Reliability Engineering for MaintenancePosts about Root Cause Analysis
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Reliability Engineering for MaintenancePosts about Root Cause Analysis
Dave, Thanks for your response and information. This is a new machine which was just commisioned in last year. after high bearing temperature appeared, site did the checking on those bearings, the wear pattern on the beairng showed obviously uneven contact but however the contact between bearing shell and bearing housing is good. Also the soft foot (by feeler gauge + dial gauge) and piping stress were checked , no problbem. The only abnormal thing we found is the destortion of gear box, out... [ more ]
Lux, This company deals with large industrial air compressors, they maybe of assistance https://rage-energy.com/ Do you have additional knowledge of this issue? New or old, major failures, just showed up after repairs/overhaul, piping also grows putting stain on stage casing. Any photos to support your analysis? Had one scenario with large gearbox that OEM machined incorrectly during rebuild/reconditioning process, one bearing always hot, wear pattern on babbit bearing showing misaligned... [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Reliability Engineering for MaintenancePosts about Root Cause Analysis
Reliability Engineering for MaintenancePosts about Capital Projects
Reliability Engineering for MaintenancePosts about Root Cause Analysis
Reliability Engineering for MaintenancePosts about Root Cause Analysis
Hello Sir, Good to see your response. Yes, it is very strange to current bearing failure status. In addition, during the investigation, we also found this compressor got surge many times in the past becasue this machine was always running at turndown mode due to low demand from customer.----this should actually contributed to this bearing failure. Thanks, LUX [ more ]
Dear Lux, Very interesting case of failure of bearing, analyzing of evidences: 1.- Only one ball was damaged. 2.- The location of failure in inner face of thrust bearing. possible causes, 1.- Not enough axial play during bearing Installation, that's mean the bearing was preloaded axially. 2.- Bad quality of bearing, it is possible to find fakes bearing in market. 3.- Excessive axial load due to coupling pre-stretch. Lack of thrust bearing temperature reading, was a factor that early action... [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Please provide details of the installation, new or old installation, has the pump worked in the past, are you sure the valve is opening, what is the inflow rate vs the outflow rate of the suction side, suction side under a vacuum or open to atmosphere, what is on suction side, discharge side, what is fluid being pumped, elevation changes, design conditions flow discharge head, have a copy of the pump curve Dave [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
ep, This has got to be someone putting the rest of us on. But, I did have a customer with a motor that looked very much like this. It sat under a leaky pipe while doing it's job. The pipe? Filled with acid.... [ more ]
No responses. I'll chime in late. It is a TEFC motor that relies on air blown from the fan on the end across those fins to remove the heat from the motor. The rust will impair that heat transfer both by obstructing the channels between fins and by providing a layer of thermal insulation on the fins. There may be a variety of other concerns... at what point does the stator allow water through into the winding. Is the mechanical structural integrity compromised. Do you have a good frame safety... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Thanks for the feedback. I will be checking the RPM very soon to make sure we are in the correct range. [ more ]
Replies from my network: 1) This is almost identical to one I experienced a few years back. Long story short, we found that when the motor had been replaced with a rebuilt unit, the rebuilder had not been very attentive. The application required 1500 rpm or less and the RE -manufacturer rewound the stator to 1800 without replacing/ correcting the data plate specifications. This coupled with product build up on the discharge side resulting in restrictive flow and additional back pressure, and... [ more ]
Thanks for replying CDTuttle but these are solid blades. From what I’ve been hearing from some reputable fan companies is that this happened from spinning faster than it was designed to do. I don’t have any evidence to prove that this happened but I also don’t have any to prove that it didn’t happen so I’ll just have to trust the professionals on this one. [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Hello Tony, Just set up vibration or ultrasound measurement points so that they are able to take 4 -6 revolutions of the shaft, at that speed waveform analysis is more useful, include demodulation or enveloping or peak vue waveforms too. You will detect bearing problems for sure, I worked in mining industry and coud detect bearing failures by using that kind of configurations [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
... [ more ]
Thanks for Replay Mr. Kishor ji. [ more ]
