A REPORT ON INDUSTRIAL STUDY & PROJECT ON

CK-2 CONVEYOR DRIVE VIBRATIONAL ANALISYS

BY

BIBRATA KUMAR SWAIN M.VASUDEV
B.TECH, III YEAR B.TECH,III YEAR
ADMN NO-2011JE0759 ADMN NO-2011JE0907



UNDER THE GUIDENCE OF

MR M.RAGHAVA RAO
D.G.M, TECHNICAL SERVICES
VIZAG STEEL PLANT












DEPARTMENT OF MECHANICAL ENGINEERING
INDIAN SCHOOL OF MINES
DHANBAD
JHARKHAND








CERTIFICATE

This is to certify that the project work entitled has been carried out by
M Vasudev and Bibrata Kumar Swain under the guidance for partial fulfilment
of requirements for the award of Bachelors Degree in Mechanical Engineering,
INDIAN SCHOOL OF MINES, DHANBAD, JHARKHAND during the year
2013-2014.




Signature of Guide









ACKNOWLEDGEMENT

We wish to show our deep sense of gratitude to Mr. M. Raghava Rao for his
valuable guidance, suggestions cooperation and encouragement throughout the
progress of our project work


M Vasudev
Bibrata Kumar Swain















ABSTRACT

A conveyor CK-2 which feeds coke to blast furnace from open yard. The drive
unit of that conveyor was having high vibration problem in the motor during our
visit for the project in steel plant. As a part of regular inspection vibration
measurement was carried out at CK-2 conveyor.
The reason for the high vibration problem was detected through vibration
analysis techniques. The presence of high overall vibration was observed at 1X
rpm in the spectrum. The problem was confirmed as unbalance and
misallignment. The problem is rectified by balancing and proper allignment.
The following chapters give a brief theory of maintainance concepts, vibration
analysis and its requirements and the procedure of fault diagnosis along with the
work done by us, as application for an industrial problem.


























INTRODUCTION TO RINL:
Visakhapatnam steel plant is the most modern and the sophisticated steel
plant in the country . Its unquiness being the first steel plant in the country to be
accredited with ISO-9K,14K and 18K.It has a labour productivity of 253 tones
per man-year.The present capacity of the steel plant is 3.4 millon ton with the
vision to expand its capacity to 10 million ton by 2019-2020.
VSP started its production in the year 1990.During the project stage the
best technologies and the latest equipment were chosen from all around the
world. crores of equipment was installed to ensure the best quality of product
process ,economy and ecological balance.

PLANT FACILITIES:

VSP has the following major production facilities:
1. Raw material handling plant
2. Coke ovens and coal chemical plant
3. Sinter plant
4. Calcining & Refractory material plant
5. Blast furnace
6. Steel melting shop
7. Light and medium merchant mill (LMMM)
8. Wire rod mill (WRM)
9. Medium merchant and structural mills.
Besides these main metallurgical units a captive power plant of 247.5 MW
capacity, oxygen plant, acetylene plant, compressed air plant, extensive repair
and maintenance facilities form part of the services available at VSP. Steel plant
can take pride in having a clean and green township with provisions of about
8000 quarters, markets, community welfare centers, clubs etc. for the employees
and families.



The overall view of steel plant from raw material stage to final rolled
products stage is shown below:


RAW MATERIAL HANDLING PLANT (RMHP):














The Raw Material Handling Plant (RMHP) receives the basic raw materials
required for the steel making process from various sources through railway
wagons and by road. These are stacked by stackers and reclaimed by reclaimers
and distributed to various departments of VSP through conveyor system. The
Iron Ore Fines, Iron Ore Lump, Sized Iron Ore, Limestone (BF&SMS grades),
Dolomite (BF & SMS grades), Sand, Quartzite and Manganese lumps are
stacked at Ore & Flux Yard. The Imported Coking Coal (ICC), Medium Coking
Coal (MCC), Boiler Coal (BC) are stacked in Coal Yard. Coke is sent directly
to Blast Furnace after tippling from ore and flux wagon tipplers.
These raw materials are sent to various departments as indicated below:

Sinter Plant: Iron Ore Fines, Lime stone (BF grade), Dolomite, Sand and LD
slag.

Stacks of coal
Conveyer belt
Stacker


Blast Furnace: Sized Iron Ore, Limestone (BF grade)/ LD slag, Manganese
Lump, Quartzite and Coke.

SMS: Dolomite (SMS grade), Sized Iron Ore, Dolo chips.

CRMP: Limestone (SMS grade), Dolomite (SMS grade), Dolo chips.

TPP: Crushed Boiler Coal.

COCCP: Imported coking coal (ICC), Medium coking coal (MCC).

The Raw Material Handling Plant is divided into two sections Coal Handling
Plant (CHP) and Ore Handling Plant (OHP).

The process taking place in coal handling plant and (CHP) is shown pictorially
in the next page.













The pictorial representation of coal handling plant


Coke Ovens and Coal Chemical Plant:-
Coal is converted into coke by heating the prepared coal blend charge in the
coke ovens in the absence of air at a temperature of 1000
o
C-1050
o
C for a period
of 16/19 hours. The volatile matter of coal liberated during carbonization is
collected in gas collecting mains in the form of raw coke oven gas passing
through stand pipes and direct contact cooling with ammonia liquor spray. The
gas cooled from 800
o
C to 80
o
C is drawn to Coal Chemical Plant by Exhauster.
The residual coke is pushed out of the oven by pusher car through a guide into
coke bucket. The red-hot coke is taken to coke dry cooling plant for cooling.
The main by product in the process of coke making is crude coke oven gas and
this has lot of valuable chemicals. Coal Chemical Plant recovers Ammonia
(NH
3
), Tar and Benzol from CO-Gas. The primary By-products from Crude CO
Gas are Ammonium Sulphate (NH
4
)
2
SO
4
, Crude Tar, Crude Benzol and cleaned
coke oven gas. The cooled coke from CDCP (Coke Dry Cooling Plant) is
separated into 3 fractions, BF Coke i.e. +25-70 mm which is sent to Blast
Furnaces, Coke Breeze i.e. +0-15 mm which is sent to Sinter making and nut
coke i.e., +15-25 mm, which is also used in the Blast Furnaces.
Facilities :-
1. There are 4 batteries, Each having 67 ovens.
2. The volumetric capacity of each oven is 41.6 m
3
.
3. Dry coal charge/oven is 32t.
Salient features:-
1. Largest and technologically unique Coke oven Batteries in the country
at the time of the commissioning.
2. 7 metre tall coke ovens batteries.
3. Selective crushing of coal to improve the coke quality.
4. 100% Dry Quenching of coke using Nitrogen gas.
5. Power generation, from the waste heat recovered, at BPTS(Back
pressure Turbine Station).
Capacity:-
Production capacities for three batteries-2.635Mt Gross coke per annum.

















