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Condition Monitoring visit summary

Feb-14
Sr

Area

LineI
L/s Crusher

Equipment

Remarks of M/s Action taken by


PM Remarks
DNPER
BCL

LineI
Clay Crusher

Remarks of M/s
DNPER

Action taken by
BCL

May-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Jul-14
PM Remarks

Q5M1 (L/S
Inclined Belt)

Gear mesh frequency of


Gear on shaft #01 with
R2AFC
side bands appears which
L# 1- Lime Stone
Limestone Stacker shows Gear problem.
Yard
Boom Belt
High vibration is
observed in axial
directions of Gear teeth.

LineI
L/s Crusher

Mar-14

Gear mesh frequencies with side


bands appear which shows Gear
problem. High vibration is
observed in axial directions of
Gear teeth. Exact problem could
not be identified as no details i.e.
bearing # and gear teeth on each
shaft are provided for Gear box.
The data reveals that there may
be eccentricity and backlash
problem in shaft #01 of Gear
box.Visual Inspection should be
carried out to confirm the
problem of severe nature

Gearbox visual
inspection carried out. No
physical damage on gears
was observed.
Gear Teeth and bearing
data has been sent to M/s
DNPER alongwith the
snaps of mating gears.

R3M2
L/s Stacker belt

High vibration is observed on


motor drive end and non drive
end; possible reason may be
Alignment checked and
due to misalignment of motor
found ok. Teflon pins
and G/Box. Check the
were replaced.
equipment for misalignment
on next scheduled
maintenance.

V4M
Clay Crusher
rotor#01

High Vibration is observed on


crusher side. Visual
inspection reveals server
componet looseness in
addition to slight woblling in
crusher side pulley. High gE Bearing replaced and
on crusher bearing is
now vibration reduced
observed. Check componet
significantly.
looseness and bearing for
remedial action. Bearing
should be checked and
replaced on next scheduled
maintenance.

Overall vibration reduce


now

High Vibration is observed on


crusher side. Visual
inspection reveals server
componet looseness in
Bearing will be replaced
addition to slight woblling in
upto
crusher side pulley. Check
25-6-14
component looseness and
pulley alignment.. Also check
centre of pulley either ecentric
or titled.

NDE Bearing
Replacement and
looseness rectifiction
work in progress .

High Vibration in axial


direction may be due to slight Alignment checked and
misalignment. Check
found ok. Teflon pins
alignment on next scheduled were replaced.
maintenance.

Vibration reduce now

High vibration observed


in axial crusher outboard,
most probably it is due to
key loose in the keyway
or belt wear.

LineI
Clay Crusher

V5M
Clay Crusher
rotor#02

LineI
Clay Crusher

V6M
Clay Crusher
Feeding Belt

High vibration observed


due to structural
looseness and soft foot
problem.

W12M
L# 1- Clay Yard Clay Crusher
Outlet Belt

The high values in axial


directions in Gear box
reveal that Misalignment
is observed in Gear
shaft#01 and Gear shaft
#02.

High values of vibration reveal


that there is component looseness
problem in gear box.Most
probably bearing is loose in the
housing and it should be checked
in the next maintenance
schedule.

No observation damage
was found through
gearbox inspection door.
Through inspection will
be carried out during any
opportunity stoppages or
planned stoppage.

Remarks of M/s
DNPER

Sep-14
PM Remarks

Slight high vibration is


observed on motor side.
Slight misalignment is
suspected.Check
Misalignment on next
scheduled maintenance.

Alignment checked and Vibration reduce after


found ok. Worn coupling replacement of coupling
pins replaced.
pin .

Gear mesh frequencies


with side bands are
appearing. Bearing
frequencies on gear
shaft#1 are also dominant
which means bearing
problem is initiated.
Bearings on shaft #1 may
be checked on next
scheduled maintenance.

Checked and 0.5 mm


shim placed to restrict
any movement of outer
race of bearing at input
shaft, as alight rolling
marks observed.

Remarks of M/s
DNPER

Action taken by
BCL

Vibration has increased on the


equipment it might be due to
excessive bearing clearing on the
Shaft # 1 which caused the shaft
to be unparallel and as a result
Vibration same as before
Checked and found
gear eccentricity has occurred.
.
normal.
Recommendations:
Bearings clearance of gear shaft
may be checked and restricted
within standards in the next
stoppage.

PM Remarks

High vibration on gear


box at drive end and non
drive end Pionion gear
bearings also loose on
housing .

Motor vibration same as


before .

High vibration is
observed on crusher side.
High vibration on
Checked and no
Crusher Axial side is due
abnormality found.
to wobbling of
pulley.Pulley may be
checked.

Vibration still as same

Observations:
Vibration values are high on the
crusher side which may be due to
misalignment.
Alignment check found
ok.
Recommendations:
Alignment of the pullies may be
checked in the next scheduled
maintenance.

