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pumps and piping
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equipment storage
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basic vibration analysis
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there are limits http://www.maintenancebits.com/2015/12/14/there-are-limits/
bearing failure http://www.maintenancebits.com/category/bearing-types/bearing-failure/
bearing types http://www.maintenancebits.com/category/bearing-types/
failure / damage analysis http://www.maintenancebits.com/category/maintenance-practices/proactive/failure-damage-analysis/
maintenance practices http://www.maintenancebits.com/category/maintenance-practices/
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importance of correct fits http://www.maintenancebits.com/category/importance-of-correct-fits/
importance of mounting http://www.maintenancebits.com/category/importance-of-mounting/
pumps http://www.maintenancebits.com/category/machines/pumps-machines/
vibration analysis http://www.maintenancebits.com/category/vibration-analysis/
1 comment » http://www.maintenancebits.com/2015/10/26/pumps-and-piping/#comments
detection of a rubbing impeller http://www.maintenancebits.com/2015/08/07/detection-of-a-rubbing-impeller/
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bearing cage failures http://www.maintenancebits.com/2015/07/08/bearing-cage-failures/
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fans http://www.maintenancebits.com/category/machines/fans-machines/
gearboxes http://www.maintenancebits.com/category/machines/gearboxes-machines/
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proactive http://www.maintenancebits.com/category/maintenance-practices/proactive/
pumps http://www.maintenancebits.com/category/machines/pumps-machines/
troubleshooting http://www.maintenancebits.com/category/maintenance-practices/troubleshooting/
vibration analysis http://www.maintenancebits.com/category/vibration-analysis/
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equipment storage http://www.maintenancebits.com/2015/06/11/equipment-storage/
maintenance practices http://www.maintenancebits.com/category/maintenance-practices/
preventive http://www.maintenancebits.com/category/maintenance-practices/preventive/
shop practices http://www.maintenancebits.com/category/maintenance-practices/shop-practices/
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storeroom http://www.maintenancebits.com/category/maintenance-practices/storeroom/
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duct tape and loctite http://www.maintenancebits.com/2015/05/21/duct-tape-and-loctite/
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importance of correct fits http://www.maintenancebits.com/category/importance-of-correct-fits/
maintenance practices http://www.maintenancebits.com/category/maintenance-practices/
shop practices http://www.maintenancebits.com/category/maintenance-practices/shop-practices/
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basic vibration analysis http://www.maintenancebits.com/2015/04/27/basic-vibration-analysis/
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operating vertical equipment http://www.maintenancebits.com/2015/04/07/operating-vertical-equipment/
pumps http://www.maintenancebits.com/category/machines/pumps-machines/
troubleshooting http://www.maintenancebits.com/category/maintenance-practices/troubleshooting/
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lubrication http://www.maintenancebits.com/2015/03/17/lubrication-2/
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bearing lubrication http://www.maintenancebits.com/category/maintenance-practices/bearing-lubrication/
importance of lubrication http://www.maintenancebits.com/category/importance-of-lubrication/
maintenance practices http://www.maintenancebits.com/category/maintenance-practices/
storeroom http://www.maintenancebits.com/category/maintenance-practices/storeroom/
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synchronous gearbox http://www.maintenancebits.com/2015/03/10/synchronous-gearbox/
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predictive http://www.maintenancebits.com/category/maintenance-practices/predictive/
vibration analysis http://www.maintenancebits.com/category/vibration-analysis/
no comments » http://www.maintenancebits.com/2015/03/10/synchronous-gearbox/#respond