Batteries:
The coal is cleaned to remove foreign materials, crushed, screened and
then transferred to coal towers before charging in to the batteries. The prepared
coal charge in the coal tower is drawn by a charging car on the top of the
batteries and charged into the ovens as per sequence. The charged coal is
gradually heated by the heating walls of the oven in the absence of air to attain a
temperature of 1000-1050
0
C at the central axis of the coke mass towards the
end of coking period. The coking period is generally specified between 16 hrs
and 19 hrs depending on oven condition and production requirement. The
volatile matter of coal liberated during Carbonization is collected in gas
collecting mains in the form of raw coke oven gas passing through stand pipes
and direct contact cooling with ammonia liquor spray. The gas cooled from
800
0
C to 80
o
C is drawn to coal chemical plant by Exhauster.

The residual coke is pushed out of the oven by pusher car through a guide into
coke bucket. The red-hot coke is taken to coke dry cooling plant for cooling.

Coal chargers
Coke oven batteries
Pusher car


There are 3 batteries, each having 67 ovens. Each oven can hold 32 tons of dry
coal charge. The volumetric capacity of each oven is 41.6 m
3
.

The heat for carbonization is supplied by under firing of coke oven gas having
CV of 4200Kcal/Nm3 or mixture of BF gas & CO gas having CV
900Kcal/Nm
3
.

Once the coke prepared it is pushed out of the batteries and then transferred to
coke dry cooling plant where the coke is cooled from 1000 1050
0
C to
180-200
0
C.Finally the coke is screened and sent to blast furnace and sinter
plant as per required sizes.


















SINTER PLANT:-
Sintering is agglomeration of fine mineral particles into a porous mass by incipient
fusion caused by heat produced by combustion within the mass itself. Sintering is
agglomeration of fine mineral particles into a porous mass by incipient fusion caused
by heat produced by combustion within the mass itself. Iron ore fines, coke breeze,
limestone and dolomite along with recycled metallurgical wastes are converted into
agglomerated mass at the Sinter Plant, which forms 70-80% of iron bearing charge
in the Blast Furnace. The vertical speed of sintering depends on the suction that is
created under the grate. At VSP, two exhausters are provided for each machine to
create a suction of 1500 mm water column under the grate. Each exhauster is
driven by a 5.6 MW motor capable of rotation of the fan at 1000 rpm with an output
of 15,000 m
3
/min



Hot Sinter
Combustion chamber
Sintering machine


Sintering:
Sintering is a process of Agglomerating iron ore fines into a porous mass by
incipient fusion caused by combustion within the mass of the ore particles.

History of Sintering:
Iron ore fines (0-10 mm) which were a result of mechanized mining could not
be charged in a Blast furnace because they reduce the permeability of burden in
a blast furnace. These iron fines that were generated at mines could not ignored
because of their

i) Huge quantity and
ii) High iron content.

To use these fines effectively in a Blast furnace many processes were
developed. Sintering being one of them and widely in integrated steel plants.

Raw materials used in sintering:

Various raw materials used in sintering process are

i) Iron ore fines (0-10 mm)
ii) Coke - used as fuel
iii) Limestone & Dolomite - to maintain required sinter basicity
iv) Sand - to maintain required sinter basicity
v) Metallurgical wastes - to use wastes effectively and thus reduce the cost of
sintering
vi) Lime - to enhance the process of sintering

Sintering process:
1) Preparation of various raw materials.
2) Mixing & Blending.
3) Mixing with sinter returns in presence of water to form green balls.
4) Charging on to the machine.
5) Ignition and suction.











VSP Sinter plant - An over view:

Sinter plant of VSP has the capacity to produce 5.256 MT of sinter per annum,
which will cater for 80 % of Iron bearing feed to Blast furnace. Two Sintering
machines of Dwight Lloyd type having 312 M
2
total grate area are provided for
this purpose. Sinter machine is designed to operate at the rate of 1.2 T/hr/M
2
for
330 days in a year.
Sinter plant consists of the following main sections:

1. Flux crushing section
2. Fuel storage yard
3. Coke crushing & Flux screening section
4. Receiving bins
5. Raw material bins
6. Material Mixing & Distribution Plant
7. Base mix yard
8. Secondary sinter mix & Pelletising Plant
9. Sinter machine building with Sinter cooling
10. Fan building
11. Slime-dewatering pump house
12. Sinter Screening Plant
13. Gas Cleaning Plant
14. Air Cleaning Plant.


The prepared sinter is sent to blast furnace. It is in figure .






CALCINING AND REFRACTORY MATERIAL PLANT



CRMP, i.e. Calcining & Refractory Materials Plant is an integrated unit of
Visakhapatnam Steel Plant. This plant plays a significant role in the
manufacturing of liquid steel.
The main customer of CRMP is Steel Melting Shop (SMS).
CRMP has two units:
1) Calcining Plant
2) Brick Plant
Calcining Plant:-
Calcining plant produces lime and calcined dolomite, which are used for
refining of hot metal to steel in the converter. This plant has 5 rotary kilns of
325 tons/day capacity. Lime is produced by calcining limestone and calcined
dolomite is produced by calcining dolomite. Limestone is procured
from Oman & Thailand and Dolomite (SMS grade) from Madharam mines of
VSP.
Brick Plant:-Brick plant produces Pitch Bonded Magnesia Carbon Bricks for
lining of Converters and Steel Ladles. The main raw material of brick are Sea
Water Magnesia (SWM) and Fused Magnesia (FM). Sea Water Magnesia is
imported from Ireland and Israel. Fused Magnesia is imported from China.


BLAST FURNACE


Iron is made in the Blast Furnaces by smelting iron bearing materials with the
help of coke and air. The solid charge materials like sinter, sized iron ore, coke
etc. are charged in the vertical shaft of the Blast Furnace at top and hot air blast
is blown through the tuyeres located at the bottom. The oxygen from the hot air
combines with the carbon of the coke and generates heat and carbon monoxide.
The gases, while ascending upwards react with the descending charge materials.
Eventually the charge melts and hot metal and slag are produced and tapped out.
The cooled gas is also used as fuel in the plant. The Paul-Wurth, bell less top
system is installed for furnace charging.

FACILITIE:-

1. One Blast Furnace of 3800 cum. Useful volume.
2. Two Blast furnaces of 3200 cum. Useful volume.












Coke, sinter and iron ore are charged at the top of the furnace by the Paul
wurth, bell loss top system. The hot gas is blown from bottom. The tueyers are
provided to support the charge. The hot metal is discharged into 140T hot metal
ladles by rocking runners in cast house. There are four railway tracks for hot
metal transportation [two on either side,] one service sub track and one track for
flue dust disposal. Independent running railway tracks are provided for delivery
of hot metal to each SMS requirement 0.5 to 3 T as per blowing conditions.

These processes are pictorially represented below.

Coal charging
Sinter and ore charging
Coal charging










Discharging of hot metal into ladles
Here slag is granulated by
high pressure water jet


STEEL MELT SHOP AND CONTINOUS CASTING:-
Steel is made in steel melting shop in the refractory lined vessels called LD
Converters by blowing oxygen through the hot metal bath. While iron making is
a reduction process, steel making is an oxidation process. The oxygen reacts
with the carbon in the hot metal and this reaction releases large quantities of gas
rich in carbon monoxide along with huge amount of dust. The gases released
from the converter are collected, cooled, cleaned and recovered for use as fuel
in the steel plant. The entire molten steel at VSP is continuously cast at the
radial type continuous casting machines resulting in significant energy
conservation and better quality steel. 100% Continuous casting on such a large
scale has been conceived for the first time in India.
Facilities:-
1. Three LD converters of 133 cum. Volume each.
2. 6 nos. of 4 - Strand Continuous Bloom Casting machines.
Salient Features:-
1. 100% continuous casting of steel.
2. Converters gas cooling, cleaning and recovery system.
3. Computerisation of the converter process.
Capacity:-
1. Production capacity- 3.0 Mt of liquid steel per annum.
2.820 Mt of CC blooms per annum










































Hot metal

LD converter

CONTINUOUS CASTING MACHINE

Copper moulds

Gas cutters

Blooms

STEEL MELTINGS SHOP



LIGHT AND MEDIUM MERCHANT MILL
The cast blooms from continuous casting department are heated and rolled in
the two high speed and fully automated rolling mills namely Light & Medium
Merchant Mill (LMMM) and Medium Merchant & Structural Mill (MMSM).
The billets produced in LMMM are further rolled in Bar Mill / Wire Rod Mill
(WRM). The finished products include wire rods & long products like
Reinforcement bars, rounds, squares, flats, angles, channels, billets etc.
Blooms from Continuous Casting Division are rolled into billets, some of
which are sold and rest are sent to Bar Mill/WRM. The continuous two-line
Bar Mill comprises of 8 Stand Double Strand roughing train, 2 nos. of 4 Stand
Single Strand intermediate train & 2 nos. of 4 Stand Single Strand finishing
train. Loppers are provided in between the finishing stands for tension free
rolling in order to obtain good surface quality and tolerances. Housings are of
closed top type. Roll necks are mounted in anti friction bearings.




L















Facilities:-
1. Breakdown Mill
7 Stand Break-Down Mill
2. Bar Mill
8 Stand Roughing Mill(2 Strand rolling)
2*4 Stand Intermediate Mill(Single Strand rolling)
2*4 Strand Finishing Mill(Single Strand rolling)
Salient Features:-
1. Evaporating cooling systems in Rolling Mill furnaces.
2. Computerization in Rolling Mill
3. Tempcore cooling process facilitating high strength with good bendability
and weldability.
Capacity:-
1. A Mill of 0.710 MT per annum production capacity.
















WIRE ROD MILL:-
The Wire Rod Mill of VSP is high speed 4 strand No-Twist continuous mill
designed to produce 8,50,000 T of wire rod coils. The mill is designed to
produce plain wire rods from 5.5 mm to 12.7 mm diameter and Rebar in 8mm,
10mm and 12mm diameter in coil form. However sizes up to 14mm are being
rolled presently. The mill is constructed at an elevated level of +5350 mm.
Rolled billets of 125 mm x 125 mm square cross section, length ranging from
9.8 m to 10.4 m and weighing approx 1250 kgs are used as input material. The
mill is designed to roll steel stock of 0.9% max. carbon content.
Facilities:-
1. 7 Stand roughing Mill(4 strand rolling)
2. 6 Stand intermediate Mill(4 strand rolling)
3. 4*2 Stand Pre-Finishing Mill(single strand rolling)
4. 4*10 Stand FinishingMill(MORGAN BLOCK-Single Strand rolling)
Salient Features:-
1. Computerization in rolling mill.
2. Controlled cooling of Wire rods, by Stelmore process giving high
strength and ductility.
Capacity:-
1. A mill of 0.85 MT per annum capacity.











AUTOMATION:
The operation of blast furnace, steel melting shop and rolling mills has been
entirely computerized to ensure consistent quality and efficient performance.
The stores and indenting procedure was fully computerized and connected to
IBM mainframe computer.

VARIOUS IRON AND STEEL PRODUCTS:
VSP holds forth promise of adequate supply to the consumers of iron and steel
products in the country.pig iron, billets, plain rounds, reinforced plain bars,
ribbed rods equal, unequal angles and beams flooring out of VSPs large
capacity mills which will ensure that the requirements of all consumers are fully
met.

PRODUCTS QUALITY:
Computerized process control of VSP starts from hot metal production.
Dynamic control of steel melting operation guarantees steel metallurgy strictly
as per specifications. products with international specifications and tolerances
are produced. Reinforcement bars of VSP produced through tempcore cooling
process, will have high strengths coupled with good malleability, ductility and
weldability. these boon to the construction sector. VSP wire rods will have high
strength and ductility because of controlled cooling of wire rods by the stelmore
cooling.

BY-PRODUCTS:
Crude tar, phenol fraction, Anthracene oil, naphthalene,benzene, toluene,
polymer, ammonium sulphate( fertilizer PUSHKAL), Pig Iron, Granulated BF
slag are some of the by products.VSP gets income through these byproducts as
much as main products.







SERVICES DEPARTMENTS IN VSP:

Air conditioning systems (ACS) .
Central maintenance - electrical (CME)
Central maintenance - mechanical (CMM)
Civil engineering department (CED)
Electrical repair shop (ERS)
Electro technical laboratory (ETL)
Energy management department (EMD)
Engg. shops & foundry (ES & F)
E nvironment management department (ENMD)
field machinery department (FMD)
instrumentation department (INSTN)
information technology department (ITD)
maintenance management systems (MMS)
plant design (PD)
power engineering maintenance (PEM)
production planning & monitoring department (PPM)
quality assurance &technology development (QATD)
raw materials department (RMD)
refractory engineering department (RED)
safety engineering department (SED)
scrap & salvage department (SSD)
spare parts cell (SPC)
technical services department (TSD)
telecommunications department (TELE)
thermal power plant (TPP)
traffic department
utilities department
water management department













Technical services department (TSD):

During 1994, condition based maintenance was introduced in VSP. It helped in
reducing the maintenance workload, by monitoring the equipment health with
gadgets. Thus helping in evaluating the condition of equipment scientifically.
This has helped in prioritizing maintenance activities and reduced unnecessary
maintenance workload. Thus relieving much needed stress on maintenance
managers. This has helped in planning manpower, spares, and time of repair.
Repair activities were taken up on the equipment when it is essential, instead of
carrying out scheduled maintenance irrespective of actual condition of the
equipment.


Various activities mainly done by Technical services are as follows:-
Inspection of Conveyors & cranes.
Vibration monitoring of critical drives.
Shock pulse monitoring (for accessing condition of antifriction bearings
done by individual departments).
Wear debris analysis of critical Gearboxes (Analysis done by an external
agency).
Thermography
Industrial Endoscopy.
Ultra sonic leak detection of valves
Study breakdown of major equipment and repetitive breakdowns.
Coordinating Statuary inspection of cranes, lifts, tackles, pressure
vessels, etc,
Central agency for procurement of condition monitoring equipment.
Tribology studies (study of fast wearing items in an equipment)
Maintenance standards for critical equipment
Maintenance auditing.
Preparation of reports on Monthly and Yearly maintenance performance.



MAINTENANCE:
Now a days Maintenance Plays a major role in any industry. The
quality of maintenance program determines how long the machines will run
how safe they are for the people working around them and how productive the
machine will be. Maintenance is generally classified in to following types:

1. Breakdown Maintenance (Maintenance when machine fails)
2. Scheduled Maintenance. (Periodic disassembly and inspection)
3. Predictive Maintenance (scheduling maintenance activities only
when a
Functional failure is detected)
4. Proactive maintenance (emphasis on tracing all failures to root
cause)



1.BREKDOWN MAINTENANCE: Not used for critical drives/Machines.
In this type of maintenance a machine is allowed to run until
complete failure, inefficiency or product spoilage forces a shutdown.
Disadvantages:
1. Failures can be most untimely and there is little one can do beforehand to
anticipate tool, manpower, and replacement part requirements.
2. Machines allowed to run until failure often require more extensive repair than
would have been required if the problem and been detected and corrected early.
3. Cost of production increases etc.
2. SCHEDULED MAINTENANCE:
Under this program each critical machine is shutdown after
a specified period of operation and partially or completely dismantled for a
thorough inspection and replacement of worn parts.
Disadvantages:-
1. Expensive and time consuming
2. It is difficult to predict the interval between Periodic inspections.

3.PREDICTIVE MAINTENANCE or CONDITION BASED
MAINTENANCE:
This is the most desirable way to maintain machinery. On line detection
and diagnosis of machinery problems is involved in this maintenance.
Advantages:
1. Shut down for repairs can be scheduled for a convenient time.
2. Repair time can be kept to a minimum, resulting in less machinery down
time.
3. Dismantling machines which are already Operating smoothly does not waste
time and money




CONDITION BASED MAINTENANCE (CBM)
The knowledge of the machines condition and its rate of change, which can be
ascertained by selecting a suitable parameter for measuring deterioration and
recording its value at intervals-either on a routine or continuous basis. Mostly it
is required to be done while the machine is running. The data obtained may then
be analyzed to give a warning of failure. This activity is called Condition Based
Maintenance.
Its essential components are Data collection, Recording and their
Interpretation. An organized data collection and collection system is very
essential part of this programme in addition to the decision regarding
parameters to be measured on machines.