Observations:
Vibration values are high on the
crusher side which may be due to
misalignment. Bearing fault has
also initiated on the crusher side.
Recommendations:
Alignment of the pullies may be
checked in the next scheduled
maintenance.

High values of vibration


reveal that there is
backlash in gear
box.Gearbox may be
checked during next
scheduled maintenance.

1 of 9

Action taken by
BCL

Gearbox checked and


found ok. However input
shaft bearings will be
replaced upto 30.11.14

High vibration on crusher


bearings due to bearings
clearance has increase .

High vibration and high


Bearing clearance has
abnrmal sound on drive
increased and its
end bearing .Mechanical
replacement is scheduled
depertment replaced the
upto 15.12.14
bearing one week .

Vibration and abnormal


sound is still there., I/p
shaft bearings will be
replaced .

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Feb-14
Sr

Area

Line I
Packing Plant

Line I
Packing Plant

Equipment

Remarks of M/s Action taken by


PM Remarks
DNPER
BCL

Line II
Packing Plant

N57M
B/E(Grid station
side)

11

Line II
Packing Plant

N58M
B/E(Line I side)

Vibration in vertical
direction on motor side is
Will be attended in
high due to soft foot
next shutdown.
issue.Check and remove
soft foot.

Action taken by
BCL

High vibration is observed on


motor side. Visual
observations reveal slight
wobbling in coupling.
Possible reasons of high
vibration are coupling
eccentricity, soft foot and
slight misalignment. Check
the alignment, soft foot and
coupling.

Jul-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Sep-14
PM Remarks

Line I
2M13M (System
Cement Mill#02 Fan-2)

High horizontal vibration


on 1xRPM in motor
inboard, motor outboard,
fan inboard and fan
outboard. Possible cause
may be unbalance.

L # 11- Cement
Mill # 4

2M13M
System Fan

High vibration is
observed on Fan inboard
horizontal side.

High observation is
observed on the
equipment. Possible
reason may be soft foot.
Check soft foot in next
scheduled maintenance.

Bearings of ist stage


pinion of main G/box
were replaced. Rubber
buffer replaced.
Alignment and soft foot
checked. Further,
Overhauling of motor is
required.

Profile of the fan


becomes mismatched
with the design profile
and Fan \Inboard bearing
outer race is damaged.
Impeller of the fan may
be replaced.

Bearing inspection was


jointly done. The outer
race is found with out
any breakage/crack. Any Bearing was inspected
how bearing clearance
outer race was ok.
was checked (0.20 mm)
which is higher than 0.12
~ 0.16 mm.

Vibration still as before

Remarks of M/s
DNPER

Action taken by
BCL

PM Remarks

Observations:
High vibration is observed which
may be due to soft foot.
Will be checked in next
Recommendations:
possible shutdown.
Soft foot of motor and gearbox
may be checked in next scheduled
maintenance.

After maintenance
Vibration same.

Observation:
High vibration is observed on the
equipment which may be due to
gear.
Bearings of ist stage
pinion were replaced.
Recommendations:
Gear data may be provided so
that detailed analysis may be
performed.

After maintenance
Vibration same.

Observations:
Vibration is slightly high on the
fan inboard horizontal which may
be due to fan unbalance.
Will be done in this
shutdown.
Recommendations:
Balancing of the fan may be
carried out in next scheduled
maintenance

Balancing carried out


Vibration reduced H=0.9.

Alginment done, soft


footing was removed
But motor vibration same
coupling may be replaced
as .
in next possible
shutdown.

High Vibration on fan inboard


horizontal side may be due to
Alginment checked and
unbalance. Unbalance may be
found ok.
checked on next scheduled
maintenance.

1M13M
System Fan

16

Remarks of M/s
DNPER

Line I
1M13M (System
Cement Mill#01 Fan-1)

L # 11- Cement
14
Mill # 3

15

May-14
PM Remarks

N58M (Bucket
Elevator)

10

13

Action taken by
BCL

N57M (Bucket
Elevator)

Vibration in vertical
direction on motor side is
Will be attended in
high due to soft foot
next shutdown.
issue.Check and remove
soft foot.

12

Mar-14
Remarks of M/s
DNPER

Vibration in range now

All vibration values are


in normal range.No
immediate action
required.

Ok

Keeping in view of the


previous and current
vibration survey of the
machine, it is observed
that no maintenance work
has been made so for,
Vibration reduce after
Universal shafts replaced
therefore, the vibration
replacement of universal
with new ones
data is same as previous
shaft. .
survey.For
recommendation about
this equipment, please
refer to vibration report
for May-July, 2014.

Line 1
1M22M-01CMCement Mill#01 RP(Mov.)

