Sample Predictive Maintenance Report Vibration Analysis
12857 E. Independence Blvd., Suite F Matthews, North Carolina 28105 800-532-0415 www.ISIservesYOU.com
Vibration Analysis Priority Criteria Repair Priority
Causal Events or Scenarios
PRIORITY 1
PRIORITY 2
PRIORITY 3
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.
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.
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.”
© 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.
Executive Summary for Vibration Analysis September 25, 2007 Equipment Chill Water Pump (E) Chill Water Pump (W) Chill Water Pump (M) C.T. Pump (NE) C.T. Pump (NW) C.T. Pump (NM) C.T. Pump (SE) C.T. Pump (SW) C.T. Fan (NE) C.T. Fan (NW) C.T. Fan (SE) C.T. Fan (SW) DA Pump (N) DA Pump (S) Electric Chiller Drive (E) K-1 Vacuum Pump K-2 Vacuum Pump K-3 Vacuum Pump K-1 Agitator K-2 Agitator K-3 Agitator T-1 Mixer Base Absorber Pump (N) Base Absorber Pump (S) ABS Heat Exchanger Pump Methanol Pump (N) Methanol Pump (S) HCHO Transfer Pump HCHO Charge Pump #1 HCHO Charge Pump #2 Resin Oxidizer Fan HCHO Oxidizer Fan Blower 150 A Blower 150 B Blower 300 A Blower 300 B Blower 700 A Blower 700 B HCHO Agitator #1 HCHO Agitator #2 HCHO Agitator #3 HCHO Agitator #4 HCHO Agitator #5 HCHO Agitator #6 HCHO Agitator #7 HCHO Agitator #8 HCHO Agitator #9 HCHO Agitator #10
Problem Description
Priority
08-07
07-07
06-07
OOS
OOS
OOS
OOS
OOS
OOS
OOS access
2
OOS OOS
OOS
OOS
Possible loose motor shaft component.
3 OOS
Process issue.
OOS 1 OOS
1 2
Structural damage. Defective motor.
2 1
1
OOS 2
OOS OOS OOS OOS
OOS OOS OOS OOS
OOS OOS OOS OOS
OOS OOS OOS OOS
OOS OOS
2 OOS OOS OOS Possible gear wear.
2
Defective gearbox component
2
Gearbox bearing lube.
2
Copyright 2007 Instrumentation Services, Inc.
2
2 OOS OOS
OOS 2
Remarks Tested OK Tested OK Tested OK Tested OK Out of service Tested OK Tested OK Tested OK Out of service Tested OK Tested OK slight trend Tested OK Tested OK Tested OK Tested OK Tested OK Out of service spike Out of service Trend improved upward trend Tested OK Tested OK Tested OK Out of service Out of service Out of service Out of service Tested OK Tested OK Tested OK Out of service Tested OK Tested OK Tested OK Tested OK Trend improved Tested OK Tested OK Tested OK erratic trend Tested OK erratic trend Tested OK Tested OK erratic trend
ABC Company 123 Street Anywhere, USA Phone Fax
Equipment Name Base Absorber Pump (N)
Priority
Equipment ID Base Absorber Pump (N)
1
Location Description Horizontal induction motor direct coupled to an overhung centrifugal pump
Horsepower 20 Voltage 480 RPM 1755
Defective motor.
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.
Recommend replacing the motor and performing a laser alignment and softfoot check. Provide feedback to ISI.
Date
Priority
Description
8/29/2007
1
Loose pump bolts.
7/24/2007
2
Motor electrical fault.
2/21/2007
3
Vibration level reduction.
Frank Vereb
Page 1
Copyright 2007 Instrumentation Services, Inc.
