Maidul Islam Naskar Engineer - Mechanical Inspection in vibration monitoring. Introduction ‘The objective of maintenance function has now shifted from “Repair Maintenance” to “Asset Management In our HPL also, Asset Management approach is adopted by defining the maintenance function as follows: To ensure that the Company's assets remain in the best possible condition so that assets’ “fitness for purpose’ throughout the plant designed life is maximized for uninterrupted operation consistent with the requirements of safety, requirements of quality, sments and ensuring compliance with statutory requi economics of operation. ‘Thus. HPL has taken many initiatives and changes in many work areas, especially in the maintenance field, Dy adopting the condition-based maintenance practice Which has the following advantages. Condition Based Maintenance (CBM) ‘© Online inspection and monitoring-based approach © Assessment of machine condition by on-line diagnostics © Prediction of machine failure © Assessment of Time to Failure and identifying of failing component © Maintenance Planning ‘© Use or creation of opportunity for undertaking repair for best overall plant economics National Conference Nov. 2007 Diagnostics of High-speed Gearbox of Propylene Feeding Drive in Petrochemical Plant Sudipta Das Engineer - Mechanical Inspection Haldia Petrochemicals Limited, East Midnapore, West Bengal 721 002 Abstract Liquid hydrocarbons in petrochemical plants are fed through very high speed straight vane centrifugal pumps, running at speeds of 7000 to 14000 rpm. Such speeds are achieved through step-up gearboxes, which if fail could cause substantial loss. One such gearbox for propylene ‘feed pump of HPL is the subject of this paper and describes a case study with the logical steps Objectives in HPL © To ensure that critical equipment failures are diagnosed and predicted in advance so as to help planning of production and maintenance functions with minimum impact on production ‘© To ensure that repeat failures of critical equipment fare minimized through diagnossic management Case Study Sundyne pump (9P-301A) located at polypropylene plant (PP) is used for feeding propylene into loop reactor, One of its gearbox bearings was found damaged and was deteriorating progressively. Through vibration analysis this problem was arrested before leading w breakage of equipment internals Description ‘¢ Vertical centrifugal pump © High head © Compact design © Output speed up to 14000 rpm ‘© Input shaft intermeshes with output shaft for a few models For other models, input shaft intermeshes. with idler which in turn rotates the output shaft © We have three models: LMV-322, LMV-311. and LMV-312.HIMER Diagnostics of High-speed Gearbox ....__Natlonal Conference Nov. 2 Pump (Model No. LMV 322) $ 7? och = coor cobs 1 soural bering macs em coe I sea s a a. (> Lube pump: aaa 2, Observation and analysis was high, our first objective was to identify the s From 1 June 06, the pump vibration started OF the vibration. increasing; on 6" December it reached to the highest value. As the vibration of the motor as well as pump Comparing the spectra, we concluded that the ge: was the source of the high vibration o overt vate ober ass i Vibration trend of 2 Motor inboard along x axial direction eT ne kere ne eiardoTo 20608 in ‘SarMaidul Islam Naskar & Re. PROPANE FEED Pt ‘Sudipta Das __National Conference Nov. 2007 “rand Dery i f° a i le eee ein Cay oon 100 Daye ezater0 To 2.00046 Analysis of the spectra captured from different points of the gearbox revealed as follows: ‘© Overall vibration of the entire gearbox was high. © Many peaks were appearing in the spectrum — these were the harmonics uf 19.36 kepm peak all the peaks were surrounded by sideband peaks spaced at about 488 cpm (0.23 to 0.4 X motor bl vec names Frequney nko ‘Sine ont wor aut Vibration trend of Gearbox along horizontal direction rpm). Though bearing details were not available, this kind of spectrum pattern helped us to confirm that the dominating peaks were BPFO (ball pass frequency outer) and BPI (ball pass frequency inner); sidebands were FTF (fundamental trend frequency), High-pitched sound was observed and the noise level was significantly high. "prone tone OvERALL= 1587 00 w= 575.6240) Spectrum of ‘gearbox along axial directionHIMER Diagnostics of High-speed Gearbox National Conference Nov. 2007: © Time wave form was showing a clear indication impacting force frequency is 13.37 kepm cof impact; time gap between two consecutive (60000/4.49). impact was 4.49 msec. This meant that the 5 i i é + ns 5 Lo OS © Crest Factor (which indicates intensity of impacts in the wave form) was also. exhibiting an increasing tend Tod feet de = {factor on gearbox | : oe ee lee ae a ‘© All the vibration parameters were compared with came to the conclusion through vibration analysis that those of sister equipment (9P-301B). the antfriction bearing within the gearbox is damaged. (On opening the gearbox, the bearing was found with’ In spite of the complicacy of the gearbox internal 1 broken cage and pitted inner race. Subsequently the: design and the non-availability of bearing details, weHIMER bearing number was noted, and as an act of, postmortem, the bearing detail was fed to the vibration analysis software. To our utter satisfaction, the bearing fault frequencies matched with our logical assumption We thank the Maintenance and Inspection team of HPL for their help in preparing this paper. Maidul Islam Naskar & Sudipta Das National Conference Nov. 2007 References 1. Manuals for CSI 2120 and RBMware 2. Sourcebook by Technical Associates of Charlotte Sadipia Das, a mechanical engineer of 15 years ti iii a Aa etlpcal is involved in inspection of static equipment and Maidut Islam Naskar, a mechanical engineer, has experience in advanced vibration analysis and other condition monitoring techniques.Hofincons 12 Tranfield Services "Group Company CERTIFICATE Awarded to Mp. Sudipta Daz L Maidul Isam Nastar Haldia Petroctemicals Limited, East Medinipon, West Bengal for their contribution to the advancement of industrial ssset maraagement by presesting a commendable techiical pager at HIMER National Cosference-2007 Case Studies in Plact Maintenance on Diagnostics of High-speec Gearbox of Propylene Feeding Drive in Petrochemical Plant conducted from Novenber 28 to 30, 2007 at GR Convertion Centre, Chennai. Soe Aer C. 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