2 of 9

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Feb-14
Sr

17

18

19

20

21

Area

Equipment

Remarks of M/s Action taken by


PM Remarks
DNPER
BCL

Mar-14
Remarks of M/s
DNPER

Action taken by
BCL

May-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Jul-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Sep-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

PM Remarks

Keeping in view of the


previous and current
vibration survey of the
machine, it is observed
that no maintenance work
has been made so for,
Vibration reduce after
Universal shafts replaced
therefore, the vibration
replacement of universal
with new ones
data is same as previous
shaft. .
survey.For
recommendation about
this equipment, please
refer to vibration report
for May-July, 2014.

Line 1
1M23M-01CMCement Mill#01 RP(Fix.)

1. The input shaft of the gearbox


has been stressed under load
condition. The shaft become
eccentric when load applied and
at no load condition the stresses
New European universal
has been released. This
shaft are being procured
phenomena my increase the
to resolve the issue.
vibration at 1xRPM of the shaft.
2. The other reason could be the
input shaft is unsupported at
motor side

Line 1
2M22M-02CMCement Mill#02 RP(Mov.)

1. The input shaft of the gearbox


has been stressed under load
condition. The shaft become
eccentric when load applied and
at no load condition the stresses
New European universal
has been released. This
shaft are being procured
phenomena my increase the
to resolve the issue.
vibration at 1xRPM of the shaft.
2. The other reason could be the
input shaft is unsupported at
motor side.

Line 1
2M23M-02CMCement Mill#02 RP(Fix.)

Line II
1M22M-03CMCement Mill#03 RP(Mov.)

1. The input shaft of the


gearbox has been stressed
under load condition. The
shaft become eccentric
when load applied and at
no load condition the
stresses has been
released. This phenomena
my increase the vibration
at 1xRPM of the shaft.

Line II
1M23M-03CMCement Mill#03 RP(Fix.)

High vibration in gear


shaft #01 is due to under
stress during load
condition; however GMF
of input and output has
also been appeared which
is a sign of Gear wear
problem.

1. The input shaft of the gearbox


has been stressed under load
condition. The shaft become
eccentric when load applied and
at no load condition the stresses
New European universal
has been released. This
shaft are being procured
phenomena my increase the
to resolve the issue.
vibration at 1xRPM of the shaft.
2. The other reason could be the
input shaft is unsupported at
motor side.

1. The input shaft of the gearbox


has been stressed under load
condition. The shaft become
eccentric when load applied and
at no load condition the stresses
New European universal
has been released. This
shaft are being procured
phenomena my increase the
to resolve the issue.
vibration at 1xRPM of the shaft.
2. The other reason could be the
input shaft is unsupported at
motor side.

Support structure for the


Universal shafts have
G/Box may be strenthened so
been sent for repair. New Vibration same as
that the vibration transmission
indented
could stop.

Keeping in view of the


previous and current
vibration survey of the
machine, it is observed
that no maintenance work
has been made so for,
therefore, the vibration
data is same as previous
survey.For
recommendation about
this equipment, please
refer to vibration report
for May-July, 2014.

Observations:
Keeping in view of the previous
and current vibration survey of
the machine, it is observed that no
maintenance work has been made
so for, therefore, the vibration
01 Universal shaft
data is same as previous survey. replaced.
Recommendations:
For recommendation about this
equipment, please refer to
vibration report for May-July,
2014.

After maintenance
Vibration Slightly
reduced.

Support structure for the


Universal shafts have
G/Box may be strenthened so
been sent for repair. New Vibration same as
that the vibration transmission
indented
could stop.

Keeping in view of the


previous and current
vibration survey of the
machine, it is observed
that no maintenance work
has been made so for,
therefore, the vibration
data is same as previous
survey.For
recommendation about
this equipment, please
refer to vibration report
for May-July, 2014.

Observations:
Keeping in view of the previous
and current vibration survey of
the machine, it is observed that no
maintenance work has been made
so for, therefore, the vibration
01 Universal shaft
data is same as previous survey. replaced.
Recommendations:
For recommendation about this
equipment, please refer to
vibration report for May-July,
2014.

After maintenance
Vibration Slightly
reduced.

Support structure for the


Universal shafts have
G/Box may be strenthened so
been sent for repair. New Vibration same as
that the vibration transmission
indented
could stop.

Support structure for the


Universal shafts have
G/Box may be strenthened so
been sent for repair. New Vibration same as
that the vibration transmission
indented
could stop.

3 of 9

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Feb-14
Sr

22

23

25

26

Area

Equipment

Remarks of M/s Action taken by


PM Remarks
DNPER
BCL

Mar-14
Remarks of M/s
DNPER

Action taken by
BCL

May-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Jul-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Sep-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

PM Remarks

Support structure for the


Universal shafts have
G/Box may be strenthened so
been sent for repair. New Vibration same as
that the vibration transmission
indented
could stop.

Keeping in view of the


previous and current
vibration survey of the
machine, it is observed
that no maintenance work
has been made so for,
Both sides universal
therefore, the vibration
shafts replaced with new
data is same as previous ones on 19.08.14.
survey.For
recommendation about
this equipment, please
refer to vibration report
for May-July, 2014.

Observation:
Vibration is reduced 3-4 times
after replacing the shaft but still
Vibration reduce after
vibration is slightly high on
replacement of universal inboard shaft of gear box.
shaft. .
Recommendations:
Trending is necessary so that if
any change in vibration, the
measures may be taken on time.

Decision will be taken

Vibration Ok.

Support structure for the


Universal shafts have
G/Box may be strenthened so
been sent for repair. New Vibration same as
that the vibration transmission
indented
could stop.

Keeping in view of the


previous and current
vibration survey of the
machine, it is observed
that no maintenance work
has been made so for,
Both sides universal
therefore, the vibration
shafts replaced with new
data is same as previous ones on 19.08.14.
survey.For
recommendation about
this equipment, please
refer to vibration report
for May-July, 2014.

Observation:
Vibration is reduced 3-4 times
after replacing the shaft but still
Vibration reduce after
vibration is slightly high on
replacement of universal inboard shaft of gear box.
shaft. .
Recommendations:
Trending is necessary so that if
any change in vibration, the
measures may be taken on time

Decision will be taken

Vibration Ok.

Line I
1M29M-01CM
Cement Mill#01 (Feeding B/E)

Structure of the motor is


uneven and also motor
and gearbox is
misaligned. Soft foot may
Will be completed upto
also be present in the
21.09.14
equipment. Soft Foot of
the equipment may be
removed and alignment
may be done.

Not completed by mech


department.

Line I
1M30M-01CM
Cement Mill#01 (Feeding B/E)

High vibration is
observed on the motor
and on first shaft in
vertical direction. It may Will be completed upto
be due to structural
21.09.14
vibration. Structure may
be strengthened to dump
the vibration.

Not completed by mech


department.

Line II
2M22M-04CMCement Mill#04 RP(Mov.)

1.The input shaft of the


gearbox has been stressed
under load condition. The
shaft become eccentric
when load applied and at
no load condition the
stresses has been
released. This phenomena
my increase the vibration
at 1xRPM of the shaft.

Line II
2M23M-04CMCement Mill#04 RP(Fix.)

High vibration in gear


shaft #01 is due to under
stress during load
condition; however GMF
of input and output has
also been appeared which
is a sign of Gear wear
problem.

L# 1- Cement
28
Mill # 2

2M30M
Bucket
Elevator(Mill no1
side)

1M29M-03CM
Line 2
29
(Feeding B/E)
Cement Mill#03
(CCR side)

Observations:
Slight high vibration is observed
on the equipment.
Recommendations:
Checked found ok.
Soft foot of gear box and
alignment of gearbox with bucket
elevator may be checked

All values are in normal range,


high Gs values are appearing on
shafts of gear box.Bearings may
be checked in the next scheduled
maintenance.

2M29M-02CM
Line 1
27
(Feeding B/E)
Cement Mill#02
Road side

High vibration in motor


side is due to structure
looseness and soft foot.
Bearings on shaft #04 are
deteriorated. Bearing
deterioration is on 3rd
stage.

Bearing frequencies are appeared


and the vibration is high on
motor side as well.Check
bearings on gear shaft #01 and
03.

High vibration on motor side


is observed. To ascertain
electrical, mechanical and
structural problems, it is
High structural vibration. No any work done
recommended that thee spare
motor may be installed before
next data collection visit.

It has been found that the mating


gear on shaft #02, and shaft #03
have excessive clearance due to
which the respective bearings are
under stressed. The bearing
condition is at stage 1 and the
machine may be operated for
next maintenance schedule.

The most probable cause of


the high vibration on shaft#03
and shaft#04 is shaft
Complete dismantling is
eccentricity. Output gear of
required for eccentricity
shaft#03 and input gear on
inspection.
shaft#04 may be checked for
eccentricity.

4 of 9

Shutdown job

Observation:
Detail analysis is performed on
the acquired vibration data. It is
suggested that gearbox may be
uncoupled from the bucket
elevator and vibration data may
be repeated for confirmation of
fault diagnosed so far.

Ok

Will be done upto


5.11.14

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Feb-14
Sr

30

31

Area

Equipment

1M30M
Line 2
Feeding B/E
Cement Mill#03
Mill no 4 side

2M29M-04CM
Line 2
(Feeding B/E)
Cement Mill#04
Road side

32

2M30M-04CM
Line 2
(Feeding B/E)
Cement Mill#04
CCR side.

