Technical Presentation

“BEAT IT”
AHU Extreme High Vibration
## “910 mm/s RMS” ##

Change out that NEWLY Installed vibration sensor !!

VTC/nk/cs25 040516 AFMC 1

 What Causes Vibration?

As the shaft turns, there are

frictional and rotational forces.

That vibration created by those

forces is transferred via the bearings
to the machine housing.

VTC/nk/cs25 040516 AFMC 2

 Project History
NEWLY Commissioned AHU #10
Information Available to Students
Situation : Newly constructed Bio chemical plant you are servicing have been hired your expertise to
conduct Analysis (All technology) with plants Reliability engineer (Certified Cat II Vib specialist) to
identify the sources of Extremely high Vibration on AHU #10 . . This unit had already 2 new
Blowers replaced but do not seems to have High Vibration Reduced. Client requested to have
Vibration sensors replaced as its newly installed for less than 1 months.

Your cost of time: Each time you use reviewing the data, performing tests or discussing the problem is
10 points towards your total cost for the case study history. Any special test you request will be
discussed with you to insure proper understanding of procedures involved. You have 90 minutes
available to review the data you’ve collected and make up a report on your assessment and
highlight findings done.

Information Provided : You are on site collecting all the data that your requires. The collection display
of the spectrums collected are listed below. The significant motor nameplate info is as follow
Motor RPM : 2,700.00 , Fan RPM : 2,625.00 Loading : Variable Speed Drive

Your Observations: The unit is obviously Vibrating Heavily . Humming noise was heard emulating
from AHU units . You feel high vibration of this unit even as you approach it. The vibration
collected form on line mounted sensor on Fans and motors are the only FFT Spectrum analysis
available.

VTC/nk/cs25 040516 AFMC 3

VTC/nk/cs25 040516 AFMC 4
 AHU 10
Diagram of AHU Belt Driven Fan

Fan

FNDE FDE
Motor

MDE MNDE

Vertical

Horizontal
Axial

Figure 1: Schematic Measurement Location and Orientation of AHU Fan

VTC/nk/cs25 040516 AFMC 5

AHU 12 Vibration Analysis –
Live View

AHU 10 Video - WMA folder

VTC/nk/cs25 040516 AFMC 6
Accelerometer Overloaded !!!

VTC/nk/cs25 040516 AFMC 7

 Initial Vibration Results
Vibration data were logged for AHU 10
1) Vibration survey indicated was within Unacceptable
operation zone of ISO 10816-3
(OEM Standard was not imposed).
Recommended to have access into ahu for inspection to
identify the cause(s).
2) Vibration data was collected from permanent mounted
Vibration in 4 locations Motor DE , NDE,
Fan DE &NDE.
Saturation of Vibration sensor at Fan DE Location causing
exceptionally high readings was
detected. Recommended to access ahu for inspection to
identify the cause(s).

3) FFT Spectrum Collected indicated Mechanical Misalignment

& Frequency @42 - 45Hz hunting in system. More field testing
required to identify root sources.

VTC/nk/cs25 040516 AFMC 8

Period Reported:
30/11/2015 - 1/2/2016 Schedule Entry Type Latest Units Date Time
Location

AHU 10

Motor DE -
Vel 6Pack 1000 Hz Spectrum Overalls 11.2 mm/s RMS 20/1/2016 2:47:05 PM
Horizontal

Motor DE - Demod Spectrum

Vel 6Pack 1000 Hz 0.2237 g RMS 20/1/2016 2:47:05 PM
Horizontal Overalls

Motor NDE -
Vel 6Pack 1000 Hz Spectrum Overalls 10.38 mm/s RMS 20/1/2016 2:47:26 PM
Horizontal

Motor NDE - Demod Spectrum

Vel 6Pack 1000 Hz 0.2001 g RMS 20/1/2016 2:47:26 PM
Horizontal Overalls

Fan DE – Horizontal Vel 6Pack 1000 Hz Spectrum Overalls 910.3 mm/s RMS 20/1/2016 2:51:18 PM

Demod Spectrum
Fan DE – Horizontal Vel 6Pack 1000 Hz 1.762 g RMS 20/1/2016 2:51:18 PM
Overalls

Fan NDE -
Vel 6Pack 1000 Hz Spectrum Overalls 13.91 mm/s RMS 20/1/2016 2:48:14 PM
Horizontal

Fan NDE - Demod Spectrum

Vel 6Pack 1000 Hz 0.2573 g RMS 20/1/2016 2:48:14 PM
Horizontal Overalls

VTC/nk/cs25 040516 AFMC 9

 FAULTY ACCELEROMETER ??
SG00134510AHU10 : Sampling Area - Fan NDE - Radial - Vel 6Pack 60000 CPM
00 1,000
100 2,000
200 3,000
300 4,000
400 5,000
500 6,000
600 7,000
700 8,000
800 9,000
900 10,000
1,000
High FreqSpectrum
Demod Spectrum
RMS
Power (mm/s...ggRMS

