EXPERIMENTAL AND ANALYTICAL EVALUATION OF BOWL MILL 2014-15

1. INTRODUCTION
Gujarat Narmada Valley Fertilizers & Chemicals Limited (GNFC) is an Indian
manufacturer of fertilizers and Chemicals.GNFC was founded in 1976. The company was jointly
promoted by the Government of Gujarat and the Gujarat State Fertilizer Company Limited
(GSFC).
This study will be carried out on the bowl mill manufactured by BHEL, installed in
GNFC,Bharuch.The capacity of producing pulverized coal of this bowl mill is 13 tone per hour.
The experimental data will be collected from the GNFC Bharuch to compare it with FEA
analysis.
Bowl mills grind pea-sized coal into a powder, which is blown into the furnace of a power
plant. Normally, there are a number of mills that supply the ground coal to the furnace and the
amount of coal going into the furnace is controlled by the amount of feed to each mill and by the
number of mills on line. In the mill considered, the bowl of the mill turned at a measured speed.
Three grinding rollers were forced against the coal bed by compression springs. There are stops
on each roller to prevent loading on a bowl with no coal. Once the coal is fed into an operating
mill the roller lifts off the stop. For 100% coal feeder loading, the coal bed on the bowl has a
thickness of about one inch.
Over the past 30 years,Bowl mills have been rapidly employed and widely used to process
raw materials in the cement industries because of their superior high efficiency . Recently, Bowl
mills have come to be adapted to the grinding of other materials such as ceramic, filler material,
etc. due to their power saving capability However, it has been reported that an unexpected
unstable vibration occurred in the course of grinding these materials. This unstable vibration may
cause mechanical damage, so the application of roller mills to this region of industry is somewhat
hesitant.

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FIG 1 : OVERVIEW OF BOWL MILL.

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1.1 APPLICATIONS
Bowl Mills are used in
1. Thermal power plants
Bowl mill is used in thermal power plant to crush the raw coal in to the fine grains to
improve the efficiency of the boiler.
2. Cement Companies
Bowl mills widely used to process raw materials in the cement industries because of their
superior high efficiency.
3. Steel Plants
In steel plant bowl mill is used for converting the row coal in to the powder form for
efficiently fired in to the boiler.
4. Recently ,the bowl mills have come to be adapted to the grinding of other materials such
as ceramic,filler materials etc

1.2 OPERATION OF BOWL MILL

The material to be ground is fed to the centre of revolving bowl.centrifugal force cause the
material to travel towards the outer perimeter of the bowl where it comes between the grinding
ring in the revolving bowl and the rolls.the rolls which Are spring loaded import the pressure
necessary for grinding.the partially pulverized material continues up over the edge of the bowl.
Air enters the mill housing below the bowl,is directed upward past the blow and passes
through the classifier vanes at the top of the inner cone.this air rising around the bowl picks up the
pulverized material.havier particles striking against the bowl deflectors are return to the bowl
immediately.the lighter particle carried by the air up and in to the adjustable classifier.the
classifier vanes impart a spinning action to the mixture with the degree of spin determining the
size of the finished product.any oversized material is returned from the classifier to the bowl for
additional grinding.the finely pulverized material and air exit from the mill through the classifier
deflector ring.
Any tramp iron or difficult to grind foreign material in the feed is carried over the top of
the bowl where it drops out through the air stream to the lower part of the mill housing pivoted
scrapers attached to the bowl hub sweep the tramp iron,etc around to the strap iron discharge
spout.if the material being ground discharged from the tramp iron spout it is usually an indication
of over feeding,although too low a spring pressure,too low an air flow,too low an outlet
temperature.excessively worn parts or improper adjustment could also cause material being
ground to be discharge.
While the bowl mill is properly adjusted it operates very quietly and smoothly at all rates
of feed.