Dear Pathu , could you post your spectrum with peak frequency labeling , so that we could identify the root cause .Also mention motor running r.p.m . As per my point of you : 1.Check Belt pulley sheaves alignment & Tension . 2.Check Belt pulley sheaves V-grove profile ,which might leads belts to uneven wear and repeated failure along with increase in vibration trend . [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
thank you. recently we spoke with predictive service agency who use and sell emerson and we understood that emerson starting to speach about a new 21xx (2150?). I think it will be here soon in not many years. [ more ]
The 2140 is 8 years old now. I talked to a Emerson rep not long ago and he indicated it will be several more year before we see a 2150. I started out with the 2120 upgraded to a 2130 then to a 2140. Most people I know have 2140's and like them. You can check with your local rep and see if they have a trade in deal going. [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
https://www.linkedin.com/pulse...ur-program-jonathan/ [ more ]
In our case, planner positions are equivalent to those engineers (executive position) becasue planners should know the work sequence and schedule. It could be a higher position if it's occupied by seninor engineers who have had hands on maintenance. [ more ]
What I was trying to say is the Maintenance Manager prefer candidates with a BS in Engineering than senior technicians to be hired as Maintenance Planners. Is more as a engineering entry level position, Maintenance Planners seems the first candidates to be internally promoted to Maintenance Engineers, Maintenance Supervisor, or Project Engineers competing against experienced Engineers from out the company. Planners salary are just a bit lower than Maintenance Engineers or Maintenance... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Hi for everione [ more ]
I intend to evaluate the reliability of the Station-keeping of the FPSO, it can be for 3DOF or 6DOF, it doesn't matter. The objective is heading optimization, mooring stability and DP optimization. I am basing myself on the treatment given by Sorensen (2011) \dot (x) = Cp(x,w) which implies switches for the different modes of operation of the Vessel, Cr determine the state space equations of the process, x is state vector and w is the environmental disturbance vector. I see station-keeping... [ more ]
Hi R eliability Scholars , Hope you all doing well. I am new in the comunity. Did any of you worked on classical reliabity of an FPSO Station-keeping using Weibull distribution. The objective is to a sure the maitenance of the position and heading. If so, can you give tips on how you got a good review? I am defining Station-keeping as the set of turret, mooring and dynamic position (DP). I evaluate each of these subsystems, and then Rsk(T) = R(turret)xR(mooring)xR(DP). With regards Hlunguane J [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Reliability Engineering for MaintenancePosts about Root Cause Analysis
As others stated, mechanical looseness is present. The sidebands are most likely from the outer or inner race spinning. When the bearing spins in the housing/shaft, it is turning at a different speed which will create a frequency very close to running speed. Have seen worn gear couplings exhibit this same pattern. Down and dirty way of checking. Dial indicator on shaft of interest at top dead center, long bar and block/s of wood, gently pry up on shaft and record total indicator movement. [ more ]
any other idea for this reading from experts [ more ]
5x?...how many blades the impeller? 1x, there is the unbalance, is clare. how many blades per impeller there is an imbalance, it is clear but, regarding the last photo, many nx armonics indicated like bearing/housing looseness... we see high 14x armonic, probably 14 impeller blades? but the sideband from 6x to 18x is look like a rotor bar problem about motor...? many things, but just my opinion [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Root Cause Analysis
Sharath, Not sure of your pumping drive or piping configuration, IF this is a self priming application, then read on. You state pump is submerged 5 meters under the water? What is design point, pressure/flow rates, pump manufacturer, model number etc You do not address the fact that the suction lift for the pumps is not possible? 15 to 17 meters is 49 feet, ALL CENTRIFUGAL PUMPS follow the same laws of physics, the maximum amount of suction lift at sea level is 10.33 meters at sea level,... [ more ]
Hey Dave thanks for your reply and ur time on this. The sea level is approximately 15 to 17 mts from the right-angle gearbox and the pump is submerged in water ~5mts. And all the pumps are placed on different platforms with different suctions and we also have 2 jockey pumps with same height and length but there is no any oscillation in column as fire pumps. All the pumps are installed recently may be 20 months. Suction lift and discharge pressure are getting as required but the only issue is... [ more ]
