audit points

MONTHLY SCHEDULE:

PLANT-1

S.NO DATE PLANT AREA

NO.OF MEASURING POINT

1 05-01-2014

PLANT-1

BANBURY MAIN MOTORS & GEARBOX, 120

2 06-01-2014 BANBURY DUMP MILLS -DAY-1 105

07-01-2014 BANBURY DUMP MILLS -DAY-2 105

3 08-01-2014 HFE & 36''CALENDER,DUST COLLECTORS,CFE MAIN MOTOR

120

5 10-01-2014

TUBE PLANT

6'' Extruder MOTORS & GB, CHILLER MOTORS,NEW 6'' Extruder MOTORS & GB

140

6 11-01-2014 BLOWER AND COOLING TOWER MOTORS 120

7 12-01-2014 10'' Extruder MOTORS,10'' Extruder GB, TCU 120

PLANT-2



8 13-01-2014

PLANT-2

DIP UNIT MOTORS-1 st DAY 100

9 14-01-2014 DIP UNIT MOTORS-2 st DAY,COOLING TOWER MOTORS

140

10 15-01-2014 DUAL TUBER MOTORS & 3 GB 114

11 17-01-2014 DUAL TUBER 3 GB & 74" Calendar MIL MOTORS

120

12 18-01-2014 74'' CALENDER MOTORS, MAIN GB & TCU 138

13 19-01-2014 20 CURING SERVICE VERTICAL MOTORS 120

14 20-01-2014 CURING HOT WATER MOTORS 114

PLANT-3



15 20-01-2014

PLANT-3

11D,F620,F270 MAIN MOTOR & GB 150

16 21-01-2014 NEW F270 MOTOR,GB & F620 MILL MOTORS & GB

120

17 22-01-2014 F270 MILL MOTORS & GB--5 150

18 24-01-2014 NEW F270 MOTOR,GB--4 ,NEW BANBURY DUST COLLECTOR

120

19 25-01-2014 DUAL TUBER-II,DUAL TUBER-III 224

OTR



21

26-01-2014

OTR EXTRUDER 144

22OTR

UTILITIES COMPRESSORS & COOLING TOWERS 114

UTILITIES



23 27-01-2014

UTILITIES

CFB 90

24 28-01-2014 800 CFM COMPRESSORS--4 144

25 29-01-2014 1000 CFM COMPRESSORS--4 144

26 31-01-2014 THERMEX BOILERS,TBW -1 & 2,IAEC,PUMPS 150

MONTHLY REPORT:

PLANT-1S.NO

DATE AREA EQUIPMENT NAME

MEASURING POINTSVIBRATION (mm/sec)

