Predictive Maintenance Report

On
Vibration Analysis & Diagnostic studies

VIBRATION ANALYSIS
REPORT

CUSTOMER CONTACT COMPANY NAME

M/s. PRIYA CEMENTS M/s. MVS ACMEI TECHNOLOGIES PVT LTD

KODADA (M), JUBILEE ENCLAVE, MADHAPUR,
TELANGANA HYDERABAD-500072

Done by:
GMVNPSriram
(+91) 7989802025

Vibration Inspection Site Information

 Customer M/s. PRIYA CEMENTS CEMENTS
Contact Person Mr. DAYAKAR
Phone +91 8008556535
E –mail Dayakar.t@priyacement.com
Date of Visit 30.11.19 TO 30.11.19
PAGE NO.

I. INDEX 02
II. SERVICES 03
III. VIBRATION STANDARDS 04
IV. SUMMARY REPORT 05
V. REPORT 06-20

VIBRATION ANALYST: Mr. G.M.V.N.P.Sriram

Sr. Engineer (Technical-Services)

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 2

We also carry out the below mentioned Condition Monitoring Services:

Vibration analysis

In-situ Dynamic Balancing

Laser Alignment

Lube Oil Analysis

Infrared Thermography

Root cause failure analysis

Ultrasonic Acoustic Inspection

Turbo Machinery & Compressor Services

NDT Services (UT, Radiography, Flaw detection, LT to MP)

Remote Data Analysis

Asset Management Services

Training Programs

Web Based offline/online remote monitoring

If there is any requirement please feel free to contact us.

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 3

ISO VIBRATION STANDARDS:
I. MACHINERY CLASSIFICATION IN ACCORDANCE WITH ISO 10816:
Velocity measurements can be categorized as follows:
CLASS I:
Individual parts of engines and machines integrally connected with the complete machine in its normal
operating condition. (Production electrical motors of up to 15 KW are typical examples of machines in
this category).
Class II:
Medium-sized machines, (typically electrical motors with 15 to 75 kW output) without special
foundations, rigidly mounted engines or machines (up to 300 kW) on special foundations.
Class III:
Large prime movers and other large machines with rotating masses mounted on rigid and heavy
foundations which are relatively stiff in the direction of vibration measurement.
Class IV:
Large prime movers and other large machines with rotating masses mounted on foundations which are
relatively soft in the direction of vibration measurement ( for example turbo-generator sets, especially
those with light-weight substructures).

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 4

 SUMMARY REPORT
S.NO EQUIPMENT NAME HEALTH STATUS PAGE NO.
1 RAW COAL HOPPER BAG FILTER FAN ALARM 06
2 KILEN FEEDER BLOWER NORMAL 07
3 PRE HEATER (8 TH
Floor) BAG FILTER FAN NORMAL 08
4 BAG FILTER FAN ALERT 09
5 CSP TOP BAG FILTER FAN (155LM) NORMAL 10
6 CSP TOP BAG FILTER FAN (156LM) NORMAL 11
7 COOLER FAN-1 NORMAL 12
8 COOLER FAN-4 NORMAL 13
9 COOLER FAN-6 NORMAL 14
10 FK PUMP-KC COAL ALERT 15
11 FK PUMP PC COAL NORMAL 16
12 KC/PC BINS BAG FILTER FAN NORMAL 17
RAW MILL DISCHARGE AIR SLIDE BLOWER NORMAL
13 18
(EM155)
RAW MILL DISCHARGE AIR SLIDE BLOWER NORMAL
14 19
(EM156)
15 SEAL AIR FAN NORMAL 20

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 5

 1. RAW COAL HOPPER Overall M/C Condition
ALARM
BAG FILTER FAN Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed 2920 RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 23.24 ALARM
FAN 29.66 ALARM

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 10.19 23.24 16.18
MOTOR DE 5.69 7.61 16.46
FAN DE 5.04 2.39 10.35
FAN NDE 29.66 7.99 15.11

MACHINE CONDITION REPORT

OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & fan both bearings are in
alarm condition
 Non-synchronous frequencies were observed in the spectrum at fan both bearings.
 Coupling wear/looseness symptoms between motor to fan.
 Misalignment is indicated between motor to fan.
 In spectrum analysis indicates dominant frequency 48.75 Hz at fan both bearings.

RECOMMENDATION:

 Inspect the fan both bearings and if required replace them on priority.

 Inspