Examples

Figure No.2 Bearing & Gear Defect detection

Solution: Tighten anchor bolts & re-gout foundation sole plate & replace pinion gear.

Figure No.3 Harmonic Analysis, Narrow Banding of the spectrum, waveform pulse analysis. Using vibration analysis the condition of bearings,
shafts, gearing, coupling can be determined with magnetically or stud mounted sensors.

Solution: Re-alignment of motor to gear box allowing for thermal growth.

 Figure No.4 Multi-Phase Analysis Sole Plate, Foundation, & Structural Steel Stability for RCA of bearing and gear failure. Phase provides direction of Vibrational force.

 Solution: Steel stiffeners added to base structure f(n) shift

Figure No.5  Using Trending for selection of maximum load data when mechanical defects are most apparent.

Solution: Rolling Mill Chatter

Figure No. 6 Sound & Acoustics with correlation to vibration signatures to determine root cause and solution.

Solution: Gear manufacturing defects  excite “resonates” housing increasing    noise level, gear quality improved.

Figure No. 7  Torque & Strain measurements for variable loading. High torque amplification factors result in high stress for bearings, shafts. gears, & rolls.

Solution: Rolling mill computer model tuned to run higher yield steels.

Figure No.8  Natural Frequency Determination Modal Analysis  when excited f(n) can become a very destructive force. Calculated F9n) can be confirmed via impact testing.

Solution: Gear f(n) shifted to avoid resonance from mill RPM

Figure No. 9  ODS (operational deflection shape) and dynamic analysis illustrating sole plate (base) instability and bearing stressing

Solution: Repair foundation & Sole Plate.

Figure No.10  ODS Model of coupling thrust instability during peak loading a transient event

Solution: Change Coupling model to high thrust model.

Figure No. 11 Reactor rotational analysis

Solution: Alignment of support rolls.

Figure No.12 Mill Stand & Steel Strip Instability Resulted in heavy impacts with mill stands

Solution:Stabilize strip with weld alignment, balance mill loads.

Figure No. 13 Conveyor Structural Dynamics

Solution: Add stiffeners to bearing structure Re-alignment of motors to share loading

Figure No. 14 FEA of critical components

Solution: Change bevel to ring gear alignment Improve lubrication to gear mesh.

Figure No. 15 Analysis of specific motor elements

Figure No. 16 Electrical Vector Analysis for per phase electrical balance.

Solution:diagnose uneven air gap, insulation problems, excessive heating, loose connections, and poor quality electrical power.

Figure No.17 Motor Efficiency & Power Stability using voltage and current waveform

Figure No.18 Motor Spectrum Analysis

Solution:  Rotor bar, & stator coil defects,can all be determined by vibration analysis electrical measurement are then used to quantify the problem and assess repairs.

Figure No.19 MCA Analysis w/ Total Harmonic Distortion (THD), V&I balance, power factor,phase impendence values can be determined using temporary sensors connected toelectrical conductors or PT’s / CT’s.

Solution:tune VFD’s to provide uniform power to motors

Figure No. 20 OEM Fan performance Data & Curves identify optimum machine loading

Solution: Understanding how the machines were designed to operate (OEM data) is a good analysis starting point.

Figure No. 21 Multi-Channel transient event Trending and Analysis compares gas velocity, static pressure, with vibration.

Solution:High vibration w/ reliability issues can frequently be traced to process disturbances.

Figure No. 22  ODS Model of Fan illustration of how Gas flow disturbances effects motor vibration levels and motor reliability.

Solution: Repair discharge damper servo, clean ducts to discharge header and replace IB pillow block bearing

Figure No.23 Foundation / Sole Plate Repair Design to meet time window