33

Line I
2M19M
Cement Mill#02 CM Main Drive

Line 1
34
Cement Mills

Remarks of M/s Action taken by


PM Remarks
DNPER
BCL

Action taken by
BCL

May-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Jul-14
PM Remarks

Remarks of M/s
DNPER

Values are slightly above


range on motor outboard
Axial which may be due
to slightly misalignment.

High vibration is observed on


both driving unit B/E 1M29M03 CCR side and 1M30M-03
Road side. The possible
reasons of the vibration are as
follows
1) Gear Eccentricity.
There is structural
2) Gear Loose on shaft.
vibration in system.
3) Weak structure / structural
vibration
Output Gear of shaft#03 and
input gear on shaft#04 may
be checked for eccentricity.
Structure may be strenthened.

Structural vibration same


before

High vibration on motor


outboard vertical side is
due to looseness of bolts.

All values are in normal


range, however a little high
vibration in vertical direction There is structural
is observed due to structure
vibration in system.
looseness. Structure may be
strenthened.

Slight high vibration on


motor is due to structure
looseness whereas
Structural vibration same vibration on the gearbox
before
is slightly increased.
Looseness problem may
be removed in the next
scheduled maintenance.

High vibration is
observed due to
Misalignment and soft
foot problem.

High vibration on motor side


is due to looseness and
structural improper design.
Structure is unsupported
which is unable to dump the
vibration.

Slight high vibration on


motor is due to structure
looseness whereas
Structural vibration same vibration on the gearbox
before
is slightly increased.
Looseness problem may
be removed in the next
scheduled maintenance.

There is structural
vibration in system.

Action taken by
BCL

Sep-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

PM Remarks

Retightening of bolts
done on 04.09.14

Observation:
Vibration is slightly high on
motor side. It may be due to slight
looseness; however vibration on
Minner Vibration reduce
gear box is normal.
Ok
.
Recommendations:
Visual inspection may be carried
out; bolts may be checked for
retightening.

Ok

Retightening of bolts
done on 04.09.14

Observation:
After taking the corrective action
by BCL, Vibration is reduced
appreciably as compare to
Minner Vibration reduce previous data and almost within
Ok
.
limit however gear frequencies
can be seen in the spectrum.
Recommendations:
On next maintenance schedule,
gear meshing may be checked.

Ok

All vibration values are in


normal range.No immediate
action required.

L9AC
Clinker Belt
Conveyor

High vibration at 1x rpm


is observed on whole
machine. The possible
reason would be
structural looseness/ soft
foot.

35

L # 1-Clinker
Doom

H17M
Belt Conveyor

High 2x vibration in
Motor Outboard Axial &
Motor Inboard Axial is
observed which reveals
Misalignment problem.

36

L# 1-Clinker
Doom

H15M
Belt Conveyor

High 2x vibration in
Motor Outboard Axial &
Motor Inboard Axial is
observed which reveals
Misalignment problem.

Line 1
37
Raw Mill

Mar-14
Remarks of M/s
DNPER

High values are observed in


Axial direction of gear box along
with radial due to foot of motor
and misalignment of gears.Soft
foot Alignment between motor
and gear may be checked
removed.

Gearbox will be replaced


in next stoppage. Proper
alignment will be carried
out to address the issue.

High vibratin is on motor and


Gear unit. Highly structural
vibration is observed in
addition to modulating sound
in G/Box. Possible reasons
are misalignment and
structural problems.
Algnment of the equipment
may be checked on next
shutdown.

Spare G/Box has been


moved to area.
Alignment will be
checked in next
shutdown.

Vibration same and


motor and gear not
replaced .

Observations:
High vibration is on the motor
and gear unit. Highly structural
vibration is observed in addition
to modulating sound in gearbox.
The reason for the high vibration
may be due to soft foot,
Will be checked in next
misalignment and looseness.
shutdown.
Recommendations:
Soft foot of both motor and gear
box, structural looseness and
misalignment may be checked in
next stoppage. Also gear details
may be provided for more
detailed analysis of gearbox

Observations:
Slight high vibration is observed
on the equipment which may be
due to misalignment and
component looseness.
Recommendations:
Alignment and component
looseness on the equipment may
be checked in next scheduled
maintenance.

The high vibration in


B49M
axial direction is due to
Raw Mill Feed belt excessive gear clearance
at shaft # 02.

5 of 9

Discussed with M/s


DNPER, they asked to
provide drawing for
structural modifications.
Accordingly
reinforcement will be
done.

Alignment coorected.

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Feb-14
Sr

38

Area

Line II
Raw Mill

Line 1
39
Raw Mill

40 L# II- Raw Mill

Equipment

Remarks of M/s Action taken by


PM Remarks
DNPER
BCL

Action taken by
BCL

Action taken by
BCL

Jul-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Sep-14
PM Remarks

Remarks of M/s
DNPER

Work in progress for modal


analysis in ANSYS.