Hz
Hz
00 Spectrum O/All 9.031
O/All 15.83 g
g RMS
RMS
71

O/All 950.2 mm/s RMS

100

80

60
mm/s RMS

40

20

0 100 200 300 400 500 600 700 800 900 1,000
Hz

VTC/nk/cs25 040516 AFMC 10

 Spectrum FFT Graphs
Graphical Report Ahu 10 Motor DE
Spectrum
43.75Hz 20/1/2016 2:47:05 PM
Cursor A: 28.75 Hz 6.32 mm/s
O/All 11.2 mm/s RMS
6

4
mm/s RMS

100 200 300 400 500 600 700 800 900

Hz

Print For CS 25 Pg3

VTC/nk/cs25 040516 AFMC 11
 Graphical Report Ahu 10 Fan NDE

45Hz Spectrum
20/1/2016 2:48:14 PM
Cursor A: 28.75 Hz 4.538 mm/s
O/All 13.91 mm/s RMS
6

4
mm/s RMS

0 100 200 300 400 500 600 700 800 900

Hz

VTC/nk/cs25 040516 AFMC 12

 Time Waveform 0 1,000
SG00134510AHU10 : Sampling Area - Motor DE - Radial - Vel 6Pack 60000 CPM
2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000

SS
00 100 200 300 400 500 600 700 800 900 1,000
100 0.01 200 300 High
400 Freq
Demod Spectrum
500
Spectrum 600 0.05 700 800 900 1,000

RM
00 0.02 0.03 0.04 0.06 0.07

S
0.1 0.2 0.3 Spectrum
0.4 0.5 0.6 0.7

RM
High Freq Hz
Waveform

RM
0 Demod Hz
Waveform
Hz
00 secs
secs

gg
00

/s
Waveform O/All
O/All 0.6559
0.1996 g RMS
g RMS
RMS

gg
O/All 14.09 mm/s

mm
O/All
O/All 0.626
0.203 gg RMS
RMS
11/2/2016 9:40:18 AM True pk-
pk-pk 3.631 gg
True pk 1.086
Crest
O/All Fac
15.12 tor
mm/s 2.901
RMS
Crest Fac tor 2.675
True pk- pk 63.75 mm/s
30 Crest Fac tor 2.108

20

10

mm/s
0

-10

-20

-30

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

secs
11/2/2016 9:40:18 AM O/All 15.12 mm/s RMS <set RPM>

SG00134510AHU10 : Sampling Area - Fan DE - Radial - Vel 6Pack 60000 CPM

00 1,000
100 2,000
200 3,000
300 4,000
400 5,000
500 6,000
600 7,000
700 8,000
800 9,000
900 10,000
1,000
RMS

0.3 High Freq Spectrum

00 100 0.01 200 300 400 500 600 700 800 900 1,000
Demod Spectrum
RMS

0.02 0.03 0.04 0.05 0.06 0.07

Spectrum
ggggRMS

0 0.1 0.2 0.4 0.5 0.6 0.7

00 High Freq
Demod Waveform
Hz
Waveform
Hz
Hz
secs
00 secs
Waveform O/All 0.5343 g RMS
RMS
mm/s

0 O/All 0.2484
O/All 6.518
O/All
O/All mm/s
0.5687
0.2579 gg RMS
g
RMS
RMS
Cursor A: 0.06372 secs 3.791
True
True mm/s1.799
pk-pk
pk-pk 4.058 g g
Crest
O/All 6.652
Crest Factor
Factor 3.568
mm/s3.488
RMS
15 True pk-pk 35.96 mm/s
Crest Factor 2.703

10

0
mm/s

-5

-10

-15

-20

0 0.1 0.2 0.3 0.4

secs
0.5 0.6 0.7
Print For CS 25 Pg5
18/4/2016 2:04:49 PM O/All 6.652 mm/s RMS <set RPM>