BENEFITS OF CONDITION BASED MAINTENANCE:
1. Prolongs Machinery Life
Expensive production machinery and plant support equipment can be
maintained at a level where it will meet or even exceed its expected service life.
2. Minimize Unscheduled Downtime:
Unexpected breakdowns play have with production schedules and dramatically
increase production costs an effective CBM program lets you detect a problem
before it becomes it critical.
3. Eliminates Unnecessary Overhauls: CBM allows a machine to run
continuously until we detect the earliest stages of a problem. This means you
can run the machine for a long time.
4. Eliminates Standby Equipment:
A good CBM program can prevent unexpected breakdown, and eliminates the
need of a Standby equipment there by reducing their maintenance cost.
5. Provides more Efficient Operation:
CBM program can help keep machines running at minimum vibration and
frequency of fatigue in machine.
6. Increases Machinery Safety:


CBM helps us to detect the signatures of breakdown long before the situation
gets out of hand.
7. Improves quality performance:
By maintaining a low level of machinery vibration, a good CBM program helps
us to assure a high level of product quality and minimizes the occurrence of
rejected parts.
PROACTIVE MAINTENANCE:

Each failure is analyzed and proactive measures are taken to ensure that they
are not repeated. It utilizes all of the predictive/preventive maintenance
techniques discussed above in conjunction with root cause failure analysis
(RCFA). RCFA detects and pinpoints the problems that cause defects. It ensures
that appropriate installation and repair techniques are adopted and implemented.
It may also highlight the need for redesign or modification of equipment to
avoid recurrence of such problems.
Disadvantages:

1. The disadvantage is that extremely knowledgeable employees in
preventive, predictive and prevention/proactive maintenance practices
are required.

2. Proactive maintenance also requires procurement of specialized
equipment and properly trained personnel to perform all these duties.

3. It is expensive maintenance.

Since proactive maintenance is expensive, condition based maintenance is
most desirable than others. But the ultimate goal is to achieve proactive
maintenance with minimum cost. The next discussion is about condition based
maintenance only.





ORGANIZATION OF PREDICITIVE MAINTENANCE
CBM program flow diagram











This all can be done and the key element for organizing CBM is essentially a
measurement of fault trend of a component which is known as CONDITION
MONITORING. Knowledge of various types of faults will be helpful in
understanding the scope of condition monitoring
CONDITION MONITORING:
Principles of condition monitoring:
Detection of developing fault
Trending of the fault
Operate the machine up to but before failure.
Condition monitoring essentially involves regular inspection of equipment
using human sensory facilities and mixture of simple aids and sophisticated
instruments. The central emphasis is however, on the fact that most of the
inspection should be preferably done while the equipment is running. While on
hand it improves the effectiveness of inspection, on the other it reduces the
down time.
1.Plant
wide survey
6.Machine base
line measurement
5.SET/review
acceptable
condition
limits
4.Establish
CBM
3.Select
monitoring
techniques
2.Machine
selection

11.Condition
analysis
10.Trend analysis
of fault detection
9.Data
recording
8.Data
collection
7. Condition
measurement
12.Fault
correction


Of those CBM techniques vibration measurement and analysis play an
important role in condition monitoring of a machine. As all machines, which
contain moving components will vibrate. The nature and magnitude of vibration
of a particular item of machinery can provide valuable information about its
mechanical condition. Vibrations arise from cyclic excitation forces within the
machine. These forces can be inherent in the design of a machine, or can be due
to the propagation of some defect.
CONDITION MONITORING TECHNIQUES:
1. Visual inspection.
2. Performance monitoring
3. Vibration monitoring.
4. Shock pulse monitoring.
5. Temperature monitoring.
6. Wear debris monitoring.

Visual inspection:
Visual inspection sometimes reveals tell tale signs of failures. Simple
aids like microscopes, photographs, stroboscopes, dye penetrates etc. A
machine condition can be identified by physical observations like sound ,
touching the machine body ,touching the lubricating oil.

Performance monitoring :
A machines operating condition can sometimes be accessed through
performance assessment by comparing inputs and outputs.





Vibration monitoring:
All machines, which contain moving components, vibrate. The nature and
magnitude of vibration of a particular component of a machine can provide
valuable information about its mechanical conditions. Vibrations arise from
cyclic excitation forces within the machine. These forces can be inherent in the
design of the machine, or can be due to the propagation of some defect.Wide
range of electronic equipment for vibration monitoring are available now a
days, which are easy to operate, can extract the required overall and
spectral information from the vibration of machine.
Shock pulse monitoring:
This is a reliable method for monitoring the condition of anti-friction
(rolling elements) bearings. In this technique the shock impulses produced by
the impact between the rolling elements and surface defects, either on raceways
or rolling elements are measured.
Temperature monitoring:
This involves Thermograph, which is a non-contact technique and
involves measurement of infrared radiations for hot objects. Simple aids like
infra red instruments and temperature tapes are handy in monitoring
temperature of bearings, motors etc

Wear debris monitoring:
It involves monitoring of lubricants for presence of wears particles, by
using debris sensitive detectors, debris collection methods, lubricant sampling
and analysis.


BASICS OF VIBRATION:
Vibration is simply the motion of a machine or its part back and forth
from its rest position. The most classical example is that of a body with mass M
to which a spring with a stiffness k is attached. Until a force is applied to the
mass M and causes it to move, there is no vibration.

A lot can be learned about a machines condition and possible mechanical
problems by noting its vibration characteristics. We can now learn the
characteristics, which characterize a vibration signal.

The characteristics of vibration are:
1. Amplitude
2. Frequency
3. Phase.

Wave fundamentals:

Amplitude: The height of a wave crest above the reference line is called the
amplitude of the wave. The amplitude of a wave gives a relative indication of
the amount of energy the wave transmits.