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www.maintenancebits.com keep the world rolling! there are limits december 14th, 2015 if you have been in maintenance for very long then you have learned that not all things work out as you have planned. one comment we often hear is that the customer had been doing his vibration monitoring by the book just like he was trained to do and yet the machine failed with no warning. the case at hand occurred when a customer in asia contacted us with the complaint that a machine that he was monitoring once a month had failed 17 days after he had done his last monitoring. he included the fft plot and amplitude trends and we concurred that there was no indication in the data that the machine was in any trouble. we asked for a teardown report for the cause of the failure. the report stated that the root cause was a failure of the cage in the bearing. rarely in the real world do we have equipment that always, every time, without fail, year after year, perform as designed. with vibration monitoring there will be occasions where the data doesn’t give a warning of impending failure. cage failures of bearings is one of these occasions. the cage is generally the lightest weight of the 4 components in a bearing. therefore, it generates the lowest amplitude signal and then the signal has to cross over three barriers; cage to ring, ring to housing, and housing to sensor. in addition, whereas a spall in a ring or rolling element will often develop over a period of weeks or months, the light weight cage, if damaged, will usually deteriorate rapidly, often in a matter of days. the results is that you may have good data on the 1st of the month, as in this case, and by the 17th, something has damaged the cage and it has entered a failure mode which shuts down the machine. on cage damage the usual suspect is installation error that is initially undetectable. on rare occasions, with continuous monitoring, we have observed cage fault signals and have shut the machine down under controlled conditions and performed the necessary maintenance but the usual scenario is a shutdown after the machine emits a loud screeching noise. two solutions for critical machinery is to increase the observation rate and the other is continuous monitoring, both of which have economic limitations. so, as the title says, there are limits. nothing is 100% sure except death and taxes. therefore we work within the limits of our equipment and do the best job possible. posted in bearing failure, bearing types, failure / damage analysis, maintenance practices | no comments » pumps and piping october 26th, 2015 one fairly common problem incurred during the installation of new pumps and piping is the condition where the pump is “pipe bound”. even with precise computer drawings, small differences in manual measurements can add up to the point where in order to get the new piping to connect to the pump, a come-a-long is used to pull the pipe into position. then the connection is made and all appears to be fine. the first time vibration measurements are made on the new pump, the resulting data is distorted because the excessive pipe forces don’t allow the pump to vibrate in its normal manner. for example these two fft’s are horizontal and vertical measurements on the outboard bearing of the pump. it is not normal to have nearly “0” movement in the horizontal direction and over 25mm/sec in the vertical direction. horizontal vertical the first response is to uncouple the piping. generally if the connecting pipe, of any size, moves more than 1 inch or 2.54 cm, the piping may be restricting the movement of the pump and should be realigned. note that pipe binding can occur in any direction. another possibility in this case is that the hold down bolts are loose or the foundation is faulty. under normal situations the horizontal vibration is usually higher than the vertical. gravity and hold down bolts prevent vertical movement but usually equipment can be excited in the horizontal direction unless there are additional supports. a good example is to grab the edge of your table or desk; it is difficult to move up and down but can be shaken back and forth fairly easily. the fft’s shown were from a new installation where in fact, the piping had bound the pump. several pipe segments were replaced and normal operations were restored. posted in importance of correct fits, importance of mounting, pumps, vibration analysis | 1 comment » detection of a rubbing impeller august 7th, 2015 as seen in this example, the speed of rotation does not change the resulting fft when there is a rubbing component. the defining signal will appear at 0.5x where x= the rotation speed. using enveloped acceleration will more likely show harmonics as the enveloping process is more sensitive than velocity. as with any vibration, the higher the amplitude, the more urgent the need for repair. the example is an fft displaying the results of a rubbing impeller, and a time spectrum is also included. the time spectrum does not add anything to the diagnosis but verifies that the signal at 750 cpm is prominent. based on the observed amplitudes, it was decided not to take the fan out of service at that time but to increase the observations and trend the specific 750 cpm signal. this is acceptable as many minor machine faults will operate for extended periods without any problem, as long as they are monitored on a cycle in accordance with their criticality. the more critical the machine, the more often it should be monitored. the data box indicates the element is rotating at 750 cpm and the frequency is 0.5x. this unit was operating on 50 hz power and rotating at 1500 rpm. the