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Vibration report of pump room motor and pump
DIRECTORATE OF NUCLEAR POWER ENGINEERINGREACTOR
Date: August 26, 2013Attention: Mr. Zaheer Ahmed Mirza Chief Engineer (Mech) P&P OGDCL
Subject: Vibration Report of Gemini Compressor-A & Compressor-B DNPER team comprising of Mr. Ghulam Mustafa, SE and Altaf Hussain, Pr. Tech, has taken the vibration data on 31 July 3 August, 2013 of Gemini Compressors of OGDCL, Peer Koh-1. Spectrum analysis of data taken has been made in frequency range of 2Hz-1.6 KHz and presented in the tables 1-15. Following are the findings and solutions to the problem of high vibration especially on the bearings of the radiator fan of Gemini compressors:Findings Vibration data on the fan bearing housings indicated that most vibration was occurring at one times, two times and three times of the fan rotational frequency in the horizontal, vertical and axial directions. High Axial and radial vibration exhibit two faults in the machine; angular misalignment & structural resonance. The vibration analysis spectrum showed that misalignment between pulleys and structural resonance of the bearing support frame are present. The vibration spectrum showed that the vibratory motion of the fan bearing pedestal and base was rocking in the axial and vertical directions. Static measurements revealed a number of factors that explain the high vibration levels measured at the bearings: Inadequate stiffness of the support frame A defect in the roller cage of the rear bearing ; A defect in the inner ring of the bearing ;
RecommendationsThe following are the recommendations to correct the identified problems: Collect vibration and phase data at 1rpm during coast down at both fan bearing housings in axial, horizontal and vertical. Analyze these data for indication of resonance. Perform impact tests at the fan bearing housings in axial, radial and vertical directions. Analyze these data for indications of resonance near operating speed. The DNPER suggested a design review of the bearing supporting structures in order to avoid the vibration levels created by excitation of the structures natural frequencies when the radiator fan is in operation. It is important to note that the vibration levels created by the natural resonance of the complete structure when in operation may be one cause of premature wear and tear in the bearings and the second cause is misaligned pulleys.Conclusions The installation of the fan bearing on the metal structure was probably as per the designer guidelines, but there were not an adequate number of supports for better stiffness. Misalignment of the pulleys is one source of high vibration.
Table 1: Reciprocating Compressor-A (Half Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Cylinder #01 Non Drive endHorizontal4.82.01135
2. Cylinder #01 Non Drive endVertical6.783.2715
3. Cylinder #02 Non Drive endHorizontal9.87.930
4. Cylinder #02 Non Drive endVertical6.52.3180
5. Cylinder #03 Non Drive endHorizontal4.61.915
6. Cylinder #03 Non Drive endVertical7.13.1180
7. Cylinder #04 Non Drive endHorizontal6.22.990
8. Cylinder #04 Non Drive endVertical6.83.315
9. Auxiliary Water PipeHorizontal14.47.2490
10. Auxiliary Water PipeVertical14.79.2690
11. Compressor Drive EndHorizontal2.871.215
12. Compressor Drive EndVertical4.072.115
13. Engine Drive EndAxial16.72.091
14. Compressor Drive EndAxial4.11.930
15. Compressor Non Drive EndHorizontal4.021.44165
16. Compressor Non Drive EndVertical3.72.115
Table 2: Pillow Block, Idler Pulley of Compressor-A (Half Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Pillow Block Bearing-01Horizontal16.710.960
2. Pillow Block Bearing-01Vertical3.661.830
3. Pillow Block Bearing-02Horizontal3.31.9990