There are three modes of amplitudes:
Displacement
Velocity
Acceleration

Frequency: When a wave train passes through a medium, a certain number of
individual waves pass a given point for a specific unit of time. The number of
vibrations, or cycles, of a wave train in a unit of time is called the frequency of
the wave train and is measured in hertz (Hz).

Phase: It is the position of vibrating part at a given instant of time with
reference to fixed point.
If we consider the two waves as depicted in Figure below. We find that the
waves are identical in amplitude and frequency but a distance of T/4 offsets the
crests of the waves. This lag of time is called the phase lag and is measured by
the phase angle.







Harmonics: multiples of the fundamental frequency.
As shown in the figure if wave 1 has fundamental frequency, wave 3 has
frequency three times of the wave 1, so its the third harmonic.















Fourier analysis:

Fourier analysis is another term for the transformation of a time
waveform into a spectrum of amplitude vs frequency values. Fourier analysis is
sometimes referred to as spectrum analysis, and can be done with a fast Fourier
transform (FFT) analyzer.
Fourier analysis of above time waveform is shown below:






Vibration terminology:
Overall amplitude: The overall level of vibration of a machine is a measure
of the total vibration amplitude over a wide range of frequencies.
The overall vibration level can be measured with an analog vibration
meter, or it can be calculated from the vibration spectrum by adding all the
amplitude values from the spectrum over a certain frequency range. When
comparing overall vibration levels, it is important to make sure they were
calculated over the same frequency range.

Vibration displacement (peak to peak)
The total distance travelled by a vibrating part, from one extreme limit
of travel to the other extreme limit of travel is referred to as the peak to peak
displacement.
Displacement is sometimes referred to only as peak (ISO 2372),
which is half of peak to peak.

Vibration velocity (peak)
As the vibrating mass moves, the velocity changes. It is zero at the top
and bottom limits of motion when it comes to a rest before it changes its
direction. The velocity is at its maximum when the mass passes through its
neutral position. This maximum velocity is called as vibration velocity peak.
It is measured in mm/s-pk.

Vibration velocity (rms)
The International Standards Organization (ISO), who establishes
internationally acceptable units for measurement of machinery vibration,
suggested the velocity root mean square (rms) as the standard unit of
measurement. This was decided in an attempt to derive criteria that would
determine an effective value for the varying function of velocity.

Velocity rms tends to provide the energy content in the vibration signal,
whereas the velocity peak correlated better with the intensity of vibration.
Higher velocity rms is generally more damaging than a similar magnitude of
velocity peak.

Crest factor The crest factor of a waveform is the ratio of the peak value of the
Waveform to the rms value of the waveform. It is also sometimes called the
peak-to-rms ratio. The crest factor of a sine wave is 1.414, i.e. the peak value
is 1.414 times the rms value. The crest factor is one of the important features
that can be used to trend machine condition.



Vibration acceleration (peak) Acceleration is defined as the rate of change in
velocity.

Displacement, velocity, acceleration which should be used?
The displacement, velocity and acceleration characteristics of
vibration are measured to determine the severity of the vibration and these are
often referred to as the amplitude of the vibration.
In terms of the operation of the machine, the vibration amplitude is
the first indicator to indicate how good or bad the condition of the machine may
be. Generally, greater vibration amplitudes correspond to higher levels of
machinery defects.
Since the vibration amplitude can be displacement, velocity or
acceleration, the obvious question is which parameter should be used to monitor
the machine condition?
The relationship between acceleration, velocity and displacement
with respect to vibration amplitude and machinery health redefines the
measurement and data analysis techniques that should be used. Motion below
10 Hz (600 cpm) produces very little vibration in terms of acceleration,
moderate vibration in terms of velocity and relatively large vibrations in terms
of displacement (see Figure below). Hence, displacement is used in this range.



EU (mils pp)
(ips)
(g)


Relationship between displacement, velocity and acceleration at constant
velocity. EU, engineering units
In the high frequency range, acceleration values yield more significant values
than velocity or displacement. Hence, for frequencies over 1000 Hz (60 kcpm)
or 1500 Hz (90 kcpm), the preferred measurement unit for vibration is
acceleration

It is generally accepted that between 10 Hz (600 cpm) and 1000 Hz (60 kcpm)
velocity gives a good indication of the severity of vibration, and above 1000 Hz
(60 kcpm), acceleration is the only good indicator.

Since the majority of general rotating machinery (and their defects) operates in
the 101000 Hz range, velocity is commonly used for vibration measurement
and analysis.

ISO 2372
The most widely used standard as an indicator of vibration severity is ISO 2372
(BS 4675). The standard can be used to determine acceptable vibration levels
for various classes of machinery. Thus, to use this ISO standard, it is necessary
to first classify the machine of interest. Reading across the chart we can
correlate the severity of the machine condition with vibration. The standard uses
the parameter of velocity-rms to indicate severity. The letters A, B, C and D as
seen in Figure below, classify the severity.





Class I Individual parts of engines and machines integrally connected with a
complete machine in its normal operating condition (production electrical
motors of up to 15 kW are typical examples of machines in this category).

Class II Medium-sized machines (typically electrical motors with 1575 kW
output) without special foundations, rigidly mounted engines or machines (up to
300 kW) on special foundations.

Class III Large prime movers and other large machines with rotating masses
mounted on rigid and heavy foundations, which are relatively stiff in the
direction of vibration.

Class IV Large prime movers and other large machines with rotating masses
mounted on foundations, which are relatively soft in the direction of vibration
measurement (for example turbo generator sets, especially those with
lightweight substructures).




























VIBRATION ANALYSIS:

Vibration analysis is a non destructive technique, which helps in early
detection faults by measuring and evaluating vibration data. vibration analysis is
a two step process involving data acquisition and interpretation of machinery
vibration data.