CBM FINDINGS WHAT TO DO ?Max Limit HOR VER AXIAL

1

04-10-2013

BANBURY

MAIN MOTOR

BANAURY-1 MAIN MOTOR

MOTOR NDE 7.1

1.180.8

4 1.63 Peak at high frequency with difference 2xFL

Harmonics

bearing deterioation started & suspected

looseness in connectionsMOTOR DE 1.06

1.77 1.77

2BANAURY-2 MAIN MOTOR

MOTOR NDE 7.1

0.760.4

9 0.32 Peak at high frequency with difference 2xFL

Harmonics

bearing deterioation started & suspected

looseness in connectionsMOTOR DE 0.54

0.95 0.55

3BANAURY-3 MAIN MOTOR

MOTOR NDE 7.1

3.431.0

2 3.94unbalance force acting clean the fan vans

MOTOR DE 4.586.9

7 4.624


MOTOR NDE 7.1

0.78 0.6 0.81RBF check the rotor bar

codition MOTOR DE 1.02

1.41 0.88

5

BANBURY

GEAR BOX

MAIN GEAR BOX-1

DE I/P

7.62-10.16

1.51.5

2 0.85

OK

NDE I/P 1.54 1.2 0.88

BANBURY SIDE STAGE-1 1.09

0.87 1.25


0.88 1.85

MOTOR SIDE STAGE-1

0.81.3

2 1.26

MOTOR SIDE STAGE-2

1.251.0

2 1.06

MOTOR SIDE STAGE-3

1.051.0

6 0.58

BANBURY SIDE STAGE-3 1.58 1.2 1.05

6

04-10-2013

MAIN GEAR BOX-2

DE I/P

7.62-10.16

1.41 1 0.26

GMF WITH SIDE BANDS Gear tooth wear

NDE I/P

0.751.0

5 0.6


0.75 0.39


0.78 0.86

MOTOR SIDE STAGE-1

1.220.7

8 1.27

MOTOR SIDE STAGE-2

0.760.6

4 1.33

MOTOR SIDE STAGE-3

0.70.5

6 0.88


0.27 1.42

7

MAIN GEAR BOX-3

DE I/P

7.62-10.16

0.852.1

3 1.23

looseness Retighten the foundation

bolts of gear box

NDE I/P

0.991.7

1 1.16


1.36 2.13


0.91 2.17

MOTOR SIDE STAGE-1

0.92.4

3 2.57

MOTOR SIDE STAGE-2

1.091.9

3 2.06

MOTOR SIDE STAGE-3 1.13 2.0 1.91

3


1.16 1.47

8

MAIN GEAR BOX-4

DE I/P

7.62-10.16

1.311.3

1 0.39

OK

NDE I/P

1.870.2

2 0.38


0.19 1.36


1.17 1.24

MOTOR SIDE STAGE-1

0.891.3

2 0.56

MOTOR SIDE STAGE-2

0.940.9

9 1.22

MOTOR SIDE STAGE-3

0.240.5

8 0.76


0.18 0.28

905-10-2013 BANBU

RY MILLS

& GEAR BOXES

BANBURY -1 DUMP MILL

MOTOR

MOTOR NDE 4.5 0.920.4

4 1.24

High frequency peaks Lubrication the bearing MOTOR DE 0.85 0.3 1.16

10

BANBURY -1 DUMP MILL GEAR BOX

DE I/P

7.62-10.16

1.23 0.9 0.76

looseness & cracked gear tooth profile

Excessive clearances in bearings supporting the

gear shaftsOr can also be caused from loss of press

fits or loose keyways locking the gear hub to the

shaft

NDE I/P 0.780.5

8 0.48

MILL SIDE STAGE-1 0.450.4

1 1.26


7 0.79

MOTOR SIDE STAGE-1 0.431.2

7 1.22


6 0.72


5 1.22


8 0.86

11 BANBURY -2 DUMP MILL

MOTOR

MOTOR NDE 4.5 1.441.0

8 1.28

High frequency peaks Lubrication the bearing MOTOR DE 1.32 1.5 1.21

12

BANBURY -2 DUMP MILL GEAR BOX

DE I/P

7.62-10.16

1.452.2

7 1.71

OK

NDE I/P 1.381.0

2 1.67


6 1.83


8 1.5


3 1.93


8 1.38


7 1.75


2 1.28

13 BANBURY -3 DUMP MILL

MOTOR

MOTOR NDE 4.5

1.960.6

8 0.86

OK

MOTOR DE 2.610.9

5 0.54

14BANBURY -3 DUMP MILL GEAR BOX

DE I/P7.62-10.16 1.31

0.54 1.12

OK

NDE I/P 0.890.7

1 0.64


6 0.62 MILL SIDE STAGE-2 0.68 0.6

60.59


7 0.65


7 0.46


2 0.4

MILL SIDE STAGE-3

15

06-10-2013

BANBURY -4 MILL-1 MOTOR

MOTOR NDE 4.5

1.263.5

5 4.08 50% change between 1x & 2x

Slight misalignment

MOTOR DE 1.050.4

4 3.09

16

BANBURY -4 MILL -1 GEAR

BOX

DE I/P

7.62-10.16

0.72 0.6 0.47

losseness check for looseness in gear box

NDE I/P 0.520.4

5 0.48


1 0.52


8 0.32


1 0.45


9 0.48


8 0.69


3 0.56

17BANBURY -4

MILL-2 MOTOR

MOTOR NDE 4.5

2.19 1 0.87

OK

MOTOR DE 1.530.6

5 0.91

18


BOX

DE I/P

7.62-10.16

0.670.5

2 0.3

OK

NDE I/P 0.530.8

7 0.57


4 0.65


4 0.57



7 0.56


6 0.65

MILL SIDE STAGE-3 0.47 0.6 0.39