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2.LITERATURE REVIEW
1. Lucas R.D.Jensen,Erling Fundal,Per Moller,Mads Jespersen identified the most
common degradation mechanisms occurring in closed circuit high stress comminution equipment
such as vertical roller mills. Both a macroscopic and a microscopic analysis of the wear parts has
been conducted. A laboratory scale vertical roller mill with a transparent roller/table has been
developed to further understand the material movements during grinding. The development of a
simple wear test apparatus has verified the type of wear mechanism dominating the process.
Optical microscopy revealed that strain incompatibility resulted in fracture and decohesion of the
carbides below the worn surface. Thus the conclusion is the size reduction in VRM occurs by the
mechanism of compression alone.Size reduction by shear is insignificant and applies to low
pressure area only. Size reduction by abrasion is also insignificant.
2. Michael T. Santucci and Rudolph J.Scavuzzo studied the dynamic displacement of
grinding rollers using instrumentation techniques developed by Engineering Consultants Group
Inc. (ECG). As a result of the resonant condition, shaft failures occurred. A finite element model
of the mill and grinding rollers was developed. The two major components of the FEA model
were tied together through the coal bed stiffness. Results showed that the displacement
measurements corresponded to the first and second vibration modes of the coal mill. A slip-stick
motion between grinding rollers and coal bed in the bowl of the mill is believed to be the
excitation source. Stronger blower is installed to carry ground coal powder to the boiler which
result in to the amplitude of vibration is decreased and friction between the bowl and the roller is
decreased.
3. Wei Hua, He Yaqun, Shi Fengnian, Zhou Niaxing, Wang Shuai and Ge Linhan uses
sampling analysis, particle size analysis, mass balance calculation to calculate the circulation ratio
of separator and cone zone and separator efficiency. Sampling ports were firstly drilled on a ZGM
coal mill in the power plant in China, and the coal samples from various points in the pulverizer
were collected under the different operation conditions. The property of the sampling material
from the mill was analyzed, applying the float–sink test, size distribution analysis, proximate
analysis. The circulating ratio and coal flow in the separator and the cone zone were calculated
using the mass balance of the circulating load. So, the feed flow of separator and cone zone all
raised with the increase of the air volume. Furthermore, the parameters of the separation functions
were obtained based on the fitting method.
4. R.K.Pandey has done macroscopic study and microscopic study to find out the causes of
failure of gear box. The premature failure of coal pulveriser gear box has been studied in this
investigation. Complete breakage as well as cracking in a number of gear teeth were noticed in
which the cracking initiated from the middle of the root-fillet of the teeth and propagated beneath
the root region. Studies were conducted using microstructural studies, hardness measurements,
fracture surface studies, etc. The failure was found to be initiated by bending fatigue from the root
fillet region of teeth which mainly constituted coarse ferrite–carbide aggregate resulting in a
relatively low hardness level. The life of gear box could be improved by local hardening of the
fillet root to provide a fine martensitic structure with hardness in the range of 55RC.

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5. Andrea Cortinovis,Mehmet Mercangoz, Tarun Mathur,Jan Poland,Marcel

Blaumann modeled a three state coal mill based on heat and mass balances as well as a single
step coarse to fine particle grinding relationship is presented with the purpose of predicting the
dynamic behavior of coal mills during both start-up and in normal operation. The parameters of
the model were identified and later validated with measurements obtained from a hard coal fired
power plant. During these studies several parameters were found to be time varying. In order to
estimate the values of these time varying parameters and the internal states of the coal mill an
extended Kalman filter was designed. The proposed solution is observed to achieve very good
agreement with measurements and can be used for various applications such as model-based
control, performance monitoring, fault detection, and maintenance scheduling. In order to
demonstrate one of these use cases a nonlinear model predictive control (NMPC) application was
developed based on the coal mill model and the performance of the NMPC was compared to a
conventional coal mill control strategy for tracking load change references and for rejecting
disturbances caused by variations in coal moisture. The results improves the characteristics of the
mill in order to better control and safer operation of the mill.The NMPC result in more efficient
and safer control of the coal mill compare to othre conventional coal mill.
6. Zuo Weira ,Zhao Yuemin, Ha Yaqun, Shi Fengnian and Duan Chenlong prepared a
shi-kojovic model for modified hardgrove mill test to investigate the effect of energy input on the
coal size reduction.Hardgrove grindability index (HGI) is an important indicator of coal
grindability, and is one of the most important parameters to determine the capacity of coal
pulverizer in power station. However, HGI is an empirical grindability index without linkages to
any known physical parameters. To investigate the effect of energy input on the grinding in
Hargrove mill, a torque meter was installed on the shaft of a modified Hardgrove mill to record
the torque driving the mill. Samples from four kinds of coals with HGI ranging from 36 to 72
were prepared according to the procedure of standard HGI test and ground in a modified
Hardgrove mill at different revolutions. The relation of sample size reduction degree to specific
comminution energy (Ecs) was studied with Shi–Kojovic model. The results show that Shi-
kojovic model is best fited for the hardgrove mill.ORE hardness indicator is more appropriate
than HGI to measure coal grindability.
7. K.fujita and T.Saito studied to reveal the mechanism of unstable vibration occurring in
the grinding operation of roller mills and to show the design guidelines for reducing the vibration.
To study the basic cause of the unstable vibration, first investigated the dynamic characteristics
of the mill vibration in its stable state and its unstable state, using a small laboratory roller mill.
This showed that the unstable vibration was due to the stick–slip motion of the rollers. Further,
the modal analysis showed that the natural frequency of the torsional driving system of the mill
corresponded with the unstable vibration frequency. Next, they researched the frictional and
compressive characteristics of the ground materials using a simplified test apparatus. This showed
that the ground material has a negative-damping property known to be the cause of the self-
excited vibration. Furthermore, they proposed the analytical vibration model for the simplified
test apparatus considering the negative-damping property, as well as the corresponding equations
of motion. By integrating them numerically, fluctuating phenomena similar to the experimental
results were obtained.

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8. M Swamy,C R Prasad,M S Rawat,P Ramaulu has done failure analysis of input shaft of
planetary gear box of a bowl mill to find the causes of failure.Thermal power plants mostly
employ bowl mills to crush coal which in turn is used in the boiler for generating steam. These
bowl mills encounter failures with respect to grinding components and/or other accessories. In the
recent times, fretting failure is assuming more significance with respect to failure of the bowl mill
components. Fretting, generally, occurs when there is a relative movement, of about a few
microns, between two mating surfaces that are under a high contact stress. In the present case
study, involving gear box of a bowl mill, input shaft has failed due to fretting and investigations
revealed concluding evidences. Various investigation techniques like, visual, stereo microscopic
examinations and Scanning Electron Microscopic studies, etc. were carried out to ascertain the
root cause for failure. These techniques revealed that the failure of the shaft has taken place due to
fretting as a result of micron level relative movement between key and keyway caused by
continuous vibrations.The material and its heat treatment are as per the requirement, which is
confirmed by the chemical analysis, mechanical tests and metallographic examination of shaft.
9. Robert Junga,Stanisław Mateuszuk,Janusz Pospolita presents the results of testing the
grind material movement in a ring-roller milling system. The tests were carried out in a 1:4 scale
model of an RP-1043x`milling system. The aim of the test was to testing the grid material
movement by determine material bulk shapes within a range of parameter changes of a model
grinding system in a ring roller milling system.Based on the measurements of material layer
thickness on the table, its average radial velocity was calculated. The results were then
supplemented with tests based on the movement of markers over the surface layer of the coal
bulk.A change in the table's rotary velocity results in accumulation or release of a considerable
part of the material. Thus, the rotary velocity may be a useful parameter in the mill control
system. Tests on milling effects confirm that the optimal rotary velocity for the considered milling
system is about 1 rev/s.A change of the rotary velocity causes accumulation or release of a certain
amount of the material.
10. A.H.V. Pavan,K.S.N. Vikrant,M. Swamy,G. Jayaraman elucidates the metallurgical
investigation that was carried out on a failed pinion shaft for analyzing the cause for failure.
Fractography revealed the initiation of a crack from the keyway corner. Mechanical testing
indicated that the yield strength of the material was lower than the specified value. Observation of
the bowl mill at site after failure indicated that hard lumps were present in the bull ring segment,
which clearly made it evidentthat there was sudden jamming of it which in turn led to overloading
of the pinion shaft leading to the initiation of crack. A small overload fracture zone was also
observed in the interior of the shaft suggesting low stress but high stress concentration torsional
failure. Hence, this investigation concluded that The pinion shaft had failed due to overload
despite the keyway and its corners manufactured as per the design specifications.