VIBRATION ANALYSIS SYSTEM:

A vibration analysis system usually consists of four basic parts:
1. Signal pickup(s), also called a transducer
2. A signal analyzer
3. Analysis software
4. A computer for data analysis and storage.
DATA ACQUISITION:

It is acquiring relevant data in terms of vibration amplitude, frequency, and
phase etc, using vibration analyzer. Vibration measurements are normally made
at the bearings of a machine, because it is through the bearings that the vibration
forces are being transmitted. Motion of the bearings is a result of the reaction in
the machine.

In addition to the essential characteristics of vibration (amplitude, frequency,
phase), it can be very helpful to measure the vibration in various direction. This
represents another essential characteristic of vibration, the direction of motion.
The three important directions of measurement are horizontal, vertical and axial.

The acquisition of accurate and reliable vibration data for analysis purposes is
one of the vibration analyst, because the ability to quickly interpret the data and
arrive at an accurate diagnosis of the specific problem(s) will depend on the
accuracy and reliability of the vibration data.

DATA INTERPRETATION:

It is analyzing the acquired data in terms of vibration amplitude, frequency to
pinpointing the problem(s) by the process of elimination. The data interpretation
will involve the detailed examine and interpretation of:
Amplitude measurement(overall)
Amplitude Vs frequency measurements
Amplitude Vs time measurements
Phase measurement
Waveform observations.


Measuring device:
Vibration analyzer used is CSI 2117 with photo tacho and reflection
tape.

ANALYSER CSI 2117:

CSI -2117 is a data collector which is used to collect data in route mode and
also in half route mode.

In route mode all machines are defined under different routes based on the
equipment type and location. This helps in defining all the parameters like
frequency, range, resolution etc; for data collection beforehand.

Where as in off route mode all these parameters are to be given at site for each
measuring point. In analysis mode data like phase, rpm etc can be taken. CSI-
2117 analyzer has a multifunction connection, which has following utilities;
provides entry for data communications between the model 2117 and the host
computer. Provides input for tacho signal.

Specifications:
Hardware specification:-
Physical dimensions:
Height : 27cm
Width : 17cm
Depth : 4cm
Weight : 2.5kg
Environmental limits:
Temperature : 10
0
C to 50
0
C (15
0
C to 120
0
C)
Relative Humidity : 0 to 95% non-condensing
Power supply:-
Battery : Rechargeable 7.2V NICAD battery pack
Capacity : 1.2 amp-hours
Recharge time :14 to 16 hrs


Operation time: Ten hours of normal usage on a full recharge .
LCD Display:
Viewable area : 2.5*4.75 INCHES (6.35* 12CM)
Dot resolution : 128 VERTICAL * 256 HORIZONTAL PIXELS
Alphanumeric text : 8 LINES*42 CHARCTERS
Data storage capacity:
Standard Memory : 320KILOBYTES
Expanded memory : 832 KB

Vibration signal Units
Acceleration G=9.806 m/sec
Velocity mm/sec
Displacement Microns

MEASUREMENT SPECIFICATIONS:
Frequency analysis:
A/d converter : 12 bits of accuracy
Dynamic range : greater than 70dB
Number of averages : 1 to 9999
FFT calculations : Approximately 50 seconds/average for 400 lines
Analysis resolution : 100, 200, 400, 800, 1600 OR 3200 lines of
resolution in FFT spectra .
Upper frequency : CONTINUOSLY SELECTABLE FROM 10HZ
TO 30KHZ



ANALYZE OVERVIEW:
When the analyzer is turned on, the power up screen will display frit as
shown below. This screen temporarily displays the size of the analyzer, the
current data and time.
If no routes have previously been loaded into the analyzer, the NO
ROUTES ARE ACTIVE screen will display next as shown below. However if
route or off route information has been entered, the analyzer will display the
measurement point screen that was displayed before the analyzer was turned
off.


MULTI FUNCTION CONNECTIONS:
Provides entry for data communications between the model 2117 and the
host computer.


Provides input for the AO720GP accelerometer and other sensors
Provides for connection to an external modem and printers
Provides for connections to the model 444 strobe light.







The following are brief descriptions of the functions located on the front panel
of the model 2117.
ON/OFF Press the on/off key once to turn on the analyzer, press again to turn it
off.
ACTIVITY LED: This light emitting diode (LED) flashes to provide visual
confirmation of keyboard entries.
CHARGING LED: This LED is illuminated when the battery charges is
connected to the analyzer and the battery pack is being charged.

COMMAND KEYS:

UTILITY: The utility accesses the utility functions mean which is used do
select from six functions that defines the control operation of the analyzer
Alt: This key enables the alphanumeric keys for entering data. The alt key is
also used to access special characters during next entry.
OFF ROUTE: The off route mode allows the user to define measurement
location that are not included in the pre programmed route. The off route
measurement points can then be accessed to collect data.
ANALYZE: This key is used to access the real-time analysis and diagnosis
functions of the model 2117
NOTES:- The key is used to access the notepad screen that provides a list of
preprogrammed or use-defined observation concerning the status of monitored
equipment.
CONTROL KEYS:
ENTER: Accepts menu selection
Initiates data collection for the measurement point during data
acquisition.



RESET: Returns to the route collection mode form any other mode aborts any
analyzer function in progress.
UP/DOWN arrows:
Moves the cursor through menu selection
Moves through measurement point screen of a route
Expands and contracts the vertical scale of a spectral plot or waveform display
by a factor of two with each press Scroll the text screen up or down when
selections are available.
MENU ITEM SELECTION:
For menus that do not contain entry fields, such as the utility functions menu
shown below, there are two methods that we use to select the desired function.
The first method is to use the analyzers up to/down arrow keys to highlight the
designed function, then press enter key. The second method us to quickly select
a menu item by presenting the numerical key corresponding to the menu item
number. The menu item will be automatically selected and the analyzer will
then advance to next screen.