19BANBURY -4

MILL-4 MOTOR

MOTOR NDE 4.5

0.870.4

4 0.43High frequency peaks Beaing is in damaged

condition MOTOR DE 0.64

0.35 0.47

20


BOX

DE I/P

7.62-10.16

0.180.2

7 0.45

OK

NDE I/P 0.19 0.1 0.3


9 0.48


3 0.81


4 0.42


4 0.32


6 0.58


5 0.23

2108-10-2013 36"CAL

ENDERMAIN MOTOR

MOTOR NDE 4.5

0.530.1

8 0.43

OK

MOTOR DE 0.71 0.31

0.58

22 FEED MILL MOTOR

MOTOR NDE 4.5

4.681.3

7 1.52Eccentric air gap Check soft foot & check for

any mechanical looseness MOTOR DE 3.64

1.88 1.59

23

FEED MILL GEAR BOX

DE I/P

7.62-10.16

3.681.9

2 1.1

Chipped tooth

NDE I/P 3.161.4

1 1.23


1 1.18


5 1.36


3 1.44


1 1.16


4 1.16


7 1.33

24

HOT FEED

EXTRUDER

HFE CRAKER MILL-I MOTOR

MOTOR NDE 4.5

3.311.3

1 1.68Random vibartion Check soft foot & check for

any mechanical looseness MOTOR DE 4.37

3.16 2.4

25

CRAKER MILL GEAR BOX

DE I/P

7.62-10.16

4.312.4

5 2.51

Gear tooth wear

NDE I/P 3.772.8

1 1.36


9 2.43



5 1.25


8 1.41


7 1.24


8 1.94

26HFE FEED

MILL-II MOTOR

MOTOR NDE 4.5

1.620.5

3 0.87High frequency peaks Lubrication the bearing &

check the grounding MOTOR DE 2.09

1.11 1.2

27

FEED MILL GEAR BOX

DE I/P

7.62-10.16

0.971.0

4 0.32

check the 2nd stage of the gear box

NDE I/P 1.10.8

5 0.43


7 0.48


6 0.39


8 0.95


3 0.41


6 0.39


9 0.37

28 HFE Main Motor

MOTOR NDE 4.5

2.320.6

8 0.64

OK

MOTOR DE 4.481.2

4 0.73

29

PLANT-1

BANBURY

CURING

BB#1 &2 SUPPLY

MOTOR 1

MOTOR NDE 4.5

2.191.1

2 3.52

OK

MOTOR DE 1.792.3

7 1.78

30BB#1 &2 SUPPLY MOTOR NDE

4.52.7

1.42 3.79

OK

COOLING

TOWER MOTOR

S

MOTOR 2 MOTOR DE 2.48 2.8 2.45

31

BB#3 &4 SUPPLY

MOTOR 1

MOTOR NDE 4.5

9.887.7

4 19.2 1x,2x & 3x dominate in axial direction

Do alignment

MOTOR DE 9.177.5

2 12.6

32

MAKE UP PUMP MOTOR-

1

MOTOR NDE 4.5 14.48.3

9 15.8 1x is more, rotor thermal bow problem

Do alignment and check the rotor bars of rotor

MOTOR DE 13.4 6.1 12.2

TUBE PLANTS.NO

DATE AREA EQUIPMENT NAME

MEASURING POINTSVIBRATION (mm/sec)

CBM FINDINGS WHAT TO DO ?Max Limit HOR VER AXIAL

1

16-10-20136"EXTRUDER MILLS

6'' EXTRUDER SURGE MILL

MOTOR

MOTOR NDE 4.5

3.622.4

2 1.592xF.L frequency is more MECHANICAL:Check the

soft foot MOTOR DE 3.2

1.51 1.8

6'' EXTRUDER FEED MILL

MOTOR

MOTOR NDE 4.5

1.191.0

4 0.82xF.L frequency is more

ELECTRICAL: Check the grounding MECHANICAL:Check the soft foot & coupling MOTOR DE 0.7

0.51 0.79

6'' EXTRUDER FEED MILL GEAR BOX

DE I/P

7.62-10.16

0.611.2

1 0.44

OK

NDE I/P 0.61.0

7 0.57


9 0.65


4 0.44


8 0.44


1 0.55


2 0.77


1 0.52

6"EXTRUDER MAIN MOTOR

MOTOR NDE 4.5

1.570.6

7 0.84

OK

MOTOR DE 1.61.3

5 0.87

2

14-10-2013

NEW 6"EXTRUDER MILLS

NEW 6'' EXTRUDER

CRACKER MILL MOTOR

MOTOR NDE 4.5

3.131.4

3 1.71

check for any mechanical looseness(like coupling

etc..) MOTOR DE 2.76

1.15 1.81

3

NEW 6'' EXTRUDER

CRACKER MILL GEAR BOX

DE I/P

7.62-10.16

0.680.6

6 0.38

OK

NDE I/P 0.470.4

4 0.34


8 0.77


2 0.52


8 0.37


9 0.46


5 0.39


4NEW 6''

EXTRUDER FEED MILL

MOTOR

MOTOR NDE 4.5

5.121.7

3 4.252xF.L frequency is more

ELECTRICAL: Check the grounding MECHANICAL:Check the soft foot MOTOR DE 3.05

2.29 3.56

5

NEW 6'' EXTRUDER FEED MILL GEAR BOX

DE I/P

7.62-10.17

0.410.3

8 0.35

OK

NDE I/P 0.320.3

2 0.38



3 0.29


2 0.36


3 0.38


5 0.25


8 0.22

6 NEW 6'' MAIN MOTOR

MOTOR NDE 4.5

8.071.3

2 2.221x is more

ELECTRICAL: Unbalance force acting & suspecting current passing through bearing MOTOR DE 4.45