The high vibration in radial and


axial directions reveal that there
is hunting tooth problem in gear.
This might be due to
manufacturing fault or
mishandling in the field.Inspect
gear for damage

B72M
Classifier

Inspection carried out, no


physical damage to gears.
Snaps of gears already
sent to M/s DNPER for
comments.

High vibration values are


observed on the equipment.
Whole structure is shaking
Equipment has structural
and vibration is transmitting
vibration.
from the structure to the unit.
Structure may be strengthened
to avoid resonance.

Noise and high temperatures


on shaft 03 and shaft 04 on
gear box are observed through
visual inspection. High
vibration values are due to
misalignment and soft foot
problem. Oil Analysis may be
carried out for metal particles
in oil, soft foot may be
removed and Alignment may
be performed on next
scheduled maintenance.

B06M
CF Silo
Bucket Elevator

42 L# II- Raw Mill

B06M
CF Silo
Bucket Elevator

High vibration on motor side


reveals that there is
Alignment issue resolved
misalignment problem between
soft foot.
the gear and motor.Check
Alignment and remove soft foot.

43 L# II- Raw Mill

B30M
Raw Mill fan

Vibration values are well in


range but high G value observed
in PeakVue at Motor Inboard
Bearing which show
development of bearing fault in
Motor inboard.

44 L# 1- kiln

F19M1
Feeding Bucket
Elevator

45 L# II- Kiln

F19M1
Feeding Bucket
Elevator

Line 1
Kiln

Remarks of M/s
DNPER

The high vibration in


radial and axial
directions reveal that
there is hunting tooth
problem in gear. This
might be due to
manufacturing fault or
mishandling in the field.

41 L# 1- Raw Mill

46

May-14
PM Remarks

Action taken by
BCL

PM Remarks

Base frame of drive is


grouted into concrete
High vibration on motor /shaft is
foundation. Foundation
due to structure/component
bolts are replaced with
looseness.Check structure
higher grade bolts to
looseness.
remove effects of
structural looseness.

B49M
Main Feed belt

B72M
Raw Mill
Classifier

Mar-14
Remarks of M/s
DNPER

The high vibration is


observed due to bearing
loose on shaft.

Alignment and softfoot


checked.Clogged
breather was cleaned and
now temperature is on
lower side.

High vibration values are


observed on the
equipment. Whole
structure is shaking and
vibration is transmitting
from the structure to the
unit. Structure may be
strengthened to avoid
resonance

Discussed with M/s


DNPER, they asked to
provide drawing for
structural modifications.
Accordingly
reinforcement will be
done.

The most probable cause


of high vibration is
misalignment. Check the
equipment for
misalignment in next
scheduled maintenance.

Alignment is acceptable.
Internal inspection of
G/box and lubricant
Alignment done now
replacement along with vibration is OK.
flushing will be carried
out upto 30.09.14

Discussed with M/s


DNPER, they asked to
provide drawing for
structural modifications.
Accordingly
reinforcement will be
done.

Breather was clogged


after cleaning the
breather now the
vibration is OK.

High vibration on out and


inboard bearings.
Gearbox has normal
vibration.
All values are well in range.
Rotor bar frequencies are
appeared however exact problem
Data will be provided by
of the motor could not be
Preventive Maintenance
mentioned due to non providing
for further proceedings.
of motor and gear data by
BCL.No immediate action is
required however trending may
be continued.
Observations:
High vibration is observed on the
equipment which may be due to
misalignment.
In next planned
shutdown.
Recommendations:
Alignment of the equipment may
be checked in the next scheduled
maintenance.

The vibration data of


F31M Cooler fan shows
F31M (PC Burner high vibration on 1x rpm.
Fan)
The values are in alert
level. Unbalance is
suspected.

6 of 9

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Feb-14
Sr

47

48

Area

Line 1
Kiln

Line 1
Kiln

Equipment

Remarks of M/s Action taken by


PM Remarks
DNPER
BCL

Mar-14
Remarks of M/s
DNPER

Action taken by
BCL

May-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Jul-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Sep-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

F32M (PC Burner


Fan)

Observations:
Slightly high vibration is
observed on equipment which
may be due to misalignment and
In next planned
unbalance.
shutdown.
Recommendations:
Misalignment and balancing of
the equipment may be checked in
the next scheduled maintenance.

Kiln Girth Gear

Observations:
Vibration has increased in
trending.
Recommendations:
Gear teeth of both gears (pinion
& Kiln Girth Gear) may be
checked in next stoppage for
tooth wear

In next planned
shutdown.

Vibration on motor side


is normal however high
vibration is observed on
fan side. Most probably
the high vibration is due
to loose/cracked vane of
impeller on a shaft.