11. Hao Xue-Di,Zhu Dong-Mei,Bian Zhi-Rui,Wang Xin used analytical method and finite
element method to determine the grinding power consumption of planetary mill.Planetary wheel
rolling on a coal-bed was simplified as rigid wheel rolling on the coal-bed with a rigid base when
a Vertical planetary mill (VPM) is running. Based on our analysis, we conclude that the Bekker
formulation for computing rolling resistance is not applicable to calculate directly the rolling
resistance of the wheel. According to the principle of the Bekker apparatus, pressure-sinkage
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curves were obtained by tests on a piece of mono-axial consolidation apparatus used in soil-
mechanics. The deformation modulus of the coal-bed was calculated using elastic mechanics. A
finite element model of the planetary wheel coal-bed was built up by the use of a rigid and a
Drucker-Prager material model in LS-DYNA. According to the simulation results, the wheel
rolling resistance, the grinding power consumption and the motor power of the mill were
calculated and the mistake in the initial design of the mill was modified. The simulation results
employment of FEM to analyze the rolling resistance of a planetary wheel was successful, the
averaged grinding power consumption of VPM is 227 kw.
12. Jing Zhao and Shijie Wang analyze for fatigue failure causes on a large-scale
reciprocating
compressor vibration by torsional vibration.The crankshaft of a large-scale reciprocating
compressor frequently cracks because of the fatigue failure and the 1st and 2nd crank bearings
often are scuffed due to torsional vibration. Such problems are handled by connecting the 2nd and
3rd shaft with two plate flanges in the form of interference fit assembling. Using numerical
simulation, models are built for the two crankshafts with modification. Modal analysis and
dynamic response calculation of crankshaft system under different modification projects are
performed. The results show that the frequency ratio r between sevenfold rotating speed of the
initial crankshaft and the first order torsional vibration natural frequency is 1.016, which makes
the initial crankshaft to resonate. With the enlarged rotating inertia-mass on modified crankshaft,
the frequency ratio r increases to 1.064, and the resonance is eliminated. The rotating vibration
displacement of the initial crankshaft at the 1st crank pin is far larger than that of the 6th, which is
the primary cause of crank bearing scuffing. The inertia-mass of initial crankshaft results to
additional stress with resonance, which is the primary cause of crank cracking for fatigue failure.

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3.PROBLEM DESCRIPTION
In bowl mill, the coal is crushed in to the fine grains by applying compression and shear
force on pea nut size raw coal between bowl and rollers. Here rollers having relative rotary
motion due to the rotation of bowl. Bowl is rotated by means of worm gear and worm wheel
which is attached at the bottom of vertical shaft. The failure of vertical shaft is a major and
frequently happens problem in to the bowl mill.Which needs to be eliminate. However in past
,research work is done over it but they have only done the microstructure analysis by doing
macroscopic and microscopic tests.They have also done the fatigue analysis over the failed shaft.
Here the major cause of the vertical shaft failure is the unstable vibration of the gear housing of
bowl mill. So it is necessary to check the vibration of the gear housing. Gear housing is an
assembly of bowl mill which is used to transmit the motion from motor to the bowl.
In this study I am going to model each and every component of gear housing of bowl mill
and then assemble it so model will operate exactly as a physical model. And then I am going to do
modal analysis over this model by using ANSYS software.
3.1 METHODOLOGY
1. In this study in first step I am going to model the components of gear housing assembly by
using AUTOCAD 3D.
2. Every component are then will be assembled using CREO software and prepare a
complete model of gear housing assembly.
3. Using ANSYS software I will do modal analysis of that model to find out the natural
frequency and mode shapes of vibration.
4. The experimental data will be collected from GNFC,Bharuch.
5. Experimental data from GNFC, Bharuch is in the form of amplitude, velocity and
acceleration of vibration.
6. These experimental data will be compared with Finite element analysis data which are in
the form of frequency of vibration, using ANSYS (Modal Analysis).
7. Amplitude, velocity and acceleration could easily convert to the frequency either by
analytical calculation or by converter.
8. So both experimental and FEA data will be in frequency so then compare them and find
the solution to minimize the unstable vibration.
3.2 MOTION TRANSMISSION BY GEAR HOUSING
In gear housing assembly the worm shaft is parallel to the horizontal axis of the mill and it
is driven by the motor. Motor rotates shaft at 980 rpm.While at the lower side of the vertical shaft
a bowl hub is fixed by a bowl hub key, to rotate the vertical shaft with bowl hub and to avoid
slipping of the shaft. Here worm gear is mounted on the bowl hub by using nut-bolt. So that at the
time of maintenance or any damage to the gear tooth, there is no need to remove the whole bowl
hub. Here worm shaft transmits the rotating motion to the worm gear and worm gear rotates the
vertical shaft. At the upper end of the vertical shaft a bowl hub is attached. Bowl is fastened to the
bowl hub by using nut-bolts. Vertical shaft rotates the bowl hub and bowl. On the other hand, non
drive end of the worm shaft is directly connected with the shaft of induced draught fan. Distance
between worm shaft and I.D. fan is too long. So to avoid the sagging of the shaft a pedestal is
used to support the shaft.
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3.3 GEAR HOUSING ASSEMBLY.

FIG 2 : GEAR HOUSING ASSEMBLY (FRONT VIEW)

FIG 3 : GEAR HOUSING ASSEMBLY(TOP VIEW)

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3.4 PART LIST OF GEAR HOUSING

SR NO AS PER PART NAME QTY

NO DRG.
1 1 Mill base and gear housing 1
2 2 Gear housing cover lower 1
3 4 Lower bearing and pump housing cover 1
4 5 Oil pump bushing 1
5 6 Oil pump key 1
6 7 Retaining ring 1
7 8 Radial bearing –lower 1
8 9 Thrust bearing –lower 1
9 11 Oil pump keeper 1
10 14 Oil pump hub 1
11 15 Lower bearing and pump housing 1
12 16 Thrust bearing adaptor 1
13 18 Worm and gear inspection cover 2
14 19 Worm shaft assembly 1
15 22 Oil collector 1
16 23 Vertical shaft 1
17 24 Gear hub key 1
18 25 Gear hub 1
19 26 Worm gear 1
20 27 Worm gear hub lock nut 1
21 28 Oil collector assembly 2
22 29 Split dust guard 1
23 30 Mill bottom 1
24 31 Upper bearing housing 1
25 34 Bowl hub key 1
26 35 Upper bearing housing cover 1
27 36 Bowl hub 1
28 37 Scrapper assembly 2
29 38 Lock nut 1
30 39 Bowl 1
31 40 Bull ring segmented 1
32 41 Bowl hub cover and clamping ring 1
33 42 Bull ring retainer-inner 1
34 43 Bowl extension ring 1
35 44 Vertical shaft bearing-radial 1
36 51 Skirt assembly 1
37 53 M24 coupling bolt 24
38 54 M33 coupling bolt 16
39 57 Wear plate 1
40 58 Jack screw 2
41 59 Dowel pin D20*70 1
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4.FUNDAMENTAL OF VIBRATION
Vibration deals with oscillatory behaviour of the dynamic systems. All the bodies having
mass and elasticity are capable of vibration. In studying mechanical vibrations, the bodies are
treated as elastic bodies instead of rigid bodies. The bodies have mass also.Because of mass it
they can possess kinetic energy by virtue of their velocity. They can possess elastic strain energy
which is comparable to the potential energy.The change of potential energy into kinetic energy
and vice-versa keeps the body vibrating without external excitation(force or disturbance).If the
cause of vibration is known, the remedy to control it can be made.
Vibration of a system is undesirable because of unwanted noise, high stresses, undesirable
wear, etc. It is of great importance also in diagnostic maintenance.

4.1 DEFINE MECHANICAL VIBRATION

Mechanical vibrations are oscillations that repeat within a time period. The design of
string instruments, such as guitars, is based on the strings vibrating at a certain frequency. The
guitar has all of the components of a vibration system including a vibration damper, and a place to
store potential and kinetic energy. Kinetic energy is converted to potential energy when the string
is moving upward, and potential energy is converted to kinetic energy when the string is moving
downward. Plucking the string supplies the energy to the system and the air damps the vibration
and slows it.
When using vibration data, especially in conjunction with modelling systems, the
measured data is often needed as an acceleration, as a velocity and as a displacement. Sometimes
different analysis groups require the measured signals in a different form. Clearly, it is
impractical to measure all three at once even if we could. Physically it is nigh on impossible to
put three different types of transducer in the same place.

 FREQUENCY:
Frequency is define as the number of cycles happen in a second. it is measured in
hertz(HZ).Frequency is denoted by “F”.
1
𝐹=
T
Where,T= Period(Time required to complete one cycle)
Frequency and period are reciprocal to each other.
 AMPLITUDE:
Amplitude is a measures of how big the wave is. Two waves might have same frequency
and period ,but the amplitude of the waves can be very different. Amplitude is measured in the
form of meter(m) or millimeter(mm).it is denoted by “A”.
 DISPLACEMENT:
Displacement is a vector which points from the initial position of an object to its final
positionDisplacement of of the object at any point in its oscillation using the equation below.

X=Acos2πFt
Where,X=Displacement in m or mm
A= Amplitude in m or mm
F=Frequency of oscillation or wave
t =time since the oscillation began.
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 VELOCITY:
Velocity is defined as the distance travel by a wave in a certain time in a specific direction.
The velocity of the object at any point in its oscillation can be calculated using the equation.

V=-ωAsinωt
Where, v=velocity in m/s or mm/s.
ω=Angular velocity.

 ACCELERATION:
Acceleration is define as the change of velocity per second(time).acceleration of the object
at any point in its oscillation can be calculated using the equation,
a = -ω2Acosωt

4.2 VIBRATION CONTROL

The vibration can sometimes be eliminated on the basis of theoretical analysis. However,
in eliminating the vibration may be too high. Therefore, a designer must compromise the
manufacturing costs involved between an acceptable amount of vibration and a reasonable
manufacturing cost. The following steps may be taken to control vibrations :

(a) The first group of methods attempts to reduce the excitation level at the source. The
balancing of inertial forces, smoothening of fluid flows and proper lubrication at joints are
effective methods and should be applied whenever possible.
(b) A suitable modification of parameters may also reduce the excitation level. The system
parameters namely inertia, stiffness and damping are suitably chosen or modified to
reduce the response to a given excitation.
(c) In this method, transmission of path of vibration is modified. It is popularly known as
vibration isolation.
As mentioned above, the first attempt is made to reduce vibration at the source. In some
cases, this can be easily achieved by either balancing or an increase in the precision of machine
element. The use of close tolerances and better surface finish for machine parts make the machine
less susceptible to vibration. This method may not be feasible in some cases like earthquake
excitation, atmospheric turbulence, road roughness, engine combustion instability.After reduction
of excitation at the source, we need to look for a method to further control the vibration. Such a
selection is guided by the factors predominantly governing the vibration level.

4.3 HOW TO MEASURE VIBRATION IN INDUSTRIES

Industrial vibration analysis is a measurement tool used to identify, predict, and prevent
failures in rotating machinery. Implementing vibration analysis on the machines will improve the
reliability of the machines and lead to better machine efficiency and reduced down time
eliminating mechanical or electrical failures. Vibration analysis programs are used throughout
industry worldwide to identify faults in machinery, plan machinery repairs, and keep machinery
functioning for as long as possible without failure.
Typical machines include motors, pumps, fans, gear boxes, compressors, turbines,
conveyors, rollers, engines, and machine tools that have rotational elements. The rotating
elements of these machines generate vibrations at specific frequencies that identify the rotating
elements. The amplitude of the vibration indicates the performance or quality of machine. An

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increase in the vibration amplitude is a direct result of failing rotational elements such as bearings
or gears. Based on the machine speed, the rotational frequencies can be calculated and compared
to the measurements to identify the failure mode.

4.3.1 INDUSTRIAL VIBRATION SENSORS

The practice of Vibration Analysis does require the measurement and analysis of rotating
machines utilizing different vibration sensors (accelerometers, velocity transducers, or
displacement probes). The most common sensor used in industry is the accelerometer.
Accelerometers are case mounted using a permanent bolt or portable magnet to hold them
in place. They will measure the vibration of the machine and output a voltage or current
proportional to the vibration and relative to a “g” level (unit of gravitational pull). This signal can
also be integrated to provide a measured output of velocity (inches/second or mm/second). It is
very important to choose the correct accelerometer, cable, connector, and mounting method for
each application. This will provide quality measurements and accurate vibration data for
identifying faults in rotating machinery. Sleeve bearing applications require displacement probes
to measure the actual movement of the shaft inside the sleeve bearing. These non-contact probes
measure the vibration of the shaft and the gap between the shaft and the internal diameter of the
bearing. Using an eddy current process, these probes will provide an output voltage proportional
to displacement (inches or mm).

4.3.2 DYNAMIC VIBRATION ANALYSIS:

The measurement and analysis of dynamic vibration involves accelerometers to measure
the vibration, and a data collector or dynamic signal analyzer to collect the data. Analysis is
usually completed by a technician or engineer trained in the field of rotating machinery vibration.
The plots of amplitude vs. time, (Time Waveform) and amplitude vs. frequency (FFT) are
required for the trained technician or engineer to analyze and determine the machine fault. Since
each rotating element generates an identifying frequency, analyzing the frequency disturbances
will identify the faulty element. Once the fault is identified, parts can be ordered and repairs can
be scheduled. Dynamic vibration analysis can be accomplished in several different manners.
1. Portable sensors and portable data collection following a predetermined route of
machinery measurements.
2. Permanent sensors and portable data collection following a predetermined route of
machinery measurements.
3. Permanent sensors and permanent data collection that provides machinery protection 24
hours/day, 7 days/week, 52 weeks/year.

4.3.3 PROCESS VIBRATION ALARMS:

A recent development in the predictive maintenance and reliability market is to leverage
the investment already made in process control systems (PLC, DCS, & SCADA). This allows the
operations, maintenance, and process control teams to monitor and alarm vibration levels on
critical machines. Using a standard 4-20 mA output, the loop power vibration transmitters and
sensors provide a current output proportional to the overall value of the machine vibration. This is
not a dynamic analog signal, and it cannot be used to analyze the machine fault, but it can be used
to alarm the machine and indicate when vibration levels are too high. When high vibrations are
measured by the process control system, action can be initiated to determine the cause of the
vibration or shut the machine down to prevent damage and failure.
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Loop power 4-20 mA outputs can be achieved using three different methods.
1. A dynamic accelerometer with a 100 mV/g analog output can be connected to a
transmitter. The transmitter provides signal conditioning and a 4-20 Ma current
output proportional to vibration. It offers several different frequency filters to
alarm the region of interest. The dynamic signal, 100 mV/g, is also available for
the trained technician or engineer to analyze.
2. A loop power sensor with a direct 4-20 mA output can also be used. This sensor
does not require a transmitter, but the frequency filters are limited to 10 – 1000 Hz
and 3 – 2500 Hz.
3. A dual output loop power sensor with a direct 4-20 mA output and secondary 100
mV/g dynamic output can also be used. This sensor does not require a transmitter,
but the frequency filters are limited to 10– 1000 Hz and 3 – 2500 Hz. It does have
the dynamic signal, 100 mV/g, available for the trained technician or engineer to
analyze.

No matter what method you choose, standard 4-20 mA outputs proportional to machine
vibration are available for process control. This allows the factory to leverage typical process
control monitoring methods and alarm schemes. Convenient alarms for critical machines.

4.4 FAULTS IDENTIFIED BY VIBRATION ANALYSIS:

There are several faults in rotating machinery that can be identified by measuring and analyzing
the vibration generated by the machine.
1. Machine out of balance
2. Machine out of alignment
3. Resonance
4. Bent shafts
5. Gear mesh disturbances
6. Blade pass disturbances
7. Vane pass disturbances
8. Recirculation & Cavitations
9. Motor faults (rotor & stator)
10. Bearing failures
11. Mechanical looseness
12. Critical machine speeds.

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5. FINITE ELEMENT ANALYSIS

Finite element analysis (FEA) is the modeling of products and systems in a virtual
environment, for the purpose of finding and solving potential (or existing) structural or
performance issues. FEA is the practical application of the finite element method (FEM), which is
used by engineers and scientist to mathematically model and numerically solve very complex
structural, fluid, and multi physics problems. FEA software can be utilized in a wide range of
industries, but is most commonly used in the aeronautical, biomechanical and automotive
industries.
A finite element (FE) model comprises a system of points, called “nodes”, which form the
shape of the design. Connected to these nodes are the finite elements themselves which form the
finite element mesh and contain the material and structural properties of the model, defining how
it will react to certain conditions. The density of the finite element mesh may vary throughout the
material, depending on the anticipated change in stress levels of a particular area. Regions that
experience high changes in stress usually require a higher mesh density than those that experience
little or no stress variation. Points of interest may include fracture points of previously tested
material, fillets, corners, complex detail, and high-stress areas.
FE models can be created using one-dimensional (1D beam), two-dimensional (2D shell)
or three-dimensional (3D solid) elements. By using beams and shells instead of solid elements, a
representative model can be created using fewer nodes without compromising accuracy. Each
modeling scheme requires a different range of properties to be defined, such as:

1. Section areas
2. Moments of inertia
3. Torsional constant
4. Plate thickness
5. Bending stiffness
6. Transverse shear
To simulate the effects of real-world working environments in FEA, various load types
can be applied to the FE model, including:

1. Nodal: forces, moments, displacements, velocities, accelerations, temperature and heat

flux
2. Elemental: distributed loading, pressure, temperature and heat flux
3. Acceleration body loads (gravity)