Sharath, The suction lift you are trying to do is not fundamentally possible? Theoretically, all centrifugal pumps can lift water not more than 10.33 m at sea level. If the liquid is below the pump datum, the vertical distance between the pump impeller and the surface of the liquid on the suction side of the pump is referred to as the suction lift . Apr 13, 2017 Are these newly installed? Are there more than 4 fire pumps? Do the each have their own suction pipe? What is the altitude of the... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Thanks Venkatesh.V.. I already check the breather condition also [ more ]
You can check breather condition also [ more ]
Thanks Kishore, Temperature is increasing gradually. We have protection tripping logic has installed at Pump bearing temperature.. That's why we are monitoring closely. Do you think bearing housing imperfections may leads to high in temperature? [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
For real-time and reliable monitoring of vibrations, offline analysis tools for validation and optimization cannot be trusted uppm. A real-time Torsional Vibration Analysis system must be implemented. It can offer you coordinated tools for vibration monitoring and analysis combined with process data in real-time. This system can monitor the individually adjustable frequency band monitoring, a self-learning module for monitoring frequency spectra, and the angular shaft motions. Integrating a... [ more ]
Hi! We have similar system for monitoring vibration for 7 channels. [ more ]
Hi Phil, I already used metrix, system 1&evo & alta solution 1250FE and i would recommend AS 1250FE if your budget is tight, this same as adre p408 or if you dont mind the cost just go to BHGE product or metrix setpoint. regards, [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reciprocating pumps and reciprocating compressors may cause severe pulsation and vibration in your assets, which could result in damages of supports, foundations and instruments. This may result in unstable process operation or malfunction of your assets. The pulsation and vibration analysis of reciprocating compressor/pump systems are required at the design stage to prevent such undesirable conditions. A Torsional Vibration Analysis system can help monitor and reduce the vibration at the... [ more ]
A reciprocating pump is a pump that uses backward and forward movement to move fluid. In a reciprocating pump , a piston, plunger, or diaphragm moves backward and forward. A reciprocating pump is one in which the liquid follows the movement of a piston during suction and delivery strokes. Talking about vibration limit ISO-10816-6 may be applicable where vibration evaluation for hydraulic power generating and pumping equipment. Have you tried Polycab self-priming monoblock pump if not have a... [ more ]
Hi, Vibration analysis is a tedious job. The below mentioned link help me to understand it better. Refer: https://rms-reliability.com/pr...on-analysis-service/ [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Lube oil analysis is crucial for the overall maintenance of machinery. However, the primary step of lube oil quality management is oil sampling . It is important to consider this aspect as 54% of machines usually fail due to poor lubrication. To ensure the smooth operation of your assets, it is imperative to first collect lube oil samples before forwarding them to your plant and have an oil filtration system in place. The main objectives of lube oil sampling are: Oil Flowing through... [ more ]
Dear Ali, All information are valued especially while coming from experienced hands. I am also planning for mandatory inspection . cleaning of lube oil tank every 5 or six year ,But major hurdle is the access and confined space issues [ more ]
Pre-filtering is a best practice. You'll need a setup for that which might be the main hurdle for most people to do the pre-filtration. This would be a necessity if the new oil is far away from the cleanliness level you target. Oil reservoirs are inspected where I work every time the oil is replaced. I'm talking about medium to large machines. Many times, the inspection reveales key findings like corrosion and pin holes. Maybe these are more common with steam turbines (most of my... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
When managing your asset’s overall health, the condition of the machine’s bearings plays a crucial role. An issue with even a single bearing can cause the machine to break down, resulting in production loss and costly downtime. Carefully lubricated bearings can almost have an infinite life. Also, if the torsional vibration is not controlled or correctly measured, it can cause unplanned machine breakdowns. This is where Torsional Vibration Analysis for bearings comes in. This technology can... [ more ]
Greetings Mr . M NADEEM ANJUM . You can monitor regular trend and analyze fault respective machine component frequencies . Typical acceleration data related to all types of bearings in general rotating equipment. (Exceptions = Diesel Engines & Rock Crushers.) EXCELLENT LEVELS = Usually .10 G or Less. No action required. GOOD LEVELS = Usually .35 G or Less. No action required unless noisy. FAIR LEVELS = Usually .50 G or Less. No action required unless noisy. (If you have no records... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