4. Pillow Block Bearing-02Vertical2.00.854240
5. Pillow Block Bearing-01Axial21.720.630
6. Pillow Block Bearing-02Axial7.64.2623
7. Idler Pulley Bearing 01Horizontal4.462.723
8. Idler Pulley Bearing 01Vertical14.210.523
9. Idler Pulley Bearing 02Horizontal3.82.2523
10. Idler Pulley Bearing 02Vertical11.49.223
11. Idler Pulley Bearing 01Axial17.513.922
12. Idler Pulley Bearing 02Axial17.114.222
13. Cooler Side Pulley BearingHorizontal3.11.815
14. Cooler Side Pulley BearingVertical4.973.538
15. Engine Outboard Fan SideAxial8.814.32180
16. Pillow Block Bearing 01Axial21.61730
Table 3: Waukesha Engine of Compressor-A (Half Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Engine Crank Shaft Right side Point 01Horizontal5.42.515
2. Engine Crank Shaft Right side Point 01Vertical3.662.830
3. Engine Foot Right side Point 01Horizontal5.232.3415
4. Skid Right side Point 01Vertical3.292.6430
5. Engine Crank Shaft Right side Point 02Horizontal4.441.4545
6. Engine Crank Shaft Right side Point 02Vertical3.02.4830
7. Engine Foot Right side Point 02Horizontal4.141.445
8. Skid Right side Point 02Vertical2.051.6730
9. Engine Crank Shaft Right side Point 03Horizontal5.52.530
10. Engine Crank Shaft Right side Point 03Vertical3.72.830
11. Engine Foot Right side Point 03Horizontal4.61.8830
12. Skid Right side Point 03Vertical2.92.2830
13. Engine Crank Shaft Right side Point 04Horizontal
10
6.642.553
14. Engine Crank Shaft Right side Point 04Vertical5.053.930
15. Engine Foot Right side Point 04Horizontal6.52.852
16. Skid Right side Point 04Vertical4.283.4330
17. Engine Crank Shaft Right side Point 05Horizontal6.72.823
18. Engine Crank Shaft Right side Point 05Vertical6.94.930
19. Engine Foot Right side Point 05Horizontal6.772.967
20. Skid Right side Point 05Vertical6.95.130
21. Engine Crank Shaft Right side Point 06Horizontal5.62.6215
22. Engine Crank Shaft Right side Point 06Vertical3.72.730
23. Engine Foot Right side Point 06Horizontal5.12.1915
24. Skid Right side Point 06Vertical3.642.4530
25. Engine Crank Shaft Right side Point 07Horizontal4.41.545
26. Engine Crank Shaft Right side Point 07Vertical3.472.530
27. Engine Foot Right side Point 07Horizontal4.241.645
28. Skid Right side Point 07Vertical3.02.430
29. Engine Crank Shaft Right side Point 08Horizontal5.472.530
30. Engine Crank Shaft Right side Point 08Vertical3.092.930
31. Engine Foot Right side Point 08Horizontal5.052.430
32. Skid Right side Point 08Vertical3.72.930
33. Engine Crank Shaft Right side Point 09Horizontal5.72.3753
34. Engine Crank Shaft Right side Point 09Vertical4.743.4730
35. Engine Foot Right side Point 09Horizontal5.72.352
36. Skid Right side Point 09Vertical4.243.330
37. Engine Crank Shaft Right side Point 10Horizontal6.72.722
38. Engine Crank Shaft Right side Point 10Vertical7.95.130
39. Engine Foot Right side Point 10Horizontal6.83.068
40. Skid Right side Point 10Vertical3.82.330
Table 4: Reciprocating Compressor-A (Full Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Compressor Drive EndHorizontal4.281.6930
2. Compressor Drive EndVertical5.112.115
3. Compressor Non Drive EndHorizontal4.92.460
4. Compressor Non Drive EndVertical4.662.330
5. Cylinder #01 Non Drive endHorizontal6.762.71
6. Cylinder #01 Non Drive endVertical9.04.260
7. Cylinder #02 Non Drive endHorizontal12.910.830
8. Cylinder #02 Non Drive endVertical12.12.315
9. Cylinder #03 Non Drive endHorizontal6.12.7120
10. Cylinder #03 Non Drive endVertical9.04.260
11. Cylinder #04 Non Drive endHorizontal7.94.890
12. Cylinder #04 Non Drive endVertical8.74.415
13. First Discharge LineHorizontal7.23.160
14. First Discharge LineVertical10.84.9105
15. 2nd Stage SuctionVertical4.53.630
16. 2nd Stage DischargeHorizontal12.16.3225
17. 3rd Stage SuctionVertical6.33.390
18. 3rd Stage DischargeHorizontal12.88.4180