Tuesday, September 25, 2007
y e a u l p l a s V i D l l d a n r e e r v T O
l a ) i x h t A r o d r N ( a o p b n m u I P r o r t e o b r M o s A b I A M e H s T a B R - O N S E E S R A B
0 0 2 1
T L U A F
6 . 5 . 4 . 3 . 2 . 1 . 0 0 0 0 0 0 0
c e S / n I n i y t i c o l e V K P
) z N H 9 A 8 5 2 : V . 5 3 9 1 2 : 0 m ( 3 6 0 u . . 4 1 r . 5 0 7 t 5 c 7 = 5 0 1 7 e 0 L 5 p - L 4 . = 1 S p e A = D = e A M t S - R E K O u 5 P o 2 V P L R R O
0 0 0 2
9 5 : 8 5 7 . 1 1 m : / r 3 0 9 o 1 9 8 9 . f . 3 e 7 0 5 1 v 0 4 = a - . = F - T W p = ) / e S e S S + E ( t - M u 5 K R o 2 R P C R
7 0 - 6 p 5 : 0 e 5 6 S - 1 : 4 5 3 . 2 1 : : : e l e t m p a i m D T A 2 1
0 0 9
0 0 5 1
9
7 0 p e S 5 2 o T 0 0 4 6 0 l u J 0 2 : s y a D
z H n i 0 y 0 c 0 n 1 e u q e r F
r e b m u N 6 n o i t u l o v e R
0 0 3
0 0 5
3
0
5 . 4 . 3 . 2 . 1 . 0 0 0 0 0 0
c e S / n I n i y t i c o l e V K P
0
5 . 0 . 5 . 0 . . 0 . 5 . 0 5 1 1 1 1 0 0 - - - 2 -
s - G n i n o i t a r e l e c c A
0
. c n I , s e c i v r e S n o i t a t n e m u r t s n I 7 0 0 2 t h g i r y p o C
ABC Company 123 Street Anywhere, USA Phone Fax
Equipment Name K1 Agitator
Priority
Equipment ID K1 Agitator
1
Location Covered Process Description Vertical induction motor direct coupled to a planetary gearbox
Horsepower 50 Voltage 480 RPM 1765
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.
Correct the problem with the process ASAP to alleviate the excessive vibration levels. Provide feedback to ISI.
Date 8/29/2007
Priority 1
Frank Vereb
Description Process problem.
Page 2
Copyright 2007 Instrumentation Services, Inc.
Tuesday, September 25, 2007
y e a u l p l a s V i D l l d a n r e e r v T O
0 0 0 1
) z N H 7 A 2 5 4 : V . 6 7 9 2 2 : 1 m ( 1 4 0 u . . 7 1 r . 0 5 t 6 c 7 = 6 0 1 7 e 0 L 2 . p - L 1 = 1 S p e A = D = e A M t S - R E K O u 5 P o 2 V P L R R O
0 0 8 l a t n o z i r o H d r r o a o t b a t n i I g r A o t 1 - o K M S H I E M R R T A T I G A 1 K
T L U A F
7 0 p 0 e 0 S 6 5 2 o T 5 0 b e F 5 0 1 0 : 4 s y a D
0 0 2
5 . 0 . 5 . 0 . 5 . 0 2 2 1 1 0
c e S / n I n i y t i c o l e V K P
0
5 . 2 . 9 . 6 . 3 . 0 1 1 0 0 0
c e S / n I n i y t i c o l e V K P
0 0 0 2
7 0 - 7 p 5 : 2 e 6 4 S - 2 : 7 5 1 . 2 1 : : : e l e t m p a i m D T A
7 6 3 5 : 5 6 4 . / 2 m : 0 r 1 6 0 o 1 9 7 5 . f 3 4 e 7 5 3 . v 0 1 = a - . = F - T W p = ) / e S e S S + E ( t - M u 5 K R o 2 R P C R
2 1
0 0 5 1
9
z H n i 0 y 0 c 0 n 1 e u q e r F
r e b m u N 6 n o i t u l o v e R
0 0 5
3
0
6 . 3 . 0 0
0
3 . 0 -
6 . 0 -
s - G n i n o i t a r e l e c c A
0
. c n I , s e c i v r e S n o i t a t n e m u r t s n I 7 0 0 2 t h g i r y p o C
ABC Company 123 Street Anywhere, USA Phone Fax
Equipment Name HCHO Agitator #10
Priority
Equipment ID F-10
2
Location Covered Process Description Horizontal induction motor direct coupled to a angle gearbox
Horsepower 1.5 Voltage 480 RPM 1750
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.
