Defect Elimination Success Story – Blend

Tank Agitator
by Allied on July 1, 2013

By: Leonard Kreiner, Vibration Analyst

Equipment Information

Figure 1: Blend Tank Agitator

Gearbox: Lightnin, 72-C-3

Motor: Toshiba, 3 HP, 1755 RPM, 182T Frame

Reported Defect
Figure 2: 1x Turning Speed and Harmonics Indicating Looseness

Problem Statement:

There is looseness in the vibration spectrum. Examination of the coupling reveals that
the coupling is cocked on the shaft.

Recommendation:

Check coupling for signs of wear, such as cracks. Repair or replace as needed. Check
shaft keys for proper length and size. Line shaft key was 180 degrees offset. Check
motor for soft foot; laser align motor to gearbox. Tighten all bolts to proper torque.

Follow-up Findings

In June of 2010, vibration data was collected on the blend tank agitator. Looseness was
seen in the vibration spectrum, as indicated in Figure 2 by a frequency peak at 1x
turning speed and several harmonics. A work order was issued to check the condition of
the coupling. While time was charged to this work order, no comments were attached.

A change in the work order’s status triggered vibration data to again be acquired and the
looseness could still be seen in the vibration spectrum. The coupling was superficially
examined by the analyst while the asset was running, with no problems noted. The work
order was closed and the analyst continued investigating for another source of the
looseness.

On December 8, 2010, vibration data was again collected on the blend tank agitator, and
the data suggested that the amount of looseness had increased. The coupling was again
examined and this time it appeared to be cocked on the shaft and wobbling. The actual
wobble of the coupling due to it being cocked could be seen in the time waveform, as
shown in Figure 3. Another work order was issued to repair or replace the coupling as
needed.

Figure 3: Motor Coupling Movement

Examination of the coupling revealed that components were in pieces and worn
(Figures 4 through 9). While still operational, the coupling would have soon failed
catastrophically.
Figure 4: Coupling Cocked on the Asset Shafts

Figure 5: The Coupling Grid, Which Connects Both Hubs, in Pieces

Figure 6: Hub with Only a Few Teeth for Power Transmission

Figure 7: Hub with Worn Teeth

Figure 8: Hub with Worn Teeth

Figure 9: Coupling with Dried Grease and Grid Pieces

Tagged as: Condition Monitoring, failure modes, machine parts, motor, motor circut
analysis, predictive maintenance, reliability, thermography

{ 2 comments… read them below or add one }

Ken Nygaard July 29, 2013 at 7:41 pm

I wonder if the Root Cause of the Imbalance Condition was related to

Load on the Blade causing a rocking motion. We have also noted
Bent Blades and also recommend a full visual inspection of this area also.

Good Work

Ken Nygaard

Leonard Kreiner July 30, 2013 at 7:29 am

@Ken Nygaard- Thanks, I do not believe there was a loose/bent blade on the
asset. Although there was not a blade inspection at the time, there wasn’t any
indications of Imbalance on the asset after the coupling was repaired. It has been
running smooth with no further issues noted