Table 5: Waukesha Engine of Compressor-A (Full Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Engine Crank Shaft Right side Point 01Horizontal5.62.022
2. Engine Crank Shaft Right side Point 01Vertical3.93.030
3. Engine Foot Right side Point 01Horizontal5.42.015
4. Skid Right side Point 01Vertical3.42.730
5. Engine Crank Shaft Right side Point 03Horizontal6.12.630
6. Engine Crank Shaft Right side Point 03Vertical3.832.930
7. Engine Foot Right side Point 03Horizontal5.301.952
8. Skid Right side Point 03Vertical3.042.3130
9. Engine Crank Shaft Right side Point 05Vertical6.94.630
10. Engine Foot Right side Point 05Horizontal8.283.868
11. Skid Right side Point 05Vertical6.854.730
12. Engine Crank Shaft Right side Point 06Horizontal5.72.122
13. Engine Crank Shaft Right side Point 06Vertical3.662.730
14. Engine Foot Right side Point 06Horizontal5.32.022
15. Skid Right side Point 06Vertical3.382.430
16. Engine Crank Shaft Right side Point 08Horizontal6.132.630
17. Engine Crank Shaft Right side Point 08Vertical4.093.0730
18. Engine Foot Right side Point 08Horizontal5.62.515
19. Skid Right side Point 08Vertical4.13.0130
20. Engine Crank Shaft Right side Point 10Horizontal8.33.468
21. Engine Crank Shaft Right side Point 10Vertical3.942.330
22. Engine Foot Right side Point 10Horizontal8.43.8268
23. Skid Right side Point 10Vertical3.942.330
Table 6: Pillow Block, Idler Pulley of Compressor-A (Full Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Engine Outboard Fan SideAxial9.15.050
2. Pillow Block Bearing 01Axial20.317.630
3. Pillow Block Bearing-01Horizontal157.060
4. Pillow Block Bearing-01Vertical3.881.730
5. Pillow Block Bearing-02Horizontal3.72.690
6. Pillow Block Bearing-02Vertical1.80.630
Table 7: Waukesha Engine Reciprocating Compressor-A (Modal Testing)Sr. No.Accelerometer PositionMechanical Natural Frequency (MNF)
1. Engine 640 Hz
2. Shaft112.5 Hz
3. Compressor400 Hz
4. First Stage Discharge Line100 Hz
5. Auxiliary Cooler Water Out let Line168 Hz
6. Frame of Compressor Skid455 Hz
7. Skid Of Engine322 Hz
8. Cylinder 01424 Hz
9. Skid of Compressor373 Hz
Table 8: Reciprocating Compressor-B (Half Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Cylinder #01 Non Drive endHorizontal5.62.875
2. Cylinder #01 Non Drive endVertical6.153.215
3. Cylinder #02 Non Drive endHorizontal7.44.615
4. Cylinder #02 Non Drive endVertical6.02.8180
5. Cylinder #03 Non Drive endHorizontal5.362.975
6. Cylinder #03 Non Drive endVertical6.23.015
7. Cylinder #04 Non Drive endHorizontal5.42.630
8. Cylinder #04 Non Drive endVertical8.43.915
9. Auxiliary Cooler Water PipeHorizontal44.237.590
10. Auxiliary Cooler Water Outlet PipeHorizontal11.85.223
11. Auxiliary Cooler Water Outlet PipeVertical10.34.483
12. 1st Discharge LineHorizontal5.653.260
13. 1st Discharge LineVertical7.474.760
14. Compressor Drive EndHorizontal3.11.215
15. Compressor Drive EndVertical3.61.630
16. Compressor Non Drive EndHorizontal3.611.7180
17. Compressor Non Drive EndVertical4.31.815
Table 9: Pillow Block, Idler Pulley of Compressor-B (Half Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Pillow Block Bearing-01 (Engine to Fan)Horizontal22.21568
2. Pillow Block Bearing-01 (Engine to Fan)Vertical5.02.0180
3. Pillow Block Bearing-02 (Fan to Engine )Horizontal5.13.6105
4. Pillow Block Bearing-02 (Fan to Engine )Vertical2.30.6225
5. Pillow Block Bearing-02 (Fan to Engine )Axial9.13.745
6. Pillow Block Bearing-01 (Engine to Fan)Axial10.25.468
7. Idler Pulley Bearing 01Horizontal2.71.223
8. Idler Pulley Bearing 01Vertical20.915.623
9. Idler Pulley Bearing 02Horizontal1915.423
10. Idler Pulley Bearing 02Vertical5.54.023
11. Idler Pulley Bearing 01Axial8.76.222
12. Fan InboardAxial9.06.238
13. Fan InboardHorizontal8.116.438
14. Fan InboardVertical3.81.822