Recommend checking the lube in the gearbox and grease the output shaft bearing. Provide feedback to ISI.
Date
Priority
Description
10/19/2005
3
Vibration decrease.
9/23/2005
1
Drive defect worsening.
8/18/2005
2
Possible gearbox defect.
Frank Vereb
Page 3
Copyright 2007 Instrumentation Services, Inc.
Tuesday, September 25, 2007
M R O y F a E l p V s A i D W d K n P e r K T P
e u v k a e P z r o H 0 1 d # r r a o o b t a n t i I g d A e e O p H S C w H o - L S E P R 3 G -
0 0 6 1
7 ) N A ) 5 : z z 8 H A H 5 : 0 8 m 9 9 3 0 u . 9 . 0 0 . 1 r ( t 1 1 2 0 0 . c 7 = 2 . 1 9 e 0 P L 1 5 p - H - L = = = S p A D e e e u S t - V R S A M u 5 k E M P o 2 P V R O L R R ( O
6 1
2 1
7 0 p e S 5 2 o T 0 4 0 0 8 n u J 8 0 : s y a D
0 1 O H C H
0 0 1
0 8
0 0 2 1
T L U A F
7 0 - 3 p 0 : 6 e 9 5 . S - 5 : 0 5 3 1 2 1 : : : e l e t m p a i m D T A
7 ) 5 : z 8 H 5 m : 0 r 3 0 4 8 1 o . 1 5 f 0 1 . 3 0 1 e 7 3 . . 0 v 0 P 3 = 0 1 a - H F = - = = T f W p ) S f e e e u S S ( E o t - V + u 5 k M K R C o 2 P R P C D R (
0 6
0 4
r e b m u N 8 n o i t u l o v e R
z H n i y c n e u q e r F
0 0 4
4 0 2
2 9 1
6
3
0
s - G n i m r o f e v a W k P - k P
0
0 . 8 . 6 . 4 . 2 . 0 1 0 0 0 0
s - G n i c c A S M R
0
2 9 1
6
3
0
s - G n i n o i t a r e l e c c A
0
. c n I , s e c i v r e S n o i t a t n e m u r t s n I 7 0 0 2 t h g i r y p o C
ABC Company 123 Street Anywhere, USA Phone Fax
Equipment Name HCHO Agitator #7
Priority
Equipment ID F-7
2
Location Covered Process Description Horizontal induction motor direct coupled to a angle gearbox
Horsepower 1.5 Voltage 480 RPM 1750
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.
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.
Date
Priority
Description
8/29/2007
2
Defective gearbox internals.
7/24/2007
2
Defective gearbox internals.
6/27/2007
2
Defective gearbox internals.
Frank Vereb
Page 4
Copyright 2007 Instrumentation Services, Inc.
Tuesday, September 25, 2007
M R O y F a E l p V s A i D W d K n P e r K T P
l a c i t r e V d r a 7 o # b r t o u t a O t i d g e A e p S O H h C i g H H S V E 2 R G -
0 0 6 1
T L U A F
7 O H C H
0 5 2 1
0 1
5
0
) z N H 8 A 3 4 4 : V . 6 3 9 4 2 : 4 m ( 3 0 0 u . . 1 1 r . 6 0 6 t 6 c 7 = 6 0 1 7 e 0 L 7 p - L 0 . = 1 S p e A = D = e A M t S - R E K O u 5 P o 2 V P L R R O
0 0 0 2
7 0 - 8 p 3 : 0 e 6 5 . S - 4 : 6 5 3 1 2 1 : : : e l e t m p a i m D T A
8 4 : 0 6 7 . 4 7 m : / r 3 9 7 o 1 8 1 . f . 4 e 7 3 1 8 . v 0 2 = a - = F - T W p = ) / e S e S S + E ( t - M u 5 K R o 2 R P C R
2 1
0 0 2 1
0 0 5 1
9
7 0 p e S 5 2 o T 0 4 0 0 8 n u J 8 0 : s y a D
z H n i 0 y 0 c 0 n 1 e u q e r F
r e b m u N 6 n o i t u l o v e R
0 0 4
0 0 5
3
0
2 3 0 . 0
4 2 0 . 0
6 1 0 . 0
8 0 0 . 0
0
s - G n i m r o f e v a W k P - k P
0
0 5 1
0
5 -
0 0 1 -
s - G n i n o i t a r e l e c c A c e S / n I n i y t i c o l e V K P
. c n I , s e c i v r e S n o i t a t n e m u r t s n I 7 0 0 2 t h g i r y p o C
ABC Company 123 Street Anywhere, USA Phone Fax
Equipment Name HCHO Agitator #5
Priority
Equipment ID F-5
2
Location Covered Process Description Horizontal induction motor direct coupled to a angle gearbox
Horsepower 1.5 Voltage 480 RPM 1750
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.
