Sample Vibration Analysis Report

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

Vibration Analysis

ABC Company 123 Street Anywhere, USA Phone Fax

Equipment Name Base Absorber Pump (N)

Priority 1

Equipment ID Base Absorber Pump (N) Location Description Horizontal induction motor direct coupled to an overhung

Horsepower 20 Voltage 480

centrifugal pump

RPM 1755

Primary Problem: Defective motor.

Detailed Problem Description: 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.

Recommended Action: Recommend replacing the motor and performing a laser alignment and softfoot check. Provide feedback to ISI.

Vibration Analysis History: Date

Priority

Description

8/29/2007

1

Loose pump bolts.

7/24/2007

2

Motor electrical fault.

2/21/2007

3

Vibration level reduction.

Analyzed By: Frank Vereb

Page 1

Copyright 2007 Instrumentation Services, Inc.

Tuesday, September 25, 2007

PK Velocity in In/Sec

PK Velocity in In/Sec

Acceleration in G-s

0

0

0

1.5 1.0 0.5 0 -0.5 -1.0 -1.5 -2.0

0

0.1

0.2

0.3

0.4

0.5

0

0.1

0.2

0.3

0.4

0.6 0.5

3

500

300

Copyright 2007 Instrumentation Services, Inc.

6 Revolution Number

1000 Frequency in Hz

600 Days: 20-Jul-04 To 25-Sep-07

FAULT

RES - Base Absorber Pump (North) BASE-NORTH-MIA Motor Inboard Axial

9

1500

900

12

Date: 25-Sep-07 Time: 13:15:56 Ampl: .460

Route Waveform 25-Sep-07 13:15:59 RMS = .4509 PK(+/-) = 1.80/1.78 CRESTF= 3.99

2000

Route Spectrum 25-Sep-07 13:15:59 OVERALL= .4603 V-AN PK = .4555 LOAD = 100.0 RPM = 1757. (29.28 Hz)

1200

Trend Display Overall Value

ABC Company 123 Street Anywhere, USA Phone Fax

Vibration Analysis

Equipment Name K1 Agitator

Priority 1

Equipment ID K1 Agitator Location Covered Process Description Vertical induction motor direct coupled to a planetary gearbox

Horsepower 50 Voltage 480 RPM 1765

Primary Problem: Process problem.

Detailed Problem Description: 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.

Recommended Action: Correct the problem with the process ASAP to alleviate the excessive vibration levels. Provide feedback to ISI.

Vibration Analysis History: Date 8/29/2007

Priority 1

Analyzed By: Frank Vereb

Description Process problem.

Page 2

Copyright 2007 Instrumentation Services, Inc.

Tuesday, September 25, 2007

PK Velocity in In/Sec

PK Velocity in In/Sec

Acceleration in G-s

0

0

0

-0.6

-0.3

0

0.3

0.6

0

0.3

0.6

0.9

1.2

1.5

0

0.5

1.0

1.5

2.0

2.5

200

3

500

Copyright 2007 Instrumentation Services, Inc.

6 Revolution Number

1000 Frequency in Hz

400 600 Days: 15-Feb-05 To 25-Sep-07

FAULT

9

1500

RES - K-1 Agitator K1-AGITATR-MIH Motor Inboard Horizontal

800

12

Date: 25-Sep-07 Time: 11:26:57 Ampl: .742

Route Waveform 25-Sep-07 11:26:57 RMS = .1359 PK(+/-) = .4760/.4536 CRESTF= 3.50

2000

Route Spectrum 25-Sep-07 11:26:57 OVERALL= .7417 V-AN PK = 1.26 LOAD = 100.0 RPM = 1765. (29.42 Hz)

1000

Trend Display Overall Value

ABC Company 123 Street Anywhere, USA Phone Fax

Vibration Analysis

Equipment Name HCHO Agitator #10

Priority 2

Equipment ID F-10 Location Covered Process Description Horizontal induction motor direct coupled to a angle gearbox

Horsepower 1.5 Voltage 480 RPM 1750

Primary Problem: Gearbox bearing lube issue.

Detailed Problem Description: 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.

Recommended Action: Recommend checking the lube in the gearbox and grease the output shaft bearing. Provide feedback to ISI.