1.03 2.86

7 NEW 6'' MAIN MOTOR BLOWER

MOTOR NDE 9

13.64.5

8 7.711x is more MECHANICAL:Unbalance

MOTOR DE 13.34.5

6 4.57

8 NEW 6'' MAIN GEAR BOX

DE I/P7.62-10.16

2.970.9

4 2.21

OK

NDE I/P 1.960.8

6 2.26

9 HOT AIR BLOWER MOTOR

MOTOR NDE 9

1.322.8

8 1.36

OK

MOTOR DE 1.142.2

2 1.45

10 17-10-2013 10" EXTRUD

ER10" EXTRUDER MILL-I MOTOR

MOTOR NDE 4.5

1.32 1.7 1.48High frequency peaks Lubrication the NDE

bearing MOTOR DE 1.96 1 0.76

11

10" EXTRUDER MILL-I GEAR

BOX

DE I/P

7.62-10.16

0.660.6

1 0.64

OK

NDE I/P 0.630.9

7 0.63


8 0.73


9 0.8



8 0.69


9 0.61


1 0.65

1210" EXTRUDER MILL-II MOTOR

MOTOR NDE 4.5

0.420.1

4 0.35

OK

MOTOR DE 0.490.2

2 0.22

13 10" EXTRUDER MILL-II GEAR

BOX

DE I/P 7.62-10.16

0.27 0.3 0.22

OK

NDE I/P 0.260.1

8 0.17


3 0.19


7 0.2


8 0.17 MOTOR SIDE STAGE-2 0.24 0.1

90.19

14 10" EXTRUDER MILL-III MOTOR

MOTOR NDE 4.5

1.050.6

4 1.07

OK

MOTOR DE 1.10.6

3 0.61

15

10" EXTRUDER MILL-III GEAR

BOX

DE I/P

7.62-10.16

0.370.3

6 0.23

OK

NDE I/P 0.410.3

1 0.25


8 0.34




1610" EXTRUDER MAIN MOTOR

MOTOR NDE 4.5

2.741.6

8 2.7

OK

MOTOR DE 2.841.9

7 1.69

17CHILLER

CHILLER MOTOR-1

MOTOR NDE 4.5

1.771.7

3 5.44Truncated time signal Do alignment

MOTOR DE 2.683.3

8 4.05

18

CIRCULATION MOTOR-1

MOTOR NDE 4.5

1.060.6

6 4.32xF.L frequency is more MECHANICAL:Check

the soft foot MOTOR DE 1.54

0.88 1.51

19

COOLING

TOWER

150 TON COOLING PUMP-2

MOTOR NDE 4.5 72.4

5 16.7 Truncated time signal Do alignment & Rotor thermal bow

MOTOR DE 7.58 12 14.3

20


MOTOR NDE 4.5

3.410.6

9 1.52

OK

MOTOR DE 2.981.2

6 0.86

21


MOTOR NDE 4.5

1.020.6

6 1.32

OK

MOTOR DE 1.111.1

5 1.22

PLANT-2

S.NO DATE AREAEQUIPMENT NAME

MEASURING POINTS

VIBRATION (mm/sec)CBM FINDINGS WHAT TO DO ?Ma

x HORVER AXIAL

1

13-10-2013

DIP

ZONE 1 CIRCULATION

BLOWER

MOTOR NDE 4.5

2.2 1.4 2.7Peaks at high frequency

Lubrication the bearing & check the looseness (like

pulley ,foundation bolts) MOTOR DE 2.3 1.7 3.1

2 ZONE -1 BLOWER SIDE BEARING 1

BEARING 1

17 5.2 6.5phase analysis shows

unbalance force Do balancing

3 ZONE -1 BEARING 2

BEARING 2

16 3.7 6.6

4 ZONE 1 EXHASUST BLOWER

MOTOR NDE 4.5

1.3 1.7 2.6Random peaks check the looseness (like

pulley ,foundation bolts) MOTOR DE 1.6 2.1 1.6

5ZONE-1 EXHAUST

BLOWER SIDE BEARING 1

BEARING 1

1.1 0.8 1.5

OK

6 ZONE-1 EXHAUST BEARING 2

BEARING 2

1.4 2 3

OK

7ZONE 2

CIRCULATION BLOWER

MOTOR NDE 4.5

2 3 5 pulley to pulley alignement

check the belt condition MOTOR DE 1.7 2.2 5.1

8 ZONE 2 HOT AIR EXHASUST FAN

MOTOR NDE 4.5

8.3 5 7.43x dominate pulley alignement & check the

looseness(key ways,pulley etc..)MOTOR DE 8.2 7 9.1

9ZONE 2 HOT AIR EXHASUST FAN SIDE BEARING 1

BEARING 1

6.5 4.3 7.9

OK

10ZONE 2 HOT AIR

EXHASUST BEARING 2

BEARING 2

6.9 7.8 7

OK

11ZONE 3 MAIN CIRCULATION

BLOWER

MOTOR NDE 4.5

1.9 4.2 4.5Peaks at high frequency Lubrication the bearing

MOTOR DE 2.2 4 4.4

12 ZONE 3 HOT AIR EXHASUST FAN

MOTOR NDE 4.5

4.7 3.1 5.71x is high

MOTOR DE 8.1 3.8 5.3

13

09-10-2013

Dip cooling tower

DIP COOLING PUMP MOTOR-3

MOTOR NDE 4.5

3.5 1.7 6.2 Peaks at high frequency Lubrication the bearing

Check the rotor ( turn to turn shorts or winding problems) &

alignment problemMOTOR DE 4 4.2 4.6

1415TR CHILLER COND. PUMP

MOTOR-1

MOTOR NDE 4.5

4.9 4.5 24 1x,2x & 3x dominate in axial direction

Do alignment & Mechanical looseness(like coupling etc..)

MOTOR DE 7.4 15 22

15HOT WELL

CHILLER MILL MOTOR-2

MOTOR NDE 4.5

1.9 1.1 2.8Peaks at high frequency Lubrication the bearing

MOTOR DE 2.1 1.8 1.7

16HOT WELL

CHILLER MILL MOTOR-1

MOTOR NDE 4.5

0.8 1.4 3Random peaks check the looseness (like coupling

etc..) MOTOR DE 1.6 2 2.7

1774'' CALENDER

MILL PUMP MOTOR-1

MOTOR NDE 4.5

3.9 1.8 3.91x is more & sign wave

time signal

Unbalance rotor (Rotor Thermal bow problem)

