King Fahd University of Petroleum and Minerals

Mechanical Engineering Departments

Vibration of Rotating Machinery in Hawiyah Gas Plant

Presented by : Ahmed Al-Jaafari

993714
Advisor : Dr. Meyasser Al-Haddad

October 19,2004

Outline:
Plant

Overview Hawiyah Gas Plant Processes Vibration Group Case Study Conclusion

Hawiyah Gas Plant

Overview:
One of the newest plant.
The first completely non-associated gas plant Completed four months ahead of schedule and under budget Designed and built from scratch to meet the increased local demand for sales gas

Overview:
Feed gas of the plant: Juaf 407 MMSCFD (sweet) Khuff 1305 MMSCFD (sour) Plant production: 1530 MMSCFD sweet gas 50 MMSCFD sulfur Increased the Kingdom's gas supply by 30 %.

Increase capacity 2,400 MMSCFD

HAWIYAH GAS PLANT PROCESSES

SULFUR RECOVERY

50 MMSCFD
Juaf Khuff(Haw) Khuff(Har) INLET AREA 407 MMSCFD

1305 MMSCFD

GAS TREAT

DEHYDRATION & DEW POINT 1225 CONRTOL MMSCFD

50 MMSCFD USES OF PLANT SALES COMPRESSORS 1530 MMSCFD SALES GAS 1587 MMSCFD
SCFD = Standard Cubic Feet per Day

Maintenance Division
Technical Support Unit Planers Work Shop Areas Maintenance Crew

Preventive Maintenance

Vibration Group

Quality Assurance Engineers

Vibration Group Devices and Software:

Data Manager2000 (DM 2000)

ADRE System (Automated Diagnosis for Rotating Equipments)

C.S.I. Machinery Analyzer Computational System( )Incorporated

Data Manager 2000

Vibration Readings

Y A A

Y A
COMPRESSOR

MOTOR

X X

CASE STUDY Bearing Defect:

Bearing Frequencies:
BSF

1. Ball Pass Frequency of Outer race (BPFO)

FTF

2. Ball pass frequency of the Inner race (BPFI)

3. Fundamental Train Frequency (FTF) 4. Ball Spain Frequency (BSF)
BPFO

BPFI

Bearing Frequencies Calculations

1. Bearing Frequency Equations:

RPM = revolutions per minute S = speed, revolutions per second Bd = ball or roller diameter Nb = number of balls or rollers Pd = pitch diameter = contact angle

Bearing Frequencies Calculations

2. Rule of Thumb:

OR = 0.4 x (speed) x N

IR = 0.6 x (speed ) x N
FTF =0.4 x (speed)
Where N is number of balls

Bearing Frequencies Calculations

3. Bearing Frequency Calculator:

Bearing Frequencies Calculations

Example: ( SKF 7311BECBJ)
1. Bearing Frequency Equations: BPFO = 142.125 Hz BPFI = 217.85 Hz FTF = 11.84 Hz BSF = 52.19 Hz
Since: S = 1800 RPM Bd = 0.9474 in Pd = 3.449 in = 40 0 Nb = 12 balls 2. Rule of Thumb:

OR = 0.4 (1800/60) 12= 144 Hz IR = 0.6 (1800/ 60) 12 = 216 Hz FTF = 0.4 (1800/60) = 12 Hz

3. Bearing Frequency Calculator:

(BPFO) = 146.27Hz (BPFI) = 213.73 Hz (FTF) =12.19 Hz (BSF) = 59.17 Hz

Zone A

Failure Modes:
1X 2X 3X

Zone B Zone C Bearing defect Bearing frequency component region natural freq. region

Zone D

Spike energy

Stage 1:
500 2000

20-60 kHz

Stage 2:

Stage 3:
Random high freq. Vibration

Stage 4:

Example 1:
Analysis:
Bearing Frequency Calculation: (BPFO) = 146.27Hz (BPFI) = 213.73 Hz (FTF) =12.19 Hz (BSF) = 59.17 Hz Findings: Non- of the bearing frequency match. Highlighted readings are the max.
Fequency Accel (G-s)

150.5
236.6 262 301.1

0.04031
0.08699 0.04385 0.1609

383.8
443.3 451.7 473.2 486.5 502

0.8523
0.4951 0.3171 0.07534 0.07493 0.05063

602.2
620.2 637.3 650 661.7 736.6

0.7262
0.2237 0.348 0.3827 0.251 0.1028

752
761.4 827.1 856.9

0.08873
0.08081 0.1279 0.1453

Example 1:
Findings: 2 BPFO & 2 BPFI. Bearing natural components freq. Side band freq. around the bearing natural freq. Recommendation: The bearing is defective
2 BPFO

Zone A

Zone B

Zone C

Natural freq. & Side Band freq.

2BPFI

in the third stage of failure and has to be replaced.

Note: harmonic means 1x(freq), 2x(freq), 3x(freq)

Replacing the bearing:

Example 2:
Analysis:
Bearing Frequency Calculation: Inner race defect frequency (BPFI) = 332.6 Hz Outer race defect frequency (BPFO) = 207.41 Hz Cage defect frequency (FTF) = 23.05 Hz Ball spin frequency (BSF) = 122.45 Hz Findings: side-bands freq. around the highest amplitude. the highest amplitude (prime spike vib.) = 6xBPFO

Example 2:
Findings:
No 1 2 BPFO harmonics 2xBPFO 3xBPFO 4xBPFO 5xBPFO 6xBPFO 7xBPFO 8xBPFO 9xBPFO 10xBPFO 11xBPFO 12xBPFO 414.82 415.4 622.23 625.7 3 4 5 6 7 829.64 833.7 1037.05 1244.46 1451.87 1659.28 1866.69 2074.1 2281.51 2488.92 1042 1251 1458 1667 1876 2085 2294 2502 1.222 2.828 4.486 2.298 2.039 0.6234 0.5266 0.6832 0.5431 0.1474 0.08629 Frequency Velocity in/sec

None of the bearing freq. match.

The harmonic freq of BPFI do not match. The harmonic freq. of BPFO match with the readings. Recommendation: The bearing outer race is in the third stage of failure and has to be replaced.

8 9 10

11
12 13

13xBPFO
14xBPFO

2696.33
2903.74

2709
2920

0.283
0.2275

Note: harmonic means 1x(freq), 2x(freq), 3x(freq)

Conclusion:

I have been exposed to different types of rotating equipments. I have gained good experience in analyzing the vibration readings and recommend the proper action. I have given the opportunity to work in the Aramco Shadgham shop and dealing with different types of rotating machines during maintenance and overhauling. I have been allowed to make studies and suggestions which improve the performance and reliability of the vibration group.