ANALYZE AND MONITOR MODES:
Analyze mode:
The analyze mode enables the model 2117 to function as a multipurpose, single-
channel signal analyzer which can perform the following functions: Display
spectral plots, wave forms, peak/phase, and dc measurements.
ANALYZE FUNCTIONS:
Display spectrum
Display wave form
Display parameters
Store data
Acquire spectrum
Monitor mode


ACQUIRE SPECTRUM:
This function is used to collect a new spectrum and wave form, which are then
temporarily stored in scratch pad memory. These data can be observed and if
desired, stored in route memory using the store data feature. Acquire spectrum
permits the storage of more than one data set on a measurement point.

FREQUENCY AND LOW CUTOFF:
These two parameters are used to determine the bandwidth of the measurement,
for example, to measure a spectrum from 100 to 500 Hz, enter 500 for
frequency and 100 for low cutoff. The frequency range does not necessarily
have to match the range that has been previously defined for this measurement
point.
FREQUENCY defines the maximum frequency of the measurement and is
specified in the HZ or CPM, depending on the frequency. Units selection of
the analyzer set up parameters.
LOW CUTOFF defines the minimum displayed frequency of the
measurement. Although frequencies below this value are measured, they are
not displayed or used to determine the overall level.
LINES: these parameters define the number of lines of resolution used for the
FFT calculations. Select 100, 200, 400, 800, 1600, 3200.
Frequency resolution determines how close two frequency peaks can be to each
other and still be distinguished as separate peaks.








CK-2 CONVEYOR:-
CK-2 conveyor is a reclaiming conveyor which carries, coke from open yard to
blast furnace for charging. The CK-2 conveyor is driven by an induction motor
of capacity 167 kw running at 1500 rpm. The motor is connected to the gearbox
through fluid coupling and multi disc coupling respectively. This gearbox is
driven by 3 phase, 167 kw, 1500 rpm. Induction motor. In turn Gearbox
transmits rotary motion to the drive end pulley of the CK-2 conveyor.


Motor details:-
Type :- AC induction motors
Rated power:- 167 kw
Rated speed:- 1500 rpm
Description of the problem:- During the course of understanding the concept
of condition Based Maintenance, a vibration problem in the above conveyor
drive was observed at the time of taking readings along with technical service
personnel. Vibration readings were taken in three directions i.e. in vertical,
horizontal and in axial directions. High overall vibrations were found on Motor


Non drive end and also in drive end side of the bearings predominantly in axial
and horizontal directions.
The following readings are recorded at different points using CSI 2117 analyzer
in presence of our guide for CK-2 assembly. The overall readings are shown in
the below table.


ON MOTOR NDE SIDE OVERALL HORIZONTAL IS HIGH (17 mm/sec)
1x RPM VIBN. PEAK IS 15mm/sec(i.e. the major share)
DIREC TION MNDE MDE GB I/P DE
GB I/P
NDE
V 5.2 5.3 4.1 3.8
H 17.0 3.6 2.1 2.9
A 14.7 14.7 5.2 4.5



ON MOTOR NDE SIDE OVERALL AXIAL IS 14 mm/sec) , 1x RPM
VIBN. PEAK IS 11mm/sec(i.e. the major share)





OBSERVATIONS:
High horizontal vibration (17mm/sec) on MOTOR-A
Vertical & Axial vibrations are different at different points on the base of
the motor.
1x RPM peak is predominant in horizontal direction.
Motor is supported eccentrically as shown & extra support is given as per
the requirement.
As it was identified as unbalanced motor rotor, it was replaced with
another spare motor-B, lying on the same plat form.
Vibrations were reduced to 11mm/sec in horizontal direction and the
pattern of the vibrations were same.

MOTOR B WAS REPLACED & NDE VIBRATIONS WERE REDUCED to
11mm/s




MOTOR-B AXIAL VIBRATIONS WERE REDUCED TO 5.6 mm/sec

AFTER BALANCING MOTOR-A HORIZONTAL VIBRATIONS ARE HIGH
18 mm/sec & DOMINENT PEAK IS AT 1XRPM ONLY



AFTER BALANCING MOTOR-A AXIAL VIBRATIONS ARE ALSO HIGH
16mm/sec & DOMINENT PEAK IS AT 1XRPM ONLY

ACTIONS TAKEN AFTER BRAIN STORMING:
REMOVED MOTOR-A WAS BALANCED AT ERS AND WAS
REPLACED WITH MOTOR-B
VIBRATIONS WERE EVEN SLIGHTLY MORE i.e.18 mm/sec WITH
SAME PATTERN.
AGAIN MOTOR B WAS PLACED WITH WHICH VIBRATIONS
WERE FOUND 11mm/sec PREVIOUSLY.
MOTOR WAS ALIGNED WITH THE HELP OF TECHNICAL
SERVICES AND FOUND THAT MOTOR WAS
MISALIGNED BY 6mm at BACK FEET & 4mm at FRONT FEET.
VIBRATIONS WERE REDUCED TO 7mm/sec in HORIZONTAL
DIRECTION AND PATTERN IS SAME BUT THE AXIAL
VIBRATIONS WERE REDUCED TO 3mm/sec ONLY.




AFTER ALIGNMENT VIBRATIONS IN HORINTAL DIRECTION
REDUCED TO 7.7mm/sec. FROM 11 mm/sec. IN MOTOR-B

AFTER ALIGNMENT VIBRATIONS IN AXIAL DIRECTION REDUCED
TO 3.9 mm/sec. FROM 5.6 mm/sec. IN MOTOR-B



CONCLUSION
AS THERE IS FLUID COUPLING ALONG WITH MULTI-DISC
COUPLING IN BETWEEN MOTOR & G.B. THE NORMAL
PROCESS OF RADIAL ALIGNMENT WITH DIAL GAUGE AND
AXIAL ALIGNMENT WITH PIECE OF ELECTRODE WAS FOUND
IN-ACCURATE.
RESIDUAL UNBALANCE LEFT OUT IS MORE THAN 6.5 GRADE
AND SO VIBRATION DUE TO UNBALANCE WAS PRESENT.