High vibration on motor side


is due to Misalignment
problem. Bearing on fan drive
end and non-drive end are in
Will be attended in this
alarming stage.Check
shutdown.
bearings on next scheduled
maintenance. Check
Misalignment as well on next
scheduled maintenance.

Bearings will be done in


this shutdown.

Observations:
High vibration is observed on the
equipment which may be due to
misalignment. Fan bearing
frequencies are also appearing in
In next planned
the spectrum.
shutdown.
Recommendations:
Misalignment of the equipment
may be checked on next
scheduled maintenance. Bearing
of the fan may also be checked.

G11M
Cooler Fan

High vibration in radial


& axial directions reveal
Misalignment between
Fan and Motor.

Vibration values are in


normal range. High G-s
values on fan side are
observed. Spectrum analysis
reveals that bearing fault on
Will be attended in this
fan side has been initiated;
shutdown.
component looseness (like
loose bearing in housing) may
also be present.Check
Bearings on next scheduled
maintenance.

Due to consistent
running, cannot checked.

Observations:
Vibration is high on the
equipment which may be due to
misalignment.
In next planned
shutdown.
Recommendations:
Alignment of the equipment may
be checked in the next scheduled
maintenance.

51 L # 1- Cooler

G17M
Cooler Fan

High peak on higher


frequencies between
1kHz& 2kHz. Possible
reasons may be due to
coincidence of resonance
frequency with the
structural frequency.

52 L # 1- Cooler

G21M
Cooler Fan

High vibration is
observed on 1x and 2x
rpm in radial direction
and 1 rpm in axial
direction which reveals
Misalignment problem in
this equipment.

G23M
Cooler Fan

High vibration is
suspected due to
Misalignment and
looseness. Motor bearing
frequencies are also
present in the spectrum.

All vibration values are in


normal range. Slight
looseness in the structure is
suspected but not in alarming Will be attended in this
stage.Check mechanical
shutdown.
looseness/ cracks in structure
on next scheduled
maintenance.

Due to consistent
running, cannot checked.

High axial vibration is


observed on crusher, Pulley
Misalignment is suspected.

Due to consistent
running, cannot checked.

49

Line 1
Cooler

50 L # 1- Cooler

53 L # 1- Cooler

G10M (Cooler
Fan)

54 L # 1- Cooler

G40M
Clinker Crusher

55 L# II- Cooler

G4M
Cooler EP fan

Bearing frequencies
appeared on motor
outboard position 3rd
stage.
The high vibration in
crusher outboard axial
reveals misalignment.

Will be attended in this


shutdown.

PM Remarks

Values are in normal range,


however bearing on motor
inboard should be under checked Feedback from E, I & C
due to little bit high Gs
required.
value.Trending is required for
early fault detection.

7 of 9

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Feb-14
Sr

Area

Equipment

56 L# II- Cooler

G10M
Cooler fan

57 L# II- Cooler

G11M
Cooler fan

58 L# II- Cooler

Mar-14

Remarks of M/s Action taken by


PM Remarks
DNPER
BCL

Remarks of M/s
DNPER

Action taken by
BCL

60 L# II- Cooler

G23M
Cooler Fan

61 L# II- Cooler

62

Line 1
Coal Mill #01

63 L# 1- Coal Mill

Vibration data is in normal


range, however bearing on Fan
Outboard is in stage two.
Bearing should be checked in
next maintenance schedule.

Jul-14
PM Remarks

Will be attended in next


planned shutdown.

Vibration values are in


normal range whereas high Gs values are observed on fan
side. Bearing fault has been
initiated.Check bearing on
next scheduled maintenance.

Remarks of M/s
DNPER

Action taken by
BCL

Sep-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

PM Remarks

All values except Fan outboard


horizontal are in range. On
motor side, 2x high peaks are
observed which may be due to
misalignment.Check the
equipment for alignment at next
scheduled maintenance.

Slightly high vibration in axial


direction is due to angular
misalignment between
sheaves.Check alignment and
tension of the belt on next
scheduled maintenance.

Alignment of G23M
Cooler Fan and G40M
Clinker Breaker will be
completed in any
stoppages of 02 to 04
hours.

Higher vibration is observed


on the equipment and possible
reasons are angular
Alignment done.
misalignment.Equipment may
be checked for possible
misalignment.

After alignment vabration


is within the range.

Overall vibration is
normal. Bearing
frequencies are appearing
on non drive end of fan
Bearing inspected and no
side. Bearing fault has
abnormality observed.
been initiated. Bearing on
fan non drive end side
may be checked on next
scheduled maintenance.

Cooler fan bearings were


checked. Balls cage are
in normal condition. No
abnormality observed.