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.
Date
Priority
Description
10/19/2005
3
Vibration level decrease.
12/21/2004
2
Motor and gearbox lube.
8/25/2004
2
Motor and reducer defects.
Frank Vereb
Page 5
Copyright 2007 Instrumentation Services, Inc.
Tuesday, September 25, 2007
y e a u l p l a s V i D l l d a n r e e r v T O
l a t n o z i r o H 5 d r # a r o o b t n a I t i d g e A e p O S H C w o H L -
0 0 6 1
N 9 A ) 4 : V z 8 6 H 3 : ) m 8 d 4 0 3 u . 9 e 7 1 . 1 r t ( t c . 8 0 . c 7 e = 3 0 0 1 9 e 0 r L 2 5 p - r o L . = = S p A = D e C e S t - T R A M u 5 S E K O P o 2 S V P L R R ( O
5 O H C H
6 1
2 1
7 0 p e S 5 2 o T 0 4 0 0 8 n u J 8 0 : s y a D
S H E 3 R G -
0 0 1
7 0 - 7 p 4 : 5 e 8 7 S - 3 : 1 5 3 . 2 1 : : : e l e t m p a i m D T A
0 8
0 0 2 1
T L U A F
9 7 4 4 : 8 8 2 . / 3 m : 8 r 3 2 7 o 1 5 2 8 . f 3 3 e 7 3 8 . v 0 0 = a - . = F - T W p = ) / e S e S S + E ( t - M u 5 K R o 2 R P C R
0 6
0 4
r e b m u N 8 n o i t u l o v e R
z H n i y c n e u q e r F
0 0 4
4 0 2
0 5 2 . 1 . 0 0
0 1 . 0
5 0 . 0
0
c e S / n I n i y t i c o l e V K P
0
5 2 9 6 3 0 1 . 1 . 0 . 0 . 0 . 0 0 0 0 0
c e S / n I n i y t i c o l e V K P
0
3 . 2 . 3 . 4 . . 2 . 1 . 0 . 1 0 0 0 0 0 0 0 - - - 0 -
s - G n i n o i t a r e l e c c A
0
. c n I , s e c i v r e S n o i t a t n e m u r t s n I 7 0 0 2 t h g i r y p o C
ABC Company 123 Street Anywhere, USA Phone Fax Equipment Name T1 Mixer
Priority
Equipment ID T1 Mixer
2
Location Covered Process Description Vertical induction motor belt-coupled to a vertical m ixer shaft
Horsepower 300 Voltage 480 RPM 1185
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.
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.
Date 6/13/2006
Priority
Description
2
Possible mixer imbalance.
Frank Vereb
Page 6
Copyright 2007 Instrumentation Services, Inc.