A long answer for a short question. If you are new to balancing, perhaps it is good to search about the vector method. I should mention, however, there are simplifications (or oversimplifications) in many of the articles, videos, etc compared to what you may face at the field/shop. Regards- Ali M. Al-Shurafa [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Is the pump running at BEP or away from it. [ more ]
what was the cause of the 5X ? [ more ]
GREETINGS WELL NOTED. THANKS FOR YOUR FEEDBACK. PLEASE FOLLOW THIS METHOD AND TRY HOW YOUR VIBRATIONS ARE INDICATING. 1. CLOSE DISCHARGE VALVE AND START THE PUMP AFTER FEW SECONDS AT FULL SPEED AT MAXIMUM PRESSURE MEASURE THE VIBRATION SLOWLY OPEN DISCHARGE VALVE AND MEASURE THE VIBRATION. IF FLOW INCREASING TIME VIBRATION RISING IT IS RELATED TO FLOW SURGES CAUSING THE VIBRATION. IF STEADY AT EVERY DISCHARGE VALVE POSITION THEN THE VIBRATION IS NOT FLOW RELATED. ALSO TAKE RUN UP AND COAST... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Predictive maintenance solutions can be implemented in a plant to predict issues and asset machine breakdowns. This technology uses machine-learning and AI-powered solutions to gather historical data and predict which parts of an asset could fail and at what time. Advanced sensors are installed and technicians can have information about accurate data points, remotely. The collected data can then be analyzed by advanced analytical tools and predictive algorithms. With this information, the... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
For the members in the forum to give meaningful comments, I guess you need to provide more details, otherwise you may receive general comments and guesses. My general comment and wild guess, this could be normal behavior. Regards- Ali M. Al-Shurafa [ more ]
Thanks Mr. Shurafa for the response. Steady State forward precession is observed steadily, but coast-down forward and reverse precession 1X orbit 💫 observed intermittently. Even though Vibration amplitudes are well within the limit, I want to know why this behavior happens and what are all the possible reasons for this issue.. [ more ]
I assume you implicitly ask if this reverse precession orbit is acceptable or not. Regards- Ali M. Al-Shurafa [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Repair in case of emergency would be my philosophy If you apply anything to impeller, it is now out of balance. Unless the material your are applying is harder than base impeller material, it too will fail. What costs more, identify and fix the cavitation issue thru piping or liquid level changes or putting a bandage on a problem. In some cases, a change of materials of construction is needed, like from bronze to stainless. As you stated originally, you have a cavitation problem, seen by... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Hi JC L., I started study RCM and read some documents about IRCMS, but I try to find the software but the links to the software isn´t working more. Is there one link to get the IRCMS software? I notice that all information about the software is out of date but I was interesting in know this software. Regards, Giuliano Luz [ more ]
Another package is RCM++ from ReliaSoft this package incorporates Criticality Analyisis, Task Packaging, costs parameters and optimisation features and links to their other reliability tools. You can download a demo and a training guide from http://www.reliasoft.com BUT it is a big programme because of the high degree of customisation and features. They have work wide offices. Dave http://www.Ramsoftuk.com ReliaSoft partner [ more ]
Can we easily do uploading into cmms? No standard tutorial? [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
Hello. We have similar column pipe bolt sheared. Shaft bent.Bottom neck ring to impeller stuck causing cold welding. But unable to find the cause. No overload motor trip. Few possibilities are 1) Column pipe bolt loose causing offset of bowl assembly. 2) Pump operating at closed shutoff. Recycle line PRV failure . 3) Low clearances of neck ring to impeller. Foreign particle stuck. Please provide your inputs. [ more ]
Hi CBM, Dave Reynolds has attached some very good info on breakages and in Dave's literature there are images of misalignment breakages with ratchet marks, this breakage appears very similar with fine ratchet marks around the circumference of the shaft breakage, if you are still trying to solve this let us know and I’ll ask our metallurgist for an opinion and if it is of use we can post his comments here to assist, regards Rob S [ more ]
The double paste can be edited by the OP, can it? [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
API 617 would be helpful [ more ]
Mohiuddin, There are many references that can be suggested to use but perhaps they are not useful for you; they may not be applicable. Your case can be for a factory test, site test, shop test, after an overhaul, collected by a routine handled analyzer, collected by an online system connected to a shutdown system, for a compressor whose bearings are anti friction type or journal bearing etc. Search for ISO and API standards on compressors and you may find some figures to start with. If you... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Capital Projects