MOTOR DE 4.4 2.1 1.9

1874'' CALENDER

MILL PUMP MOTOR-2

MOTOR NDE 4.5

3.9 2.4 4.51x Hamonics Check the coupling

MOTOR DE 4.6 2.6 2.9

19 T.F MAIN PUMP-1MOTOR NDE

4.52.6 2.4 5.6

2x is more compare to 1x Do alignement & check the coupling & Bearing

MOTOR DE 2.1 3.7 4.1

20 COOLING TOWER PUMP MOTOR-1

MOTOR NDE 4.5

11 13 30 1x,2x & 3x dominate in axial direction

Do alignment MOTOR DE 9.2 22 23

21

21-10-2013

DIP UNIT

LINT EXH. BLOWER MOTOR

MOTOR NDE 4.5

6.3 4.2 6.41X Axial vibration is more

Blower misalignment with rotating shaft & check the

loosenessMOTOR DE 5.4 2.8 6.4

22 ACCUMULATOR POWER PACK

MOTOR NDE 4.5

0.6 0.4 1

OK

MOTOR DE 0.6 0.8 1

23 HOLD BACK MOTOR

MOTOR NDE 4.5

11 3.7 3.3Unbalance force acting Brake drum is wobbling

MOTOR DE 4.9 2 3.2

24 HOLD BACK BLOWER

MOTOR NDE 14

43 9.6 16Unbalance force acting Blower unbalance

MOTOR DE 28 8.7 4.6

25 PULL ROLL MOTOR-1

MOTOR NDE 4.5

1.7 0.8 0.9

Check the SCR condition

MOTOR DE 0.9 0.7 0.8

26 PR-1 BLOWER MOTOR NDE

148.7 5.2 3.1

Unbalance force acting Clean the blower vanes MOTOR DE 8.7 7.3 6.5


MOTOR NDE 4.5

1.8 2.1 2.4

OK

MOTOR DE 1.9 2.4 2.2

28 PULL ROLL BLOWER-2

MOTOR NDE 14

4 5.4 6.91X Axial vibration is more Blower misalignment with

rotating shaftMOTOR DE 2.9 2.4 8.5


MOTOR NDE 4.5

2.3 1.3 0.8

OK

MOTOR DE 0.6 0.9 0.8

30 PULL ROLL BLOWER-3

MOTOR NDE 14

11 2.9 2.81x Hamonics Retighten the blower bolts

MOTOR DE 9.4 1.3 2.6


MOTOR NDE 4.5

2.7 0.5 1

OK

MOTOR DE 2.6 1 0.9

32 WINDER MOTOR -2

MOTOR NDE 4.5

0.3 0.2 0.4

OK

MOTOR DE 0.3 0.2 0.3

33

22-10-2013

CURING

TRENCH-1 SOUTH MOTOR

MOTOR NDE 4.5

2.9 2.3 3.1

OK

MOTOR DE 3.2 2.6 2.9

TRENCH-1 EAST

MOTOR

MOTOR NDE 4.5

4.4 3.6 7.4 1x,2x & 3x dominate in axial direction

Do alignment & Mechanical looseness(like coupling etc..) MOTOR DE 5.8 3.9 6.8

34 TRENCH-2 EAST MOTOR

MOTOR NDE 4.5

3.1 1.3 3.6Random peaks check the looseness (like

coupling,foundation bolts etc.) MOTOR DE 3 2.1 3.3

35 TRENCH-3 EAST MOTOR

MOTOR NDE 4.5

6.5 1.1 1.42xF.L frequency is more Check the soft foot

MOTOR DE 7.1 1.4 1.1

36 TRENCH-4 SOUTH MOTOR

MOTOR NDE 4.5

1.4 1.5 5.2

OK

MOTOR DE 1.6 1.6 1.6

37 TRENCH-5 NORTH MOTOR

MOTOR NDE 4.5

6.2 2.3 4.21x is more Unbalance force acting

MOTOR DE 4.8 3 4.2

PLANT-3

S.NO DATE AREA EQUIPMENT NAMEMEASURING POINTS

VIBRATION (mm/sec)CBM FINDINGS WHAT TO DO ?

Max HOR

VER

AXIAL

1

23-10-2013

DUAL TUBER-2 BASE CRACKER MILL

MOTOR MOTOR NDE

4.53.3 0.7 0.9

Mechanical looseness Check the coupling looseness etc...

MOTOR DE 3.5 1 0.7

BASE CRACKER MILL(NOTE:VALUES IN MICRO METER)