operating speed of the machine is not significant, if a rub is present it will be indicated by a signal at 0.5x by placing the two harmonic markers on adjacent marked signals, the time lapse of 0.0798 seconds equates to a frequency of 752.2 cpm. (f=1/t) the accuracy of all measurements is dependent on the resolution of the spectrum and minor variations are not significant. posted in uncategorized | no comments » bearing cage failures july 8th, 2015 there are two aspects of a bearing cage failure, one is that they are fortunately rare and second, when they do occur, the damage is such that it is difficult to determine that a cage failure caused the problem. vibration monitoring with enveloped acceleration frequency analysis of the bearing components is the ideal way to monitor bearings. it is advised to trend the data and set the alarm limits so that an alert is given with an increase in the trend amplitudes. even with due diligence cage degradation can occur very rapidly and maintenance may not be scheduled with enough lead time to prevent a failure of the cage. for example, a customer was monitoring the cage frequency, noted that the trend of that frequency was increasing and notified maintenance. no action was taken and 23 days later the bearing failed. another customer provided the following frequency plot with the cage frequency (ftf) noted. in this case, the amplitude is well above the upper limits for replacement and they were fortunate the bearing was immediately changed. the two figures are the fft and a picture of the bearing after removal. the lesson here is that it is not a good idea to wait after determining that the cage has developed a problem. in the second case, the amplitude is well above the recommended replacement value of 1.0 ge. it is best to be safe than sorry. if you are having what appears to be an unusual number of bearing cage problems it would be advisable to review your bearing mounting procedures. if improper tools are used to mount the bearings, it is possible to damage the cage which will later lead to failure. mounting damage may not be visible with a casual inspection. posted in ball bearings, electric motors, fans, gearboxes, predictive, preventive, proactive, pumps, troubleshooting, vibration analysis | no comments » equipment storage june 11th, 2015 the famous comedian, bob hope, once said that there are no new jokes, just new versions of jokes that are hundreds of years old. he was an expert so he should know. in the same manner, except when a new technology comes along, there are no new maintenance problems. how many articles have you read concerning machine storage? i’m sure if you look back through maintenancebits, that you will find articles on machine, or machine components and their storage. even with all that information available the following letter was recently received from an skf european customer who related one of his current problems. “all i can add at this time is we too have had failure of equipment which has been in storage for a few years. an example is our conveyor pulleys have the bearing mounted and pulleys stored just sitting on the ground, with the bearing mounted in the pillow blocks and hanging on the shafts. these bearings are skf 241/600 eca/w33 so a fairly large bearing and every one had false brinelling once installed 5 years ago. since the pulley is not in a stand where one can come along and rotate it every few weeks the bearings are guaranteed to fail. our last plant outage which is every 4 years we took all of our pulleys and had them shipped off site to have all bearings replaced, these were new pulleys with new bearings but stored improper, i believe that it is $100,000 per bearing plus two bearings per pulley and a total of 5 pulleys, and cost of labour and shipping, so this was a huge loss. without proper procurement procedure you lose a lot of money. another interesting fact is some vendors will ship equipment to you under “short term” storage procedures, short term is like 3 months. if you require longer storage then their storage procedure is much different. this detail needs to be included in the contracts and procurement part of your project. it is disappointing that we all know the equipment must be rotated and some require special storage stands but this never gets the attention it should.”  