Vibration Analysis History: Date

Priority

Description

10/19/2005

3

Vibration decrease.

9/23/2005

1

Drive defect worsening.

8/18/2005

2

Possible gearbox defect.

Analyzed By: Frank Vereb

Page 3

Copyright 2007 Instrumentation Services, Inc.

Tuesday, September 25, 2007

Pk-Pk Waveform in G-s

RMS Acc in G-s

Acceleration in G-s

0

0

0

3

6

9

12

0

0.2

0.4

0.6

0.8

1.0

0

0

3

6

9

12

20

4

400

Frequency in Hz

60

Copyright 2007 Instrumentation Services, Inc.

8 Revolution Number

40

800 Days: 08-Jun-04 To 25-Sep-07

FAULT

12

1200

RES - HCHO Agitator #10 HCHO-10 -G3P Low Speed Inboard Horz Peakvue

80

16

Date: 25-Sep-07 Time: 13:59:03 Ampl: 10.56

Route Waveform 25-Sep-07 13:58:57 (PkVue-HP 1000 Hz) RMS = 3.31 PK(+) = 10.54 CRESTF= 3.18 DCoff = 0.0

100

Route Spectrum 25-Sep-07 13:58:57 (PkVue-HP 1000 Hz) OVERALL= 1.98 A-AN RMS = 1.22 LOAD = 100.0 RPM = 59. (.99 Hz)

1600

Trend Display PK-PK WAVEFORM

ABC Company 123 Street Anywhere, USA Phone Fax

Vibration Analysis

Equipment Name HCHO Agitator #7

Priority 2

Equipment ID F-7 Location Covered Process Description Horizontal induction motor direct coupled to a angle gearbox

Horsepower 1.5 Voltage 480 RPM 1750

Primary Problem: Defective gearbox internals.

Detailed Problem Description: 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.

Recommended Action: 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.

Vibration Analysis History: Date

Priority

Description

8/29/2007

2

Defective gearbox internals.

7/24/2007

2

Defective gearbox internals.

6/27/2007

2

Defective gearbox internals.

Analyzed By: Frank Vereb

Page 4

Copyright 2007 Instrumentation Services, Inc.

Tuesday, September 25, 2007

Pk-Pk Waveform in G-s

Acceleration in G-s

PK Velocity in In/Sec

0

0

-10

-5

0

5

10

0

0.008

0.016

0.024

0.032

0

0

5

10

15

20

3

500

400

FAULT

Copyright 2007 Instrumentation Services, Inc.

6 Revolution Number

1000 Frequency in Hz

800 Days: 08-Jun-04 To 25-Sep-07

HCHO-7

9

1500

1200

RES - HCHO Agitator #7 -G2V High Speed Outboard Vertical

12

Date: 25-Sep-07 Time: 13:46:38 Ampl: 16.50

Route Waveform 25-Sep-07 13:46:48 RMS = 2.13 PK(+/-) = 8.89/7.70 CRESTF= 4.17

2000

Route Spectrum 25-Sep-07 13:46:48 OVERALL= .1043 V-AN PK = .0766 LOAD = 100.0 RPM = 1766. (29.43 Hz)

1600

Trend Display PK-PK WAVEFORM

ABC Company 123 Street Anywhere, USA Phone Fax

Vibration Analysis

Equipment Name HCHO Agitator #5

Priority 2

Equipment ID F-5 Location Covered Process Description Horizontal induction motor direct coupled to a angle gearbox

Horsepower 1.5 Voltage 480 RPM 1750

Primary Problem: Possible gear wear.

Detailed Problem Description: 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.

Recommended Action: 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.

Vibration Analysis History: 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.

Analyzed By: Frank Vereb

Page 5

Copyright 2007 Instrumentation Services, Inc.

Tuesday, September 25, 2007

PK Velocity in In/Sec

PK Velocity in In/Sec

Acceleration in G-s

0

0

0

0.3 0.2 0.1 0.0 -0.1 -0.2 -0.3 -0.4

0

0.03

0.06

0.09

0.12

0.15

0

0.05

0.10

0.15

0.20

20

4

400

FAULT

Frequency in Hz

60

Copyright 2007 Instrumentation Services, Inc.

