DRI EQUIPMENT BREAKDOWN analysis REPORT

Date: 19/05/2015
Name and Tag no. of the equipment: - PROCESS GAS COMPRESSOR STAGE 1
(CP-A 57)
Short Details of Equipment:1) Driven by a motor of 8.5 MW (1480 RPM).
2) An intermediate gear box (multiplier) having double helical gears (Herringbone
gear).
3) A cantilever supported rotor having two journal bearings at its DE & NDE side
and a thrust
bearing in between them and running at 5600 RPM.
4) It is a centrifugal compressor.
Lubrication Details:- Oil lubricated ( Servo Press Gr. T-32) by a centralized lube oil
system.
Breakdown Downtime:

Started from 2200 hrs on May 5th, 2015

Ended at 2130 hrs on May 9th, 2015.
Actual downtime: 96 hrs/5760 minutes

Probable causes of breakdown:1)

2)
3)
4)
5)
6)
7)
8)

Rotor unbalance.
Journal bearing failure.
Oil contamination with water or due to wear & tear.
At a sudden jerk on rotor due to plant tripping can budge the axial float of the
impeller.
Motor can also encounter some problems.
Wear and tear in gear box.
Couple unbalances.
Structural looseness.

DRI EQUIPMENT BREAKDOWN analysis REPORT

CBM Report:- Vibration readings ( Velocity RMS-mm/sec)

LOCATION

MOTOR
NDE

02.05.15

After
Maintenance
09.05.15 at
09:20 PM

10.05.15

16.05.15

2.3

2.6

2.6

2.4

1.2
0.9
0.7
1.4
1.0
0.8
0.8
1.1
0.6
0.7
1.5
0.6
2.0
1.5
0.9
1.4
1.1
0.7
1.0
0.9
0.8
0.7
0.9

1.1
0.7
1.3
1.0
0.9
0.8
0.6
0.9
0.6
0.6
1.0
0.9
1.9
1.2
0.9
1.7
0.8
1.0
1.1
1.0
1.0
0.9
1.1

1.1
1.0
1.0
1.3
1.2
0.8
0.7
0.9
0.6
0.8
1.5
0.6
2.0
1.4
0.8
1.7
1.5
0.8
0.9
0.6
0.6
0.7
0.7

1.2
0.9
1.1
1.3
1.1
0.8
0.8
0.9
0.6
0.8
1.4
0.8
2.2
1.4
1.0
1.4
1.3
0.7
0.9
0.6
0.5
0.7
0.8

DIRECTIO
N

CLASS &
LIMITS AS
PER ISO
10816

A
H

MOTOR DE

V
A

GEARBOX
I/P DE
GEARBOX
I/P NDE
GEARBOX
O/P DE
GEARBOX
O/P NDE
COMPRESS
OR DE
COMPRESS
OR NDE

H
V
A
H
V
A
H
V
A
H
V
A
H
V
A
H
V
A

Class 3
&
11.2mm/
sec

Compressor trial was taken thrice but tripped on every trial due to high
vibration in DE bearing , magnitude being measured as 10.82 mils, 6.6
mm/sec(11.2 mils), 13.4 mm/sec(13.25 mils) respectively. So the spectrums
could not be recorded at the time of conducting trial but after the corrective
measures the spectrums were recorded which can be referred in the next
section the report.

DRI EQUIPMENT BREAKDOWN analysis REPORT

Prompt Action Taken:1) On the basis of jamming problem reported by operation crew in plant start up
after a short duration S/D, motor to gear box and gear box to compressor decoupling done and each drive is independently rotated manually and
observed that all three drives i.e. motor, gear box and compressor were
freely rotating without any obstruction.
Rectifications and Corrections done:-

S. No

Date

05/05/1
5

06/05/1
5

06/05/1
5

06/05/1
5

07/05/1
5

07/05/1
5

08/05/1
5

09/05/1
5

Description of Job
Reported that PGC 1 is not rotating, decided to rotate manually
but in vain, then motor to g/box & g/box to compressor decoupled
& all 3 equipments found free.
Chain block fixed, and cleaning done around the gearbox and
compressor. Clamp fixing on motor side. Solo run taken in slow
speed, after that clamp removed and solo run in full speed take,
running normal.
PGC-1 motor to gear box coupling done after solo run & after
electrical clearance .Hand over to Prod at 8:30PM, Comp Started
at 9PM, But after 45 Sec Running Comp got tripped due to High
Vibration in DE bearing, Instrument person are checking
PG Compressor no.1 started twice in a shift, but tripped due to
high vibration in DE bearing. Chain block shifted and fixed at
compressor. Compressor coupling guard removed
Coupling inspected and found one bolt missing and one bolt loose
towards gear-box side of high speed coupling. Same replaced with
new one. Compressor started two times but both times tripped on
higher vibration.
Compressor to gear-box decoupled. Bearing to be inspected.
All lube oil fittings removed and blind fixed. CMP bearing cover
bolt removed & Kept in Position.
DE bearing removed after removing the cover, one nozzle
fabricated with v/v and metallic hose fixed to arrest CO leakage.
All three bearing removed, cleaned and inspected, journal pads all
dimensions recorded and fixed back. Casing and all lube oil
fittings put back at their respective positions. Lube oil started at
5.30 am. Motor to G/B coupled back.
Motor to gear box alignment checked and found O.K. Clearance
given for Motor gearbox trial. Max vibration of 2.8mm/sec
observed on Motor and 1.2mm/sec on gearbox. To mark magnetic
center, motor to gearbox again decoupled to take motor solo run.
Rotor axial float also checked and found 0.28 mm on either side.

DRI EQUIPMENT BREAKDOWN analysis REPORT

09/05/1
5

Motor forced to stop at magnetic center. Motor to gear box and

gear box to compressor coupling done. Seals piping mounted.
Both coupling guards mounted. Chain block removed and kept
aside.
Compressor started and running normal with 1.6 mm/sec
vibrations.

SPECTRUMS FOR REFERENCE:Compressor DE H:-

v rms [mm/s]
0.70

PGC 1\COMPR E SSOR \COMP DE H\6000 R PM\Spectrum 5/16/2015 10:59:18 AM

0.65
(88.50 / 0.59)
0.60

M
D

0.55
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
0

200

400

600

800

1000

1200

1400

1600

1800

2000
f [Hz]

DRI EQUIPMENT BREAKDOWN analysis REPORT

Compressor DE V:-

v rms [mm/s]
0.80

PGC 1\COMPRE SSOR\COMP DE V\6000 RPM\Spectrum 5/16/2015 10:59:33 AM

(1063.00 / 0.71)

0.75

M
0.70
0.65
0.60
0.55
0.50
0.45

(88.50 / 0.38)

0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
0

500

1000

1500

Compressor DE A:-

2000

2500

3000
f [Hz]

DRI EQUIPMENT BREAKDOWN analysis REPORT

v rms [mm/s]
1.6

PGC 1\COMPR E SSOR \COMP DE A\6000 R PM\Spectrum 5/16/2015 10:59:46 AM

1.5
1.4
1.3
1.2
1.1
1.0
0.9
0.8
0.7
0.6
0.5
(88.50 / 0.34)
0.4

0.3
0.2
0.1
0.0
0

500

1000

1500

2000

2500

3000
f [Hz]

Compressor NDE H:
v rms [mm/s]
0.40

PGC 1\COMPR E SSOR \COMP NDE H\6000 RPM\Spectrum 5/16/2015 11:00:49 AM

0.38
0.36

(88.50 / 0.33)

0.34
0.32
0.30
0.28
0.26
0.24
0.22
0.20

(1063.50 / 0.17)

0.18

0.16
0.14
0.12
0.10
0.08
0.06
0.04
0.02
0.00
0

500

1000

1500

2000

2500

3000
f [Hz]

DRI EQUIPMENT BREAKDOWN analysis REPORT

Compressor NDE V:v rms [mm/s]

0.70

PGC 1\COMPR E SSOR \COMP NDE V\6000 R PM\Spectrum 5/16/2015 11:01:03 AM

0.65
0.60

(88.50 / 0.55)

0.55
0.50
0.45
0.40
0.35
0.30
0.25
(1063.50 / 0.18)
0.20

0.15
0.10
0.05
0.00
0

500

1000

1500

Compressor NDE A:-

2000

2500

3000
f [Hz]

DRI EQUIPMENT BREAKDOWN analysis REPORT

v rms [mm/s]
0.65

PGC 1\COMPRE SSOR\COMP NDE A\6000 RPM\Spectrum 5/16/2015 11:01:18 AM

0.60

(1063.50 / 0.55)
M

0.55
0.50
0.45
(88.50 / 0.36)
0.40

0.35
0.30

0.25
0.20

0.15
0.10
0.05

0.00
0

500

1000

1500

2000

2500

3000
f [Hz]

Present Health Status:NORMAL, As per ISO standards present vibration levels are in satisfactory

zone.
Root Causes of Breakdown:-

Recommendations & Suggestions for future: Monitor the vibration trend levels for further course of action.

Oil sampling should be done at periodic intervals.

PMI( Preventive Maintenance Inspection) of compressor should be
done at particular intervals as per Preventive maintenance schedule.