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