Table 10: Waukesha Engine of Compressor-B (Half Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Engine Crank Shaft Right side Point 01Horizontal8.94.515
2. Engine Crank Shaft Right side Point 01Vertical2.71.130
3. Engine Foot Right side Point 01Horizontal1.70.730
4. Skid Right side Point 01Vertical1.240.4630
5. Engine Crank Shaft Right side Point 02Horizontal2.51.315
6. Engine Crank Shaft Right side Point 02Vertical2.261.715
7. Engine Foot Right side Point 02Horizontal7.55.815
8. Engine Crank Shaft Right side Point 03Horizontal2.862.0515
9. Engine Crank Shaft Right side Point 03Vertical2.952.4615
10. Engine Foot Right side Point 03Horizontal9.68.315
11. Engine Crank Shaft Right side Point 04Horizontal
10
3.21.915
12. Engine Crank Shaft Right side Point 04Vertical3.42.515
13. Engine Crank Shaft Right side Point 05Horizontal4.02.630
14. Engine Crank Shaft Right side Point 05Vertical4.22.730
15. Engine Foot Right side Point 05Horizontal9.77.615
16. Skid Right side Point 05Vertical9.57.715
17. Engine Crank Shaft Right side Point 06Horizontal6.74.015
18. Engine Crank Shaft Right side Point 06Vertical2.5153.4
19. Engine Foot Right side Point 06Horizontal6.53.815
20. Skid Right side Point 06Vertical3.83.015
21. Engine Crank Shaft Right side Point 07Horizontal7.35.615
22. Engine Crank Shaft Right side Point 07Vertical2.51.215
23. Engine Foot Right side Point 07Horizontal7.05.315
24. Skid Right side Point 07Vertical2.81.815
25. Engine Crank Shaft Right side Point 08Horizontal9.78.415
26. Engine Crank Shaft Right side Point 08Vertical3.02.015
27. Engine Foot Right side Point 08Horizontal8.77.415
28. Skid Right side Point 08Vertical3.52.815
29. Engine Crank Shaft Right side Point 09Horizontal9.27.415
30. Engine Crank Shaft Right side Point 09Vertical3.11.915
31. Engine Foot Right side Point 09Horizontal8.56.715
32. Skid Right side Point 09Vertical3.83.015
33. Engine Crank Shaft Right side Point 10Horizontal9.87.415
34. Engine Crank Shaft Right side Point 10Vertical5.373.315
35. Engine Foot Right side Point 10Horizontal9.27.015
36. Skid Right side Point 10Vertical4.83.315
Table 11: Waukesha Engine of Compressor-B (Full Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Engine Crank Shaft Right side Point 01Horizontal6.63.615
2. Engine Crank Shaft Right side Point 01Vertical3.41.430
3. Engine Foot Right side Point 01Horizontal5.92.715
4. Skid Right side Point 01Vertical2.120.930
5. Engine Crank Shaft Right side Point 02Horizontal7.55.615
6. Engine Crank Shaft Right side Point 02Vertical2.81.245
7. Engine Foot Right side Point 02Horizontal7.15.315
8. Skid Right side Point 02Vertical2.41.515
9. Engine Crank Shaft Right side Point 03Horizontal9.77.815
10. Engine Crank Shaft Right side Point 03Vertical3.42.015
11. Engine Foot Right side Point 03Horizontal8.66.915
12. Skid Right side Point 03Vertical3.42.515
13. Engine Crank Shaft Right side Point 04Horizontal159.67.315
14. Engine Crank Shaft Right side Point 04Vertical3.51.715
15. Engine Foot Right side Point 04Horizontal9.56.715
16. Skid Right side Point 04Vertical3.42.115
17. Engine Crank Shaft Right side Point 05Horizontal9.97.315
18. Engine Crank Shaft Right side Point 05Vertical4.42.530
19. Engine Foot Right side Point 05Horizontal9.056.015
20. Skid Right side Point 05Vertical4.32.530
21. Engine Crank Shaft Right side Point 06Horizontal6.43.615
22. Engine Crank Shaft Right side Point 06Vertical3.82.515
23. Engine Foot Right side Point 06Horizontal6.43.515
24. Skid Right side Point 06Vertical4.32.915
25. Engine Crank Shaft Right side Point 07Horizontal7.15.415
26. Engine Crank Shaft Right side Point 07Vertical2.81.252
27. Engine Foot Right side Point 07Horizontal6.85.115
28. Skid Right side Point 07Vertical3.21.715