this is a real life example. $100,000/bearing, 2 per pulley, and 5 pulleys. my math says just that cost was $1,000,000. i wonder who had to explain that to the plant manager! so a word to the wise, make arrangements for the proper storage of your equipment and their components. your job may depend on it! posted in maintenance practices, preventive, shop practices, spare parts, storeroom | no comments » duct tape and loctite may 21st, 2015 maintenance personnel are often placed in the position of “get it fixed, now”. this pressure often seems to occur around 02:00 in the morning after a long day. the initial vibration analysis was that the bearing appeared to be loose on the shaft, the fft spectrum showed multiple harmonics of the rotation speed and the 4th harmonic was higher than the 3rd and 5th. multiple harmonics of rotation speed is an indication of looseness and when the 4th harmonic is elevated, the bearing is loose on the shaft. when the bearing was removed, an skf 22248 cc/w33c3, the clearance between the shaft and the inner race was found to be 0.32mm. in an effort to speed up the repair, a new bearing was installed and loctite applied between the shaft and inner race. unfortunately loctite is not the proper fix for a worn shaft. a more permanent solution would be to remove the shaft, place it in a lathe and apply a new surface to the shaft with a plasma torch. then while the shaft is in the lathe, turn it down to the proper size and reinstall. and the duct tape? it was successfully applied to a crack in the fan housing that was leaking air. several years later, the tape is still there and there is no air leakage. posted in importance of correct fits, maintenance practices, shop practices | no comments » basic vibration analysis april 27th, 2015 there are numerous mechanical conditions that can be observed using portable vibration data collectors such as the skf microlog. the following series of blogs are the major faults and conditions one may find. balance: as a general rule whenever a machine is vibrating, the first impulse is to assume the rotating element is out of balance. the quickest way to verify this is to collect an fft in the velocity spectrum. with the cursor on the high peak, the data box tells us that this fan is rotating at 1600 rpm and the imbalance is 1.4 ips (35mm/sec); an extreme amplitude for any machine and completely unacceptable. the small spike of energy at 800 rpm is probably from two components rubbing together because energy at 1/2 rotation speed is an indication of a rub. the other spikes are insignificant and can be ignored. this fan was the suction fan on a bag house. a bag had come loose and hung up on one blade of the fan, putting it out of balance. the bag was removed and the following spectrum taken. what do you see different between the two spectrums? warning, this is a trick question to illustrate an important point. most data collectors can be set to “auto range”. that means that it will change the values in the “y” axis so that the spectrum will fill the screen, as this one does. visually one would say, “there’s hardly any change”. however the amplitude box tells us that the rpm is still 1600 but the amplitude is now 0.09 ips (2.3 mm/sec), a 15 fold decrease in amplitude that is very acceptable for continuing operations. posted in uncategorized | no comments » operating vertical equipment april 7th, 2015 a fairly common vertical installation is a pump submerged in a fluid and the drive motor mounted on the foundation above with a drive shaft that descends to the pump. these vertical installations can develop some unique problems. starting with the motor, it usually has bolts anchoring the frame to the floor. if you’ve ever balanced a pencil on the tip of your finger you know that it is much easier to balance the pencil in a horizontal position vs a vertical position. the vertical drive motor is in the same situation. in addition to having bearings designed to carry the vertical load, it has a tendency to oscillate around the floor mounting. if the floor mounting is not plum and level, it is easy for a resonance to develop. one of the first things to be done with a vibrating vertical motor is to check the security of the mounting bolts then do a bump test on the unit. if there was resonance present, the bearings should be monitored as resonance conditions are very detrimental to bearings. very long drive shafts should have supports to prevent shaft whip. the number and type of support will be determined by the shaft diameter and rpm. often all that is needed is a sleeve to maintain the shaft position although in some cases this intermittent support contains a shaft bearing. at the bottom the pump is subjected to the usual forces with the addition of being submerged. a common installation of this type is a fire pump submerged in the river to provide fire support. because of the rise and fall of the river depth during the seasons, long shafts are needed. installations using tidal water have the same requirements as the tides raise and lower the surface level. ideally the pump will be mounted on some type of foundation to prevent movement. and finally the pumps may be operating in a hostile environment such as the river or ocean bay. posted in pumps, troubleshooting | no comments » lubrication march 17th, 2015 in any bearing the purpose of lubrication is to prevent contact between the rolling elements and the races or between the shaft and a plain bearing. the lubricant is necessary, being composed of the proper additives and of the proper viscosity. the correct lubricant to be used is determined by the speed and load carried by the bearings. other than special cases, grease and oil are the most common lubricants. your skf bearings dealer can provide you with the data