SHIVAJIRAO S.

JONDHALE
COLLEGE OF ENGINEERING

SHIVAJIRAO S. JONDHALE COLLEGE OF ENGINEERING

DEPARTMENT OF MECHANICAL
DEPARTMENT OF
MECHANICAL
-CONDITION MONITORING
AND MACHINERY FAULT
DIAGNOSIS
– BEND SHAFT
 BENT SHAFT
SUBMITTED IN PARTIAL FULLFILMENT OF THE
REQUEREMENT OF THE BACHELORE OF ENGENNERING
IN MECHANCIAL DEPARTMENT

SUBMITTED BY
SUDHANSHU M KAMBLE
ONKAR P RATHOD
SHUBHAM GODKE
NILESH LOHAR
IN THE GUDIENCE OF
PROF.NAGESH KONDRA

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CONTENT

 INTRODUCTION
 OBJECTIVE
 WORKING PRINCIPLE OF BENT SHAFT
 COMPONENT OF BENT SHAFT
 ADVANTAGES AND DIS ADVANTAGES
 CONCLUSION

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INTRODUCTION OF BENT SHAFT
 A bent shaft and bowed rotor are actually the same
phenomena. The bent shaft is measurable outside the
machine housing while the bowed rotor is the same
condition inside. These defects sometimes develop
on a motor that has been allowed to sit stationary for
a long time. When sitting stationary, the weight of the
rotor causes the shaft to deflect. After a period of
time (about 6 months), the deflection takes a
permanent set. When running, the vibration
spectrum appears identical to imbalance, and in fact
it is an imbalance condition. If a perfectly balanced
rotor (such as a fan impeller) is attached to a bent
shaft, it will run out of balance. It can be balanced
back to a smooth-running condition. But then this
rotor and this shaft are matched. Any other rotor on
this shaft (even a new, well-balanced one) will run
out of balance.

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IMAGES OF ECCENTRIC ROTOR

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 OBJECTIVES
 1. Avoid Unplanned Downtime
Avoiding unplanned downtime offers a range of beneficial outcomes for an industrial
environment. By removing unplanned downtimes you prevent unplanned production delays which
can lead to a loss of reputation if orders are not completed on time and the need to pay overtime to
complete a job. In addition, there is no need to pay for an emergency call out to maintenance staff,
which is more expensive than pre- scheduled maintenance.
 2. Protect Your Other Assets
A machine failure can cause damage in other systems, compounding the problem further while
also increasing repair or replacement costs. As a result, there will be no need to buy and store large
numbers of replacement assets or parts in case of an unexpected failure. Instead, you will be
forewarned of the need to replace a part and can order it as required in time for scheduled
maintenance.
 3. Eliminate Unnecessary Maintenance to Maximize ROI
Using condition monitoring as part of a predictive maintenance program can increase the return
on investment (ROI) of mechanical assets. Preventive maintenance programs are set at regular
intervals (i.e. annually) or after a set number of operating hours, irrespective of whether the
maintenance is required or not. Through condition monitoring, it is possible to eliminate unnecessary
maintenance and downtimes by only scheduling repairs when required. This means that you can get
more working value from each machine, reducing the total cost of ownership and maximizing the ROI
for your equipment.

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 4. More Efficient Maintenance
Condition monitoring allows for more efficient maintenance by indicating where a fault may lie. This
means that maintenance engineers do not need to check working components while locating the fault. This
not only saves time and gets your maintenance completed faster, but also saves the cost of paying a
maintenance engineer for wasted time.
 5. Improved Safety
Checking and repairing machines before they break safeguards employee safety and helps ensure safer
work practices. Condition monitoring means that owners can plan maintenance before failure occurs that
could pose a threat to employees working nearby.
 6. Improved Asset Efficiency
Condition monitoring can also improvements the efficiency of assets. By having a record of which parts are
running poorly, you can focus efficiency improvement efforts on those specific parts, thereby improving the
overall capabilities of your equipment

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WORKING

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 The machine simple in working it consist of a shaft mounted on bearing and it is
connected to motor by the universal coupling. The motor having 1200 rpm rotation it
is is connected to the veriable resistance for the motor speed control . When the
motor is connected to the power supply it starts rotation in a perticular speed and the
power is transferred to the shaft and the shaft starts rotating.
 Here if the shaft is not centralised conned then the diagnosis report shows high
apllitude of the Graf which indicates the shaft is bend or either the mounting are not
placed centrally.
 If tha shaft is straight and do not have any irregularities like bend and the shaft
mounted centrally then tha graft shows very low amount of increased in amplitude in
the graph.

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 WHAT IS SHAFT ALIGNMENT?
 For the vast majority of close coupled rotating machines this catenary bow is negligible, and
therefore for practical purposes can be ignored.
 On long drive machine trains, e.g. turbine generators in power generation plants or machines
with long spacer shafts e.g. cooling tower fans or gas turbines, the catenary curve must be
taken into consideration.
 Operation above critical speed When a very long, flexible shaft begins to rotate, the bow of
the shaft tries to straighten out, but will never become a perfectly straight line. It is
important to understand that the axis of rotation of a shaft could very possibly run on a
curved axis of rotation. In situations where two or more pieces of machinery are coupled to
get

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SHAFT ALIGMENT PHOTOS

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 Alignment Techniques
 There are many methods to align a machine. The appropriate method is selected based on the type
of machine, rotational speed, the machine’s importance in production, and the maintenance policy
and alignment tolerances.
 show the most common techniques used in machines alignment, laser beam and dial indicator gage
methods

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 Alignment parameters

 Since shaft alignment needs to be measured and subsequently corrected, a method of quantifying
and describing alignment condition is necessary

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 Looseness Mechanical looseness

 OR the improper clearance between component parts, is generally characterized by a long string of
harmonics of running frequency with abnormally high amplitudes.
 In some machines vibration levels may be excessive as a consequence of components being
assembled too loosely, for example in the case of a bearing, which is not properly secured.
 Mechanical looseness can be classified for three categories: 1) Internal assembly looseness. 2)
Looseness at machine to base plate interface. 3) Structure looseness

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 ADVANTAGES

 REQUIRES VERY LESS TIME.

 GIVES MORE ACCURATE RESULTS.
 REQIRES LESS SPACE TO STORE.
 USES LATEST TECHNOLOGY TO GIVE BEST RESULS.
 MEASURE FAULT IN RUNNNG CONDITION.
 NO ANY ROTATING PART IN MACHINE .
 IT CAN DIFFERENCIATE THE GRAPH OD BEFORE THE FAULT AND AFTER THE FAULT
OCURS.

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DISADVANTAGES

 IT IS VERY COSTLY SO EVERY ONE CAN NOT USE THIS

 THE COMMERCIAL FAULT DIAGNOSIS MACHINE REQIRE VERY HIGH QULITY OF
MATERIAL.
 THE SOFTWERE IS USED FOR THE DIAGNOSIS MACHCINE IS VERY COSTLY.

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 CONLUSION
 BENT OUT OF USAGE
 INSTALLATION
 FAILURE IN MANUFACTURING PROCESS
 SHIPPING
 BENT BECAUSE OF USAGE
 UNEVEN HEAT DISTRIBUTION IN THE ROTOR CAUSE BY A DEFECT ROTOR BAR
 ECCENTRICITY OF OUT SHAFT MASS

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