Independent companies are exclusive organizations, associations, or sole ownerships that have less workers and additionally less yearly income than a normal estimated business or partnership. From; South African Trademark Search [ more ]
Hi everyone, I am new to this forum but have some suggestions on business centered maintenance. My view is why not treat maintenance like a business? The goal of any business is to maximuize the outcome while minimizing the input. That is to improve the return on investment. In maintenance you do this by improving usable capacity, reducing costs and reducing the working capital investment. From this everything else follows. I could go on about how targeting PM programs is analogous to... [ more ]
Did you have an industrial/pharmaceutical companies association back there in Malta? [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
david, thank zou very logical analysis, i will go through these points thx Pizo [ more ]
Pizo, Your original post said that this has happened three times this year, I take that to mean that it does not happen every shutdown. This could be an error in the operator shutdown procedure or it could be an error in the operator running procedure. They may not be siphoning all of the condensate out during normal operations. You'll have to look for inconsistencies in how they run as well as how they shut down. Keep in mind that this only happens in one dryer section, what is different... [ more ]
Hi, David, thank you... we opened all the cylinders check hole, the water was in several cylinder but little. it seems that this little water in many cylinders form an extra load on the motor. this happen only in a specific drying group, the other groups are working fine. they checked the siphons, they are ok. what a human error could be ? thx Pizo [ more ]
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Reliability Engineering for MaintenancePosts about Capital Projects
The design of the motor at 4000hp running at 6000rpm will be critical, the mechanical stresses on the windings especially winding overhangs of the rotor will require special material and construction, something to consider for long term management of the asset and its reliability. [ more ]
Dear Johan, totally agree with you.. the challenge is huge.. I heard with modern VFD not is necessary to get Gear Box, because the VFD can reach 7200 rpm in the motor, that is enough for the compressor. but I dont know the power limits for this application. thanks. [ more ]
Evening Ramon, some comments, depending on the voltage a VFD could be better option however voltage would dictate, high speed motors comes with its own challenges, keep an eye out for that, select gearbox carefully, high quality especially for that speed will be critical, wouldn't like to recommend publicly (can discuss with you if you are interested). Yes numerous ways to inspect and make foundation and base is suitable, would imagine if you go from steam turbine to electric motor there... [ more ]
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Reliability Engineering for MaintenancePosts about Root Cause Analysis
I think you are dealing with critical mechanical looseness, probably coming from the fan DE bearing (bearing housing / coupling / attachment as alternatives). Your spectra should have better resolution for detail analysis with some peak markers. Besides, imbalance could also be well increased, although it is hard to say in such bearing condition. I wouldn't operate much longer [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
thank you @Registered Member For you replay [ more ]
Hi Ahmad, Firstly, redundancy is not a maintenance strategy, it is an engineering/design strategy. I disagree with the explicit statement that "no need for condition monitoring for redundant system". Industry best practice would dictate that the decision on whether or not to conduct condition monitoring should be based from criticality of the equipment, regardless if it is spared or not. Your company should establish your risk matrix first similar to what you showed in slide 5, determine... [ more ]
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Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
Reliability Engineering for MaintenancePosts about Reliability Engineering for Maintenance
I suggest checking the axial location of the bearings seats. Mind! There always MUST be one bearing on the shaft which is axially free (allows for shaft axial expansion). Bearings do NOT have enough internal clearance to compensate for such expansion!! If this is problem you will always see strange spikes during load change (usually start-ups) [ more ]
Greetings Mr. Vibration Expert, With the given data nothing can be concluded. give some vibration reports when normal load operation, How you noticed 10% amps dropped and minor maintenance carried out and what was the maintenance. When DE bearing increased to 60*C more what is the ambient temperature and what is actual temperature showing? What are the vibration readings when the temp rise was 60*C also what were the temperatures on Motor side. Motor DE/NDE and Blower side How many bearings,... [ more ]
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