecs
500
600
700
800
Freq: 1365.3 Ordr: 1.000 Spec: 4.279
Label: PKVUE CHIP TOOTH
Set-up: Same fault as prev, Standard Magnet Sensor. Fmax 60000cpm, Accl, PkVue 1000Hz Filter 6400 Lines.
Case No.5 Ball Mill Output Gears Misaligned Gears ( 146 rpm )
Fts - Gearbox ( MISALIGNED GEARS ) Misalign -B2H Output bearing outboard horiz
0.5
ROUTE SPECTRUM 14-DEC-99 14:25:02
MISALIGNED OUTPUT GEARS
0.4
s G n i
n o i t a r e l e c c A S M R
OVRALL = 4.84 V-DG RMS = .4014 LOAD = 100.0 RPM = 147. RPS = 2.44 3XGMF
0.3
0.2
2XGMF 0.1 1XGMF
Wear sidebands @ 146 rpm
0 0
4000
8000 Frequency in CPM
12000
Freq: 2784.9 Ordr: 19.00 Spec: .03485
Label: Misaligned gears / worn input
Set-up: Standard Magnet sensor, Fmax 10000 cpm, 6400 Lines Res, Acceleration.
Case No.6 Extruder Gearbox Damaged Gear ( 97 rpm )
s G n i n o i t a r e l e c c A S M R
Fts - Ext - ( GEARWEAR ) Gearwear -G2A Gearbox Input Outboard Axial
0.004
B
B
ANAL YZE SPECTRUM 11-MAR-98 14:56:28 RMS = .0112 LOAD = 100.0 RPM = 97. RPS = 1.61
B
0.003
0.002
B=59 teeth : 5707.
GEARMESH WITH SIDEBANDS @ 97 CPM 0.001
0 0
4000
8000
12000
16000
20000
Frequency in CPM 0.03 s G n i n o i t a r e l e c c A
WAVEFORM DISPLAY 11-MAR-98 14:56:28 RMS = .0106 PK(+) = .0319 PK(-) = .0320 CRESTF= 3.02
0.02 0.01 0 -0.01 -0.02 -0.03 -0.04 -0.05 0
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
Freq: 5706.7 Ordr: 59.00 Spec: .00199
2.7
Time in Seconds Label: Gearwear 59 toot h gear
Set-up: Standard Magnet sensor, Fmax 18000 cpm, 6400 Lines Res, Acceleration. Case No.7 Diffuser Gearbox Misaligned Gears ( 5 rpm ) DG - Diffus er Gearbox Citreon Mes Stream C -29H GBX 5th SHAFT MTRSIDE HORIZ
0.0024 s G n i n o i t a r e l e c c A K P
J
J
J
0.0016
ROUTE SPECTRUM 05-FEB-01 14:47:24 (SST-Corrected) OVRALL = .0046 A-DG PK = .0046 LOAD = 100.0 RPM = 5. RPS = .08
J
3xgmf Misaligned Gears
0.0008
J=Output Gear 25 : 125.8
2xgmf 1xgmf 0 0
100
200
300
400
500
600
Frequency in CPM 0.012 s G n i n o i t a r e l e c c A
ROUTE WAVEFORM 05-FEB-01 14:47:24 PK = .0045 PK(+) = .0090 PK(-) = .0100 CRESTF= 3.14
0.008 0.004 0.000 -0.004 -0.008 -0.012 0
20
40
60
80 Time in Seconds
100
120
140
160
Freq: 126.37 Ordr: 25.12 Spec: .00005
Set-up: Slow speed sensor, Fmax 600 cpm, 1600 Lines Res, Acceleration, Magnet mount, SST Enabled. PkVue also taken.
Case No.8 Slow Speed Diffuser Gearbox Bearing Defect ( 9 rpm shaft )
DG - Diffuser Gearbox Shackleton Stream B -27A GBX 4th SHAFT MTRSIDE AXIAL
0.00012 s G n i n o i t a r e l e c c A K P
D
D
D
D
D
D
D
D
D
D
D
ANAL YZE SPECTRUM 19-DEC-00 11:23:07 (SST-Corrected) PK = .0007 LOAD = 100.0 RPM = 9. RPS = .16
D
0.00008
0.00004
>SKF 24052C D=BPFO : 104.5
0 0
400
800
1200
1600
Frequency in CPM 0.018 s G n i n o i t a r e l e c c A
ANAL YZE WAVEFORM 19-DEC-00 11:23:07 PK = .0036 PK(+) = .0123 PK(-) = .0141 CRESTF= 5.48
0.012 0.006 0.000 -0.006 -0.012 Impacting matches outer race impact fr eq
-0.018 0
3
6
9
12
15
18
Time in Seconds
21
24
27
30
33
Freq: 104.26 Ordr: 11.20 Spec: .00001
Set-up: Slow speed sensor, Fmax 3000 cpm, 3200 Lines Res, Acceleration, Magnet mount, SST Enabled. PkVue also taken.
Case No.9 Reduction Gearbox Bearing Defect ( 231 rpm shaft )
Set-up: Slow speed sensor, Fmax 30000 cpm, 6400 Lines Res, Acceleration, Magnet mount, PkVue 500 Hz Filter.
Reliabil ity Maintenance Solu tion s Ltd Email :
[email protected] Websites:
www.rms-training.com & www.rms-reliability.com
Head Offi ce : +44 (0)1206 791917