FRONT ROLL MOTOR SIDE 21 10 18

looseness is more

Check the connecting gears

FRONT ROLL 21 11 14 Check the Bearing condition (BPFI) BACK ROLL

MOTOR SIDE 20 27 20

BACK ROLL 37 76 17

2

BASE CRACKER MILL GEAR BOX

DE I/P

7.62-10.16

1.2 1 1.1

OK

NDE I/P 1.5 1 1.1



MOTOR SIDE STAGE-1 0.9 1 1.2


3 BASE FEED MILL MOTOR

MOTOR NDE 4.5

1.9 0.7 1.3

OK

MOTOR DE 2.1 1 1

4

BASE FEED MILL GEAR BOX

DE I/P

7.62-10.16

1.7 1.3 1.9

cracked tooth problem

NDE I/P 1.7 1.7 2.4





5 CAP FEED MILL MOTOR

MOTOR NDE 4.5

0.7 0.5 0.4

Suspected EIBD problem Check the grounding MOTOR DE 0.6 0.3 0.4

6

CAP FEED MILL GEAR BOX

DE I/P

7.62-10.16

0.2 0.2 0.2

OK

NDE I/P 0.2 0.2 0.2





7 CAP SURGE MILL MOTOR

MOTOR NDE 4.5

1.5 0.6 0.8

OK

MOTOR DE 1.5 0.9 0.68 CAP SURGE MILL DE I/P 7.62- 0.5 0.3 0.5 OK

GEAR BOX 10.16

NDE I/P 0.3 0.3 0.4





9 CAP CRACKER MILL MOTOR

MOTOR NDE 4.5

5.2 2.4 3.42xFL is more Check the soft foot (Base

flatness or looseness etc..)MOTOR DE 3.3 3.4 3

10 CAP CRACKER MILL GEAR BOX

DE I/P 7.62-10.16

0.6 0.5 0.6

OK

NDE I/P 0.6 0.5 0.7

11 DUAL EXTRUDER MOTOR 1

MOTOR NDE 4.5

1 0.3 0.7

OK

MOTOR DE 0.9 0.3 0.6

12 DUAL EXTRUDER MOTOR 2

MOTOR NDE 4.5

0.9 0.6 0.9

OK

MOTOR DE 0.7 0.8 0.5

13

09-10-2013 COOLING TOWERS

D/T-3 CRACKER MILLS CIRCULATION

PUMP-1

MOTOR NDE 4.5

3.8 4.4 1.2

OK

MOTOR DE 1.8 1.8 1.1

14D/T-2 CRACKER

MILLS CIRCULATION PUMP-1

MOTOR NDE 4.5

2.5 2 2.2Peaks at high frequency Lubrication the bearing

MOTOR DE 1.6 1.3 1.1

15COOLING TOWER

CIRCULATION PUMP-2

MOTOR NDE 4.5

10 4.6 11 Time signal shows mis alignment

Do alignment MOTOR DE 8.7 7.5 6.1

16COOLING TOWER

CIRCULATION PUMP-2

MOTOR NDE 4.5

2.7 1.1 5.9 1x,2x & 3x dominate in axial direction

Do alignment MOTOR DE 3.6 3.6 5.2

17

DT-3 COOLING TOWER

CIRCULATION PUMP-1

MOTOR NDE 4.5

2.1 1.1 3.9

OK

MOTOR DE 2.4 1.7 2.9

NEW BANBURY

S.NO DATE AREA EQUIPMENT NAME MEASURING POINTS


Max HOR VER AXIAL

1

25-10-2013 NEW BANBURY

11D BANAURY MAIN MOTOR

MOTOR NDE 7.1

0.9 1 1.5

SCR firing frequency

Check the electrical loose connections ,

shorted control cards and SCR condition MOTOR DE 0.8 1 1.1

2

11D BANAURY MAIN GEAR BOX-1

DE I/P

7.62-10.16

0.9 0.8 0.9

OK

NDE I/P 0.9 0.8 1.1



MOTOR SIDE STAGE-1 0.5 0.8 1

MOTOR SIDE STAGE-2 0.7 0.7 1


BANBURY SIDE STAGE-3 0.8 1 1.3

3 F620 BANAURY MAIN MOTOR NDE 7.1 1.1 0.7 1.5 Suspected SCR firing

MOTOR-A

problem please check itMOTOR DE 1.2 0.6 1

4

F620 BANAURY MAIN GEAR BOX-A

DE I/P

7.62-10.16

0.5 0.4 0.4

OK

NDE I/P 0.9 0.5 0.5





5 F620 BANAURY MAIN MOTOR-B

MOTOR NDE 7.1

0.6 0.6 0.8

OK

MOTOR DE 0.7 0.5 0.8

6

F620 BANAURY MAIN GEAR BOX-B

DE I/P

7.62-10.16

0.5 0.7 0.5

OK

NDE I/P 0.6 0.6 0.5





7 F270 BANAURY MAIN MOTOR

MOTOR NDE 7.1

0.8 0.4 0.2

OK

MOTOR DE 1 1 0.5

8

F270 BANAURY MAIN GEAR BOX

DE I/P

7.62-10.16

0.3 0.2 0.2

OK

NDE I/P 0.2 0.2 0.7



MOTOR SIDE STAGE-1 1 0.9 0.3




9 NEW F270 BANAURY MAIN MOTOR

MOTOR NDE 7.1

0.8 0.5 0.6

OK

MOTOR DE 1.5 0.5 1.3

10

NEW F270 BANAURY MAIN GEAR BOX

DE I/P

7.62-10.16

0.6 1 1.2

OK

NDE I/P 0.8 0.6 0.8







DUST STOP LUBE MOTOR Check the coupling

3 & 4

11

27-10-2013

F270 DUST COLLECTER MOTOR NDE

6.41 0.5 0.6

OK

MOTOR DE 1.3 0.6 0.6

12 F270 FUME COLLECTER MOTOR NDE

6.41 0.8 1.3

OK

MOTOR DE 1 1 1.2

13 NF270 DUST COLLECTER MOTOR NDE

6.43.3 2 2.1

Clean the blower vanes MOTOR DE 3.3 0.9 2.3

14 F620 DUST COLLECTER MOTOR NDE

6.44.6 2 5.2

AXIAL VIBRATION IS MORE(Blower

wobbling )

