Rectification Report

Area: 316

Equipment Tag ID: 316-01-P001A

Equipment Description: Hot Oil Circulation Pump B

Before Corrective Action

Problem: High vibration in pump causing tripping, which is directly proportional to product temperature.

History: In Sep 2015 motor DE bearing was found having bearing fault frequencies, After investigation it was
found that wrong type of grease was being used, after recommendation for using the right grease as per
manual the correct grease was injected without removal of previous (wrong) grease, hence two different
type of greases were mixed together. Motor was decoupled, grease was removed correct grease was used
and motor was cold aligned without consideration of thermal growth (as it wasn’t available in manual), and
pump was put to standby for use on urgent conditions from the production to be on safe side as the motor
DE bearing is with deterioration.

Now few days back this pump was started and high vibration was observed which was proportional to
product temperature.

Observation: FFT was showing dominating 1x on pump horizontal direction which was directional on DE
side, Phase across coupling was out of phase indicating misalignment/coupling related fault.

Conclusion: The above circumstances lead to misalignment due to thermal growth.

Recommendation: It was recommended to carryout coupling inspection, motor solo-run, Cold alignment,
pump startup on load for thermal growth, hot alignment to get thermal offset and correct it and save it for
future reference

Corrective Action

Step #1 Check cold alignment: Initial value of cold alignment was checked and were found as following

Vertical Angularity: 0.02 Vertical Offset: 0.15

Horizontal Angularity: 0.03 Horizontal Offset: -0.20

Step# 2 Motor decouple: Motor was decoupled, coupling visual inspection was done.

Step #3 Run-out and clearance readings:

Motor radial run-out: 0.02 Motor axial run-out: 0.03 Motor radial clearance: 0.02

Pump radial run-out: 0.03 Pump axial run-out: 0.03 Pump radial clearance: 0.12
Step#4 Piping support adjustment: The flexible piping support on suction and discharge line weren’t at
load, hence they were adjusted, placing one dial indicator on pump casing and other on coupling to know
the movement in pump while support adjustment.

While adjustment the maximum movement on pump shaft was about 0.2mm

Step#5 Motor solo-run and vibration measurement: Motor was started for one hour to check motor
bearing condition with vibration analysis.

The motor DE bearing has deterioration in its cage and rolling elements but is stable (not increasing) hence
it can be utilized further to have optimized utilization of resources.

Step#6: Motor coupling & Cold alignment adjustment: Motor was coupled and cold alignment adjustment
was carried out with following results

Vertical Angularity: 0.00 Vertical Offset: 0.07

Horizontal Angularity:-0.02 Horizontal Offset: -0.03

Step# 7 Pump Startup on load for thermal growth: Pump was started on load for about 03 hours to attain
the thermal growth but due to production limitation the operation temperature of 140’C couldn’t be
attained to get the real thermal growth offsets.(only temperature reached up-to 70’C)

Step#8 Check hot alignment: Hot alignment readings were checked immediate after equipment shutdown.

Vertical Angularity: 0.04 Vertical Offset: 0.34

Horizontal Angularity:-0.01 Horizontal Offset: -0.16

Step#9 Re-check cold alignment: After cool down of the equipment the cold alignment was verified
showing that the equipment restores to its position on cooling down, hence there isn’t any
major/considerable movement taking place in pump due to piping.( The only change in reading was due to
thermal expansion at 70’C)

Vertical Angularity: 0.03 Vertical Offset: 0.07

Horizontal Angularity:0.01 Horizontal Offset: 0.06

Step#10 Check cold alignment on standby pump C for reference: As the vibration levels on Pump C are
normal at high (operational) temperature hence the cold alignment was checked on pump C for the
reference of thermal growth, the readings were as under

Vertical Angularity: 0.16 Vertical Offset: -0.83

Horizontal Angularity:-0.02 Horizontal Offset: 0.34

Step#11 Align pump B as per pump C Specs: Finally the Pump B was aligned as per align specs of Pump C,
final readings are

Vertical Angularity: 0.12 Vertical Offset: -0.81

Horizontal Angularity: 0.00 Horizontal Offset: 0.40

Step# 12 Final Vibration Measurement Verification:

Vibration Alarm limit in Bentley Nevada Sys1 is 6.5mm/s, tripping at 9mm/s

Before corrective action at 140’C vibration increased 9mm/s

As per control room operator and trend history in control room the usual oil temperature is between 90-
100’C, only in rare conditions the temperature is increased up-t0 140’C

The vibration at 90’C is about 2.1mm/s and at 140’C is about 4.5mm/s like pump A and C