High vibration is
observed on the
equipment. Possible
reason for high vibration
may be due to
misalignment. Bearing
frequencies are also
appearing in spectrum of
Alignment checked.
Motor DE, Fan DE and
Fan NDE. Check
Alignment of the
equipment on next
scheduled maintenance,
along with Motor DE,
Fan DE and Fan NDE of
the system.

High vibration is observed on


the equipment. Possible
reason for high vibration may
be due to misalignment.Check
Alignment of the equipment Alignment done and
on next scheduled
coupling buffer replaced.
maintenance, regular
monitoring is recommended
due to slight high Gs value
on fan NDE bearing.

G40M
Clinker Breaker

Now vibration is
dropped.

High vibration on crusher side


in axial direction is observed.
Visual observation reveals
that crusher side pulley is
Alignment of v-belt
wobbling and belts are either pulley checked and found Now vibration is less.
loose or pulleys are
ok.
misaligned.Check pulley for
alignment and crusher pulley
for wobbling.

Higher vibration is
observed on the
equipment and possible
reasons are angular
Alignment checked.
misalignment. Equipment
may be checked for
possible misalignment.

Balancing of G23M may


be done in this shutdown.

High vibration on crusher


side in axial direction is
observed. Visual
observation reveals that
Alignment will be
crusher side pulley is
completed up to
wobbling and belts are
20.09.14.
either loose or pulleys.
Check pulley for
alignment and crusher
pulley for wobbling.

Alignment done and Vbelt replaced.

Observations:
High vibration is observed on the
compressor side which may be
due to misalignment. Bearing
problem may have initiated as
All the bearings were
well.
replaced in previous
Recommendations:
shutdown.
Check the equipment for
misalignment in the next
scheduled maintenance. Bearings
of the compressor may also be
check for any possible fault.

K01M (Roots
Blower)

K1M
Roots Blowe

Action taken by
BCL

High values on motor


drive end in horizontal
and axial direction is due
Alignment done.
to Misalignment problem.
Check and remove
misalignment.

G21M
Cooler Fan

Remarks of M/s
DNPER

All vibration values are in


normal range. Slightly higher
values of G-s are observed.
No immediate action as
No immediate action is
mentioned in report.
required whereas trending is
recommended.

G17M
Cooler Fan

59 L# II- Cooler

May-14
PM Remarks

Overall vibration values


on few locations are high
due to looseness of the
components such that
blower fan.

8 of 9

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Feb-14
Sr

Area

Equipment

Line 2
Coal Mill

K43M
Roots Blower

Line 2
65
Coal Mill #02

K43M (Roots
Blower)

64

Remarks of M/s Action taken by


PM Remarks
DNPER
BCL

Mar-14
Remarks of M/s
DNPER

Action taken by
BCL

May-14
PM Remarks

Remarks of M/s
DNPER
High vibration on male and
female rotor is may be due to
eccentricity between the
rotors.Check male and female
rotor for eccentricity.

Action taken by
BCL

Jul-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Sep-14
PM Remarks

Remarks of M/s
DNPER

Action taken by
BCL

Now vibration is
dropped.

High vibration on male


and female rotor is may
be due to eccentricity
between the rotors. See
Vibration Analysis
Report for May-July
Visit.

All the bearings were


replaced in previous
shutdown.

Now vibration is
marginallay dropped.

31150
(Condensate
Pump)

Observations:
High vibration is observed on
motor side however pump
vibration is normal.
Recommendations:
The motor side vibration may be
due to Bearing Misalignment.
Bearing fitting on motor side may
be checked on next scheduled
maintenance.

69 WHRPP

31151
(Condensate
Pump)

Observations:
High vibration is observed on
motor side however pump
vibration is normal.
Will be checked on next
Recommendations:
The motor side vibration may be maintenance schedule.
due to Bearing Misalignment.
Bearing fitting on motor side may
be checked on next scheduled
maintenance.

70 WHRPP

28.01D
(Compressor
motor

Observations:
Bearing frequencies are
appearing on motor driven side.
Recommendations:
Bearing may be checked on next
scheduled maintenance.

71 WHRPP

Water Pump
35150

68 WHRPP

72 WHRPP

Water Pump
35151

High values of vibration are due


to cavitation problem. Check
impeller for any
erosion/corrosion and metal loss.

Standby pump not ready


due to E, I & C
High values of vibration are due Department.
to cavitation problem. Check
impeller for any
erosion/corrosion and metal loss.
Trending is required.

PM Remarks

Recently Motor bearing


was changed but problem
was in pump. Pump
Vibration is in range
bearing was damaged on now.
28.10.14 and was
changed on 29.10.14.

Vibration is in range
now.

Will be checked on next


maintenance schedule.

Mar

High values of vibration


are due to Cavitation
problem. Check impeller
for any erosion/corrosion
and metal loss.

Mar

9 of 9

Vibration same as .
Pump Off (stand By)

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