8 Revolution Number

40

800 Days: 08-Jun-04 To 25-Sep-07

HCHO-5

12

1200

RES - HCHO Agitator #5 -G3H Low Speed Inboard Horizontal

80

16

Date: 25-Sep-07 Time: 13:38:47 Ampl: .175

Route Waveform 25-Sep-07 13:38:49 RMS = .0835 PK(+/-) = .3228/.2847 CRESTF= 3.87

100

Route Spectrum 25-Sep-07 13:38:49 (SST-Corrected) OVERALL= .1746 V-AN PK = .2038 LOAD = 100.0 RPM = 59. (.98 Hz)

1600

Trend Display Overall Value

Vibration Analysis ABC Company 123 Street Anywhere, USA Phone Fax Equipment Name T1 Mixer

Priority 2

Equipment ID T1 Mixer Location Covered Process Description Vertical induction motor belt-coupled to a vertical mixer shaft

Horsepower 300 Voltage 480 RPM 1185

Primary Problem: Structural damage.

Detailed Problem Description: 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.

Recommended Action: 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.

Vibration Analysis History: Date 6/13/2006

Priority

Description

2

Possible mixer imbalance.

Analyzed By: Frank Vereb

Page 6

Copyright 2007 Instrumentation Services, Inc.

Tuesday, September 25, 2007

PK Velocity in In/Sec

PK Velocity in In/Sec

Acceleration in G-s

0

0

-0.8

-0.4

0

0.4

0.8

0

0.06

0.12

0.18

0.24

0.30

680

0.21

0.24

0.27

0.30

0.33

0.36

0.39

720

300

4

760

Copyright 2007 Instrumentation Services, Inc.

8 Revolution Number

600 900 Frequency in Hz

800 840 880 Days: 11-Jan-05 To 25-Sep-07

FAULT

12

920

RES - T-1 Agitator T1-AGITATR-MOH Motor Outboard Horizontal

1200

960

16

Date: 25-Sep-07 Time: 14:04:06 Ampl: .390

Route Waveform 25-Sep-07 14:04:09 RMS = .1683 PK(+/-) = .5898/.6040 CRESTF= 3.59

1500

Route Spectrum 25-Sep-07 14:04:09 OVERALL= .3898 V-AN PK = .2541 LOAD = 100.0 RPM = 1199. (19.99 Hz)

1000

Trend Display Overall Value

ABC Company 123 Street Anywhere, USA Phone Fax

Vibration Analysis

Equipment Name Cooling Tower Fan (SW)

Priority 3

Equipment ID Cooling Tower Fan (SW) Location Description Horizontal induction motor direct coupled to a reducer

Horsepower 100 Voltage 480 RPM 1770

Primary Problem: Possible loose motor shaft component.

Detailed Problem Description: 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.

Recommended Action: Recommend checking the motor shaft for excessive endplay using a dial indicator and inspect for loose or worn shaft components.

Vibration Analysis History: Date

Priority

Description

11/28/2006

3

Vibration level reduction.

10/27/2006

1

Defective reducer.

9/27/2006

1

Defective reducer.

Analyzed By: Frank Vereb

Page 7

Copyright 2007 Instrumentation Services, Inc.

Tuesday, September 25, 2007

Acceleration in G-s

PK Velocity in In/Sec

PK Velocity in In/Sec

0

0

3 2 1 0 -1 -2 -3 -4

0

0.02

0.04

0.06

0.08

0.10

800

0.08

0.12

0.16

0.20

0.24

0.32 0.28

880

3

500

Copyright 2007 Instrumentation Services, Inc.

6 Revolution Number

1000 Frequency in Hz

960 1040 1120 Days: 08-Jun-04 To 25-Sep-07

FAULT

9

1500

RES - Southwest CT Fan CTFAN-SW -MIH Motor Inboard Horizontal

1200

12

Date: 25-Sep-07 Time: 12:23:54 Ampl: .203

Route Waveform 25-Sep-07 12:23:55 RMS = .8487 PK(+/-) = 3.33/3.53 CRESTF= 4.15

2000

Route Spectrum 25-Sep-07 12:23:55 OVERALL= .2028 V-AN PK = .1829 LOAD = 100.0 RPM = 1800. (29.99 Hz)

1280

Trend Display Overall Value