Blower alignment with rotating shaft & check the dust colector BAG'S

(Check the accumulation on bag !) MOTOR DE 4.9 5 6.7

OTR

S.NO DATE AREA EQUIPMENT NAME

MEASURING POINTS


Max HOR VERAXIA

L

1

27-10-2013EXTRUDE

R

EXTRUDER MAIN MOTOR

MOTOR NDE 4.5

1.3 0.7 0.5

OK

MOTOR DE 1.4 0.4 0.7

EXTRUDER MAIN GB

DE INPUT 7.62-10.1

6

0.6 0.4 0.6

OK

NDE INPUT 0.6 0.4 0.5

2FEED MILL MOTOR

MOTOR NDE 4.5

4.4 1 1.9

OK

MOTOR DE 3.2 0.6 1

3

FEED MILL GEAR BOX

DE I/P

7.62-10.1

6

1 0.2 0.5

OK

NDE I/P 0.8 0.7 0.4

4MILL SIDE STAGE-1 0.8 0.4 0.5






5SURGE MILL MOTOR

MOTOR NDE 4.5

1.4 0.5 0.6

OK

MOTOR DE 1.2 0.6 0.7

6

SURGE MILL GEAR BOX

DE I/P

7.62-10.1

6

0.4 0.6 0.5

OK

NDE I/P 0.4 0.5 0.4




MOTOR 0.3 0.3 0.3

SIDE STAGE-2



7 CRACKER MILL MOTOR MOTOR NDE 4.5 7.2 1.6 2.7 Unbalance Force check the voltage

unbalance & Suspected rotor bar failure MOTOR DE 8.7 1.9 2.9

8

CRACKER MILL GEAR BOX

DE I/P

7.62-10.1

6

3.1 1.8 1.3

OK

NDE I/P 1.5 1.1 1.5

MILL SIDE STAGE-1 1.4 1 1.2

MILL SIDE STAGE-2 3 1.5 1.4


MOTOR SIDE STAGE-2 2 1.1 1.1

MOTOR SIDE STAGE-3 1.9 1 1.2


UTILITIES

S.NO DATE AREA

EQUIPMENT NAME

MEASURING POINTS

VIBRATION (mm/sec)

CBM FINDINGS WHAT TO DO ?Max Limit

HOR

VER

AXIAL

1

28-10-2013 CFB

FEED WATER MOTOR-1

MOTOR NDE 4.5

2.2 1 0.9

OK

MOTOR DE 2.4 1.5 0.5

2

FEED WATER MOTOR-2

MOTOR NDE 4.5

2.4 0.9 1.3

OK

MOTOR DE 2 1.9 0.6

3FD FAN MOTOR 1

MOTOR NDE 4.5

0.6 0.4 0.7

OKMOTOR DE 0.7 0.9 0.5

4 BLOWER SIDE BEARING 1 0.2 0.9

5FD FAN MOTOR 2

MOTOR NDE 4.5

1.3 0.5 1.2

OKMOTOR DE 1.2 1 1.1

6 BLOWER SIDE BEARING 1.2 0.6 0.9

7PA FAN MOTOR 1

MOTOR NDE 4.5

3.7 1.5 4.4

OK

MOTOR DE 3.2 3.1 2.2

8 BLOWER SIDE BEARING 7 10 Spike Energy in g's = 2.11 Bearing shows deterioration.

9 MOTOR SIDE BEARING 2.7 1.6

10PA FAN MOTOR 2

MOTOR NDE 4.5

2 3 3.3

OK

MOTOR DE 2.8 3 3.5

11 BLOWER SIDE BEARING 4.1 1.9

OK

12 MOTOR SIDE BEARING 3.2 2.6

13 ID FAN MOTOR 1 MOTOR NDE 4.5 0.5 0.4 0.8 OK

MOTOR DE 0.8 0.6 0.5

14 BLOWER SIDE BEARING 0.4 0.6 0.8

15ID FAN MOTOR 2

MOTOR NDE 4.5

0.9 0.6 1.1

OK

MOTOR DE 1 0.9 0.8

16 BLOWER SIDE BEARING 2 1.4 4.1 Axial movement (looseness) Check the looseness

17

30-09-2013 POWER HOUSE

800 CFM COMPRESSOR-2

MOTOR

MOTOR NDE 8.3

3.3 2.4 4.3

OK

MOTOR DE 4.7 3.8 3.9


MOTOR

MOTOR NDE 8.3

1.7 3.2 2.6

OK

MOTOR DE 2 3.5 2.2


MOTOR

MOTOR NDE 8.3

8.2 1.8 4.31x is more (unbalance

force ) check the coupling MOTOR DE 10 4.1 2.2

14


MOTOR

MOTOR NDE 8.3

3.6 2.7 3.6

OK

MOTOR DE 5.1 3.4 5.2

15


MOTOR

MOTOR NDE 8.3

4.6 4.5 8.9 Truncated time wave & axial dominate check the pulley to pulley

alignment MOTOR DE 3.4 3.6 7

16


MOTOR

MOTOR NDE 8.3

1.1 2.4 4.3

OK

MOTOR DE 1.7 3.8 3.3

17


MOTOR

MOTOR NDE 8.3

4 2 3.7

OK

MOTOR DE 4.7 3.3 2.8

19

THERMEX BLOWER MOTOR

1

MOTOR NDE 9.5

1.7 0.5 5.2Random vibration Clean the blower vans &

check the blower wobbling MOTOR DE 0.9 1.5 3

20

THERMEX BLOWER MOTOR

2

MOTOR NDE 9.5

1 0.8 3.5

high frequency peaks

check the DE side bearing (shows deterioration)

MOTOR DE 0.7 2.4 3.4

21

TBW-1 FD FAN MOTOR

MOTOR NDE 9.5

0.8 0.7 1.9

looseness frequency

check the any mechanical looseness (like

coupling ,foundation bolts etc..)MOTOR DE 1.3 0.9 1.5

22

TBW-2 FD FAN MOTOR

MOTOR NDE 9.5

1.1 0.9 2.2

OK

MOTOR DE 1.4 3.6 1.7

23

IAEC FD MOTOR 2

MOTOR NDE 9.5

7.1 1.8 3.11x is more in Hor

Do the balancing MOTOR DE 6.4 2.2 3.2

MONTHLY WISE INCREASING POINTS:

MONTH Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14POINTS 750 1130 2150 2450 2750 2880 2880 3220 3220 3220

GRAPH:

Apr/13 May/13 Jun/13 Jul/13 Aug/13 Sep/13 Oct/13 Nov/13 Dec/13 Jan/140

500

1000

1500

2000

2500

3000

3500

POINTS

POINTS

FEED BACK & PROBLEMS UNDER OBSERVATION:

S.NO PLANT AREAEQUIPMENT NAME PROBLEM STATUS

1

PLANT-I

OLD BABURY


LOOSENESS AND BEARING PROBLEM

Initial stage

2 BANBURY -1 DUMP MILL GEAR BOX

GEAR MESH BACKLASH Initial stage

3 BANAURY-3 MAIN MOTOR

UNBALANCE FORCE ACTING Need to be test

4 BANAURY-4 MAIN GEAR BOX






7HFE

HFE FEED MILL-II MOTOR

BEARING PROBLEM Initial stage

8 HFE CRAKER MILL GEAR BOX

GEAR TOOTH PROBLEM Initial stage

9

TUBE PLANT

6'' EXTRUDE

R

6'' EXTRUDER FEED MILL MOTOR FLATNESS OF THE BASE

Need to be

correct

106'' EXTRUDER CRACKER MILL

MOTORFLATNESS OF THE BASE

Need to be

correct

116'' EXTRUDER CRACKER MILL

CONNECTING GEAR BACKLASH

Need to be

correct

128'' EXTRUDER

8" EXTRUDER MILL-I (CRACKER MILL

MOTOR)DE BEARING PROBLEM Initial

stage

13NEW 6''

EXTRUDER

HOT AIR EXHAUST BLOWER UNBALNCE

Need to be

correct

14NEW 6'' EXTRUDER

MOTOR INCREASE THE RIGIDITY Need to

be correct

15

PLANT-II

DIP UNIT

PR-1 BLOWER UNBALANCE FORCE ACTING Initial stage

16ZONE-2 MAIN CIRCULATION

BLOWER UNBALANCE FORCE ACTING

Need to be

correct

17 ZONE-2 HOT AIR EXHAUST BLOWER

UNBALANCE Initial stage

18

TYRE CURING

#2

TRENCH#1 SOUTH MOTOR


19TRENCH# 2 NORTH

& EAST MOTOR MISALIGNMENT Need to

be correct

20TRENCH# 3 EAST

MOTOR MISALIGNMENT Need to

be

correct

21TRNCH # 5 MIDDLE & NORTH MOTOR MISALIGNMENT

Need to be

correct

22TRENCH # 7 KSB

MOTOR MOTOR BASE PROBLEM Need to

be correct

23 DUAL TUBER#1

CAP MILL MOTOR SOFT FOOT PROBLEM Initial stage

24

PLANT-III

NEW BANBURY

COMPRESSOR #7 MOTOR MISALIGNMENT

Need to be

correct

25

DUAL TUBER# 2

BASE FEED MILL GEAR BOX

GEAR TOOTH PROBLEM Initial stage

26 BASE CRACKER MILL BEARING PROBLEM Initial stage

27 CAP CRACKER MILL BEARING PROBLEM Initial stage

28

DUAL TUBER# 3

8'' BASE EXTRUDER MOTOR


29 10'' CAP EXTRUDER MOTOR


30 MILL #2 & BASE FEED MILL

CONNECTING GEAR BACKLASH

Initial stage

3171''

CALENDER

CRACKER MILL #2 BEARING PROBLEMInitial stage

32

UTILITIES

CFBID FAN BLOWER # 2 AXIAL MOVEMENT Initial

stage

33 PA FAN 2 BEARING PROBLEM Initial stage

34

POWER HOUSE

800 CFM COMPRESSOR # 4 MISALIGNMENT

Need to be

correct

35 THERMEX BLOWER # 2


36 IAEC FD MOTOR #2 UNBALANCE Need to

be correct

GOOD OBSERVATION:

S.NO PLANT AREAEQUIPMENT NAME S0lVED PROBLEM

CURRENT STATUS

1

PLANT-I

OLD BABURY

BANBURY # 4 MAIN MOTOR

COUPLING LOOSENESS DUE TO WEAR BUSH

PINSOK

2 HFE HFE MAIN MOTOR SCR PROBLEM OK

3TYRE

CURING #1

275 PSI CWS PUMP MOTOR ALIGNMENT PROBLEM OK

4 TUBE NEW 6''

EXTRUDER

NEW 6'' EXTRUDER MOTOR BEARING PROBLEM OK

5

PLANT-II DIP UNIT

ZONE 2 MAIN CIRCULATION

BLOWER BALANCING PROBLEM

NEED TO BE IMPROVEMEN

T

6ZONE 2 MAIN CIRCULATION

MOTOR

PULLEY TO PULLEY ALIGNMENT OK

715 TR CHILLER COND. PUMP

MOTOR-1

BASE DEFORMATION PROBLEM OK

8 TYRE CURING

#2

TRENCH # 3 NORTH MOTOR

LOOSENESS OK

9 TRENCH # 4 NORTH MOTOR

ALIGNMENT PROBLEM OK

10PLANT#

III

DUAL TUBER #

2

CAP CRACKER MILL MOTOR ALIGNMENT PROBLEM OK

11 DUAL

TUBER # 3

BASE FEED MILL MOTOR BEARING PROBLEM OK

12 UTILITIES

CFB PA FAN # 1 BEARING PROBLEM OK

audit points

Documents

banbury main motor banaury

cfe main motor

connections motor

banbury main motors

f270 main motor gb150

new f270 motor

main motormotor nde

banbury gear boxmain