needed to determine the proper lubricant for your application. for oils, viscosity is the prime determination in the selection of a lubricant. high or low temperature and speed determine the required viscosity. the lubricant forms a thin film between the races and the rolling elements. insufficient viscosity will allow the two surfaces to make contact generating heat, wear and surface degradation. once a lubricant is selected it is just as important to use the proper amount. excess lubricant will generate heat and can cause damage to the bearings. bearing cages and rolling elements are not supposed to plow through grease or oil bath. in the case of electric motor bearings, excess lubricant will often escape into the motor housing causing a short in the electrical components. some studies have shown that more bearings are damaged by excessive lubricant than those that lack a lubricant. skf will also provide you with data on the amount of lubricant needed, based on your application. figure 1 storage of lubricants is very important. if a storage drum is exposed to conditions where water can mix with the lubricant, degradation will occur. at standstill, free water in the lubricant will accumulate at the bottom of the bearing. the water concentration will be highest at a certain distance from the rolling contact (fig 1). the reason is that the free water is heavier than the oil and will sink until it comes to a suitable gap between the rolling element and the raceway. this can lead to deep-seated corrosion, called etching (fig 2). etching is even more likely to occur in applications where there are aggressive chemicals and high temperatures, like the dryer section of a paper machine. figure 2 etching usually leads to premature, extended spalling as the material is subjected to a structural change and the surfaces in the load zone are reduced to such an extent that overloading occurs. the best way to avoid corrosion is to keep the lubricant free from water and aggressive liquids by adequately sealing the application. using a lubricant with good rust-inhibiting properties also helps. posted in bearing lubrication, importance of lubrication, maintenance practices, storeroom | no comments » synchronous gearbox march 10th, 2015 one of the best ways to be alerted to changes in your machinery condition is to trend your data. there are multiple programs that will do this and if used, will alert you either by a % change or an amplitude change in the flow rate, vibration level, electrical load, etc. if you contract a consultant to evaluate your equipment, among the first things he/she will ask for is to see the trend charts. without this information all you are offering is a one-time look at the situation which limits the evaluation. an example of this was the situation where the customer provided an fft spectrum and a time domain spectrum of a critical unit with no historical data. below are the two spectrums. when using enveloped acceleration, ge, anytime you have multiple harmonics of the rotating frequency, 1x, you can almost always know there are problems. although the amplitudes are low, so is the rotational speed of 79 rpm and these amplitudes become significant. when collecting data on a gearbox you should always collect a time spectrum. from the fft you can see there are problems but it is not clear what or where they are, it may just be looseness but you can’t tell from just the fft. in the time spectrum notice the pattern of the signals, the rise and fall of the amplitudes. if the time between two peaks is measured, approximately 0.76 sec, this equals a rotation speed of 79 rpm so you then know that the vibration occurs once per revolution. since this is a synchronous gearbox, both shafts are rotating at the same speed so a physical inspection will be necessary to determine which of both gears are in trouble. a physical inspection of the gears was ordered and this picture shows the damage that was found. early detection of the damage prevented an expensive failure and allowed the work to be done on a scheduled basis rather than unscheduled overtime. posted in gearboxes, predictive, vibration analysis | no comments » « older entries blogroll what's this blog about? interesting links skf knowledge centre skf.com categories allowed speed ball bearings bearing failure bearing housings bearing lubrication bearing types electric motors failure / damage analysis fans gearboxes importance of correct fits importance of lubrication importance of mounting industrial shaft seals leak detection machines maintenance practices plain bearings predictive preventive proactive pumps question of the month roller bearings run to failure shaft alignment shop practices spare parts storeroom tools troubleshooting uncategorized vibration analysis workshop archives december 2015 october 2015 august 2015 july 2015 june 2015 may 2015 april 2015 march 2015 february 2015 december 2014 november 2014 august 2014 july 2014 june 2014 may 2014 april 2014 march 2014 february 2014 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