29. Engine Crank Shaft Right side Point 08Horizontal9.98.115
30. Engine Crank Shaft Right side Point 08Vertical3.11.715
31. Engine Foot Right side Point 08Horizontal8.56.915
32. Skid Right side Point 08Vertical3.62.515
33. Engine Crank Shaft Right side Point 09Horizontal9.46.715
34. Engine Crank Shaft Right side Point 09Vertical3.51.615
35. Engine Foot Right side Point 09Horizontal8.76.015
36. Skid Right side Point 09Vertical4.02.515
37. Engine Crank Shaft Right side Point 10Horizontal10.16.815
38. Engine Crank Shaft Right side Point 10Vertical5.33.015
39. Engine Foot Right side Point 10Horizontal9.76.415
40. Skid Right side Point 10Vertical5.03.115
Table 12: Pillow Block, Idler Pulley of Compressor-B (Full Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Pillow Block Bearing-01Horizontal22.712.367
2. Pillow Block Bearing-01Vertical6.162.9368
3. Pillow Block Bearing-02Horizontal7.085.6105
4. Pillow Block Bearing-02Vertical2.570.7225
5. Pillow Block Bearing-01Axial16.5737
6. Pillow Block Bearing-02Axial155.467
7. Idler Pulley Bearing 01Horizontal4.12.123
8. Idler Pulley Bearing 01Vertical22.615.323
9. Idler Pulley Bearing 02Horizontal3.571.623
10. Idler Pulley Bearing 02Vertical18.013.123
11. Idler Pulley Bearing 01Axial251823
12. Idler Pulley Bearing 02Axial261823
13. Cooler Side Pulley BearingHorizontal3.71.823
14. Cooler Side Pulley BearingVertical9.77.938
Table 13: Reciprocating Compressor-B (Full Load)Sr. No.Accelerometer PositionVibrationPlaneVibration VelocityComments
LimitVelocity(mm/s)OverallVelocity(mm/s)Max.Velocity(mm/s)PeakFrequency(Hz)
1. Cylinder #01 Non Drive endHorizontal63.430
2. Cylinder #01 Non Drive endVertical106.460
3. Cylinder #02 Non Drive endHorizontal9.96.930
4. Cylinder #02 Non Drive endVertical7.53.660
5. Cylinder #03 Non Drive endHorizontal6.23.260
6. Cylinder #03 Non Drive endVertical9.04.760
7. Cylinder #04 Non Drive endHorizontal10.04.515
8. Cylinder #04 Non Drive endVertical6.9430
9. Compressor Drive EndHorizontal52.160
10. Compressor Drive EndVertical4.72.130
11. Compressor Non Drive EndAxial5.93.760
12. Compressor Drive EndAxial4.82.030
13. Engine Inboard Axial5.91.923
14. Compressor InboardAxial3.92.230
15. Engine OutboardAxial5.81.723
16. Engine InboardAxial5.81.922
17. Engine upper/Top Cylinder#01Horizontal10.47.615
18. Engine upper/Top Cylinder#08Horizontal14.311.215
19. Auxiliary Cooler Water outlet LineHorizontal8.544.515
20. Auxiliary Cooler Water outlet LineVertical9.053.790
21. 1st Discharge LineHorizontal7.44.160
22. 1st Discharge LineVertical14.711.260
23. 2nd Stage SuctionVertical6.24.3105
24. 2nd Stage DischargeHorizontal10.77.8165
25. 3rd Stage SuctionVertical5.73.845
26. 3rd Stage DischargeHorizontal13.78.4210
Table 14: Waukesha Engine Reciprocating Compressor-B (Modal Testing)Sr. No.Accelerometer PositionMechanical Natural Frequency (MNF)
1. Engine 640 Hz
2. Shaft112.5 Hz
3. Compressor400 Hz
4. First Stage Discharge Line100 Hz
5. Auxiliary Cooler Water Out let Line168 Hz
6. Frame of Compressor Skid455 Hz
7. Skid Of Engine322 Hz
8. Cylinder 01424 Hz
9. Skid of Compressor373 Hz
Table 15: Waukesha Engine Reciprocating Compressor TemperatureSr. No.MeasurementPointBearing Temperature(OC)Comments
1Engine to Fan Bearing49Satisfactory
2Fan to Engine Bearing49Satisfactory
3Idler pulley Bearing39Satisfactory
4Fan Bearing39Satisfactory
5Engine Outboard Bearing70Satisfactory
6Engine Inboard Bearing70.8Satisfactory
7Compressor Inboard Bearing73Satisfactory
8Compressor Outboard Bearing80Satisfactory
9Engine Right side Point-01(Above foot 01)83Satisfactory
10Engine Right side Point-02(Above foot 02)83.7Satisfactory
11Engine Right side Point-03(Above foot 03)83.9Satisfactory
12Engine Right side Point-04(Above foot 04)84.2Satisfactory
13Engine Right side Point-05(Above foot 05)81.4Satisfactory