Tuesday, September 25, 2007
y e a u l p l a s V i D l l d a n r e e r v T O
0 0 0 1
) z N H 9 A 9 0 9 : V . 4 8 9 0 1 : 9 m ( 4 8 0 u . . 3 1 r . 1 0 9 t 9 c 7 = 4 0 1 1 e 0 L 5 p - L 2 . = 1 S p e A = D = e A M t S - R E K O u 5 P o 2 V P L R R O
0 0 5 1
7 0 - 6 p 0 : 0 e 4 9 S - 0 : 3 5 4 . 2 1 : : : e l e t m p a i m D T A
9 0 4 0 : 0 4 6 . / 0 m : 8 r 4 9 9 o 1 3 8 5 . f 3 5 e 7 8 6 . v 0 1 = a - . = F - T W p = ) / e S e S S + E ( t - M u 5 K R o 2 R P C R
6 1
0 6 9
l a t n o z i r o H d r a r o o b t a t u t i O g A r o t 1 - o T M S H E O R M R T A T I G A 1 T
0 0 2 1
0 2 9
T L U A F
2 1
7 0 0 8 p 8 e S 5 2 o T 0 5 4 0 8 n a J 1 1 0 : 0 s 8 y a D
0 0 9 z H n i y c n e u q e r 0 F 0 6
0 6 7
r e b m u N 8 n o i t u l o v e R
4 0 0 3
0 2 7
0 8 9 6 3 0 7 4 1 6 3 . 3 . 3 . 3 . 2 . 2 . 2 . 0 0 0 0 0 0 0
c e S / n I n i y t i c o l e V K P
0 4 8 2 6 0 3 . 2 . 1 . 1 . 0 . 0 0 0 0 0
c e S / n I n i y t i c o l e V K P
0
8 . 4 . 0 0
0
4 . 0 -
8 . 0 -
s - G n i n o i t a r e l e c c A
0
. c n I , s e c i v r e S n o i t a t n e m u r t s n I 7 0 0 2 t h g i r y p o C
ABC Company 123 Street Anywhere, USA Phone Fax
Equipment Name Cooling Tower Fan (SW)
Priority
Equipment ID Cooling Tower Fan (SW)
3
Location Description Horizontal induction motor direct coupled to a reducer
Horsepower 100 Voltage 480 RPM 1770
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.
Recommend checking the motor shaft for excessive endplay using a dial indicator and inspect for loose or worn shaft components.
Date
Priority
Description
11/28/2006
3
Vibration level reduction.
10/27/2006
1
Defective reducer.
9/27/2006
1
Defective reducer.
Frank Vereb
Page 7
Copyright 2007 Instrumentation Services, Inc.
Tuesday, September 25, 2007
y e a u l p l a s V i D l l d a n r e e r v T O
0 8 2 1
) z N H 5 A 9 5 9 : V . 3 8 9 2 2 : 2 m ( 2 0 0 u . . 2 1 r . 9 0 0 t 0 c 7 = 2 0 1 8 e 0 L 8 p - L 1 . = 1 S p e A = D = e A M t S - R E K O u 5 P o 2 V P L R R O
0 0 0 2
5 5 : 3 3 5 . 2 3 m : / r 2 3 5 o 1 7 3 1 . f . 4 e 7 8 4 3 v 0 8 = a - . = F - T W p = ) / e S e S S + E ( t - M u 5 K R o 2 R P C R
7 0 - 4 p 5 : 3 e 3 0 S - 2 : 2 5 2 . 2 1 : : : e l e t m p a i m D T A 2 1
0 0 2 1
l a t n o z i r o H n a d F r a T o C b t I n s r e T o L w t h t o U u M A o F S H - I M S E R W S N A F T C
0 2 1 7 1 0 p e S 5 2 o T 0 4 4 0 0 1 n u J 8 0 : s y a 0 D 6 9
0 0 5 1
9
z H n i 0 y 0 c 0 n 1 e u q e r F
r e b m u N 6 n o i t u l o v e R
0 0 5
3
0 8 8
2 8 4 0 6 2 3 . 2 . 2 . 2 . 1 . 1 . 0 0 0 0 0 0
0 0 8 8 0 . 0
0 8 6 4 2 0 1 . 0 . 0 . 0 . 0 . 0 0 0 0 0
0
3 2 1 0 1 - 2 - 3 - 4 -
s - G n i n o i t a r e l e c c A c e S / n I n i y t i c o l e V K P
c e S / n I n i y t i c o l e V K P
0
. c n I , s e c i v r e S n o i t a t n e m u r t s n I 7 0 0 2 t h g i r y p o C