5.1 BENEFITS OF FEA

FEA can be used in new product design, or to refine an existing product, to ensure that the
design will be able to perform to specifications prior to manufacturing. With FEA you can:

1. Predict and improve product performance and reliability

2. Reduce physical prototyping and testing
3. Evaluate different designs and materials
4. Optimize designs and reduce material usage

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5.2 MODAL ANALYSIS

Any physical system can vibrate. The frequencies at which vibration naturally occurs, and
the modal shapes which the vibrating system assumes are properties of the system, and can be
determined analytically using Modal Analysis.
Detailed modal analysis determines the fundamental vibration mode shapes and
corresponding frequencies. This can be relatively simple for basic components of a simple
system, and extremely complicated when qualifying a complex mechanical device or a
complicated structure exposed to periodic wind loading. These systems require accurate
determination of natural frequencies and mode shapes using techniques such as Finite Element
Analysis.
Four main steps in a modal analysis:
• Build the model
• Choose analysis type and options
• Apply boundary conditions and solve
• Review results

5.3 BENEFITS OF MODAL ANALYSIS

• Allows the design to avoid resonant vibrations or to vibrate at a specified frequency
(speakers, for example).
• Gives engineers an idea of how the design will respond to different types of dynamic
loads.
• Helps in calculating solution controls (time steps, etc.) for other dynamic analyses.

5.4 STEPS FOR MODAL ANALYSIS

1. For model analysis ANSYS workbench is required.
2. In ANSYS workbench select model(ANSYS) option in toolbox and drag and drop it in
work area.
3. Enter material properties in engineering data editing.
4. Import geometry in geometry option and then update your project so right tick mark
will appear in all six option boxes.
5. Right click in model option and select edit option so mechanical editor will open
which shows imported geometry.
6. Mesh imported geometry.
7. Apply boundary condition and loading.
8. Select number of modes required and then solve the project by right clicking on
solution option and then select create mode shape result of total deformation.

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5.5 MODELING OF GEAR HOUSING COMPONENTS

5.5.1 BOWL

FIG : 4 BOWL 2D

FIG 5 : BOWL 3D

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5.5.2 BOWL HUB

FIG 6 : BOWL HUB 2D

FIG 7 : BOWL HUB 3D

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5.5.3 WORM GEAR HUB

FIG 8 : GEAR HUB 2D

FIG 9 : GEAR HUB 3D

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5.5.4 SKIRT ASSEMBLY

FIG 10 : SKIRT ASSEMBLY(SEGMENT)2D

FIG 11 : SKIRT ASSEMBLY 3D

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5.5.5 BOWL HUB COVER

FIG 12 : BOWL HUB COVER 2D

FIG 13:BOWL HUB COVER 3D

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5.5.6 GEAR HUB KEY

FIG 14 :GEAR HUB KEY 2D

FIG 15:GEAR HUB KEY 3D

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5.5.7 LOCK NUT

FIG 16:LOCK NUT 2D

FIG 17:LOCK NUT 3D

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5.5.8 OIL COLLECTOR

FIG 18:OIL COLLECTOR 2D

FIG 19:OIL COLLECTOR 3D

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5.5.9 OIL PUMP BUSHING

FIG 20:OIL PUMP BUSHING 2D

FIG 21:OIL PUMP BUSHING 3D

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5.5.10 OIL PUMP KEY

FIG 22:OIL PUMP KEY 2D

FIG 23:OIL PUMP KEY 3D

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5.5.11 SPLIT DUST GUARD

FIG 24:SPLIT DUST GUARD 2D

FIG 25:SPLIT DUST GUARD 3D

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5.5.12 THRUST BEARING ADAPTOR

FIG 26:THRUST BEARING ADAPTOR 2D

FIG 27:THRUST BEARING ADAPTOR 3D

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5.5.13 UPPER BEARING HOUSING

FIG 28:UPPER BEARING HOUSING 2D

FIG 29:UPPER BEARING HOUSING 3D

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5.5.14 UPPER BEARING HOUSING COVER

FIG 30:UPPER BEARING HOUSING COVER 2D

FIG 31:UPPER BEARING HOUSING COVER 3D

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5.5.15 WEAR PLATE

FIG 32:WEAR PLATE 2D

FIG 33:WEAR PLATE 3D

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6.CONCLUSION

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