VTC/nk/cs25 040516 AFMC 13

Remedy : Additional Stronger Reinforce on Blower Foundation To eliminate BEAT

VTC/nk/cs25 040516 AFMC 14

Remedy : Additional of Reinforce on Blower Foundation

Before After

VTC/nk/cs25 040516 AFMC 15

 Final Vibration Results
Schedule
Location Type Latest Units Date Time
Entry
SG00134510AHU10 : Sampling Area
Motor NDE - Vel 6Pack 31/5/2016
Brg Condition 0.2675 g RMS
Radial 60000 CPM 1:33:21 PM
Motor NDE - Vel 6Pack Spectrum 31/5/2016
5.111 mm/s RMS
Radial 60000 CPM Overall 1:33:21 PM
Motor DE - Vel 6Pack 31/5/2016
Brg Condition 0.1301 g RMS
Radial 60000 CPM 1:33:41 PM
Motor DE - Vel 6Pack Spectrum 31/5/2016
3.298 mm/s RMS
Radial 60000 CPM Overall 1:33:41 PM
Fan DE - Vel 6Pack 31/5/2016
Brg Condition 0.3355 g RMS
Radial 60000 CPM 1:33:57 PM
Fan DE - Vel 6Pack Spectrum 31/5/2016
6.68 mm/s RMS
Radial 60000 CPM Overall 1:33:57 PM
Fan NDE - Vel 6Pack 31/5/2016
Brg Condition 0.09759 g RMS
Radial 60000 CPM 1:34:13 PM
Fan NDE - Vel 6Pack Spectrum 31/5/2016
4.733 mm/s RMS
Radial 60000 CPM Overall 1:34:13 PM

Vibration Sensor is Resonating at its Natural Frequency During BEAT

VTC/nk/cs25 040516 AFMC 16
 SG00134510AHU10 : Sampling Area - Motor DE - Radial - Vel 6Pack 60000 CPM
00 1,000
100 2,000
200 3,000
300 4,000
400 5,000
500 6,000
600 7,000
700 8,000
800 9,000
900 10,000
1,000
High FreqSpectrum
Demod Spectrum

gg RRMS
MS
Hz
Hz
00 Spectrum O/All 0.1303
O/All 0.3656 gg RMS
RMS
Power (mm/... 31/5/2016 1:33:41 PM
11

2
Cursor A: 43.75 Hz 1.426 mm/s
O/All 3.301 mm/s RMS
1.8
43.75Hz
1.6 z
1.4

1.2
mm/s RMS

0.8

0.6

0.4

0.2

0 100 200 300 400 500 600 700 800 900 1,000
Hz

VTC/nk/cs25 040516 AFMC 17

 SG00134510AHU10 : Sampling Area - Fan NDE - Radial - Vel 6Pack 60000 CPM
00 1,000
100 2,000
200 3,000
300 4,000
400 5,000
500 6,000
600 7,000
700 8,000
800 9,000
900 10,000
1,000
RMS
ggRMS
High FreqSpectrum
Demod Spectrum
Hz
00 Hz
Spectrum
Cursor A: 45 Hz O/All 0.3113
0.0176 gg RMS
31/5/2016 1:34:13 PM O/All 0.09821 g RMS
Power (mm/...

11

Cursor A: 45 Hz 1.746 mm/s

3 O/All 4.737 mm/s RMS

2.5

2
45Hzz
mm/s RMS

1.5

0.5

0 100 200 300 400 500 600 700 800 900 1,000
Hz

VTC/nk/cs25 040516 AFMC 18

 Root Cause Analysis
Dia Dia
Motor RPM : 2,700.00 Fan RPM : 2,625.00

VTC/nk/cs25 040516 AFMC 19

 3D Analysis (ODS)
Operating Deflection Shape
Functions:

 To produce animations of the deformation characteristics of a vibration

mechanical system at any discrete frequency.

 Provide information regarding operating equipment that can be made into an

animation

 Define areas of structure weakness

 Identifying areas with mechanical looseness

 Provide an estimate of the mode shape for the natural frequency that is being
excited.

VTC/nk/cs25 040516 AFMC 20

VTC/nk/cs25 040516 AFMC 21
ODS in Operation – Blower speed at 1796 rpm

VTC/nk/cs25 040516 AFMC 22

ODS in Operation – Blower speed at 3593 rpm

VTC/nk/cs25 040516 AFMC 23

ODS in Operation – Oven speed at 1514 rpm

VTC/nk/cs25 040516 AFMC 24

ODS in Operation – Oven speed at 1433 rpm

VTC/nk/cs25 040516 AFMC 25

Exhaust Fan MCSA Case Study

• AC Induction
• General Electric
• 400 Horsepower
• 1780 RPM
• 509LL Frame
• 460 Volt
• 442 Amps

PdMA Corporation
 Problem Description
• Four (4) Variable Frequency Drive failures
within a short life span (all within 3 years)
• Electric Motor recently refurbished
• VFD’s always replaced with new components
at a cost of $45,000 each
• Frequent trips of the motor causing additional
process problems

PdMA Corporation
 Initial Standard Test
• Data collected from Test Date 07/28/2003

local disconnect Test Time 09:17:08 AM

Frequency 1200

• Quickly noticed the Mohm Ph 1 to Gnd

Charge Time
Voltage
60
1000

corrected Mohm value Motor Temp

Measured Mohm
Corrected Mohm
30
289.3
145.0

was only 145 pF Ph 1 to Gnd

ohm Ph 1 to 2
41750
0.01951
ohm Ph 1 to 3 0.01956

• All other data ohm Ph 2 to 3

mH Ph 1 to 2
mH Ph 1 to 3
0.01952
2.775
2.575

appeared to be within mH Ph 2 to 3
Avg. Inductance
% Res. Imbalance
2.790
2.713
0.15

acceptable limits % Ind. Imbalance

$ Power Loss
5.10
10.37
Test Location T-Leads
MCE # 030452HV
User
Notes Yes

PdMA Corporation
Polarization Index Test
Final value less than 400 Mohm

Erratic graph indicative of moisture

and/or contamination

PdMA Corporation
 Standard Test - At Motor Leads
Test Date 07/28/2003
Test Time 10:08:57 AM
• Data collected from Baseline
Frequency 1200
motor leads to isolate Mohm Ph 1 to Gnd
Charge Time 60
circuit from motor to Voltage
Motor Temp
1000
30
disconnect Measured Mohm
Corrected Mohm
3400.0
1700.0

• Quickly noticed the pF Ph 1 to Gnd

ohm Ph 1 to 2
40500
0.01925
ohm Ph 1 to 3
corrected Mohm value ohm Ph 2 to 3
0.01913
0.01918
mH Ph 1 to 2 2.830
increased from 145 to 1700 mH Ph 1 to 3 2.780
mH Ph 2 to 3 2.615
• Began to suspect a Avg. Inductance
% Res. Imbalance
2.742
0.33
problem within the conduit % Ind. Imbalance
$ Power Loss
4.62
24.90
between disconnect and Test Location
MCE #
Motor Leads
030452HV

motor User
Notes Yes
 Polarization Index - At Motor
Final value increased to over 12000 Mohm

Graph has more slope - less erratic

PdMA Corporation
 Remedial Actions
• Due to problem with low Mohm values
apparently residing between the local
disconnect and motor junction box, we
suspected water in the conduit
• Conduit was removed
• NO water found
• Spirits were low

PdMA Corporation
 Remedial Actions (Continued)
• Due to some abrasions on lead-wire jacket, it
was decided to have it replaced
• Would allow further investigation of the
conduit - still leaning on water in conduit
• Would allow further investigation of the circuit
for other possible sources of our problem

PdMA Corporation
 New Lead Wire
• Old lead wire was removed from conduit
• New lead wire was brought to project site for
measurement and cutting
• We were faithfully inspecting conduit for
water
• During lead wire measurement, our problem
was found!

PdMA Corporation
 Root Cause

Phase 1 Phase 2 Phase 3

PdMA Corporation
 Before/After Lead Change
Test Date 07/28/2003 07/28/2003
• Corrected Mohm Test Time 10:08:57 AM
Baseline
03:03:13 PM

value now very close Frequency

Mohm Ph 1 to Gnd
1200 1200

to when tested at Charge Time

Voltage
60
1000
60
1000

motor Motor Temp

Measured Mohm
30
3400.0
38
1745.0
Corrected Mohm 1700.0 1500.0
• Corrected Mohm pF Ph 1 to Gnd 40500 42250
ohm Ph 1 to 2 0.01925 0.02000
value increased from ohm Ph 1 to 3 0.01913 0.02000
ohm Ph 2 to 3 0.01918 0.02000
145 to 1500 mH Ph 1 to 2
mH Ph 1 to 3
2.830
2.780
2.780
2.860
• Resistive mH Ph 2 to 3
Avg. Inductance
2.615
2.742
2.620
2.753

Imbalance, although % Res. Imbalance

% Ind. Imbalance
0.33
4.62
0.00
4.84

low before now at $ Power Loss

Test Location
24.90
Motor Leads
0.00
Bot Fuses LD
MCE # 030452HV 030452HV
0.00 User
Notes Yes Yes

PdMA Corporation
 Problem Follow-Up
• Unit has operated flawlessly for 9 months without
as much as a nuisance trip
• Process problems have as a result been
tremendously reduced
• Maintenance budget has experienced a much
needed rest from drive replacement costs
• Huge “round of applause” for our PdMA MCE
Testing Technology

PdMA Corporation
 Nick Kang

• 25 Years
– Field Vibration Diagnostic
– Certified Vibration Institute VI (USA) –
Course Trainer
* Certified Infrared Thermal Inspection Specialist

VTC/nk/cs25 040516 AFMC 38

The End

VTC/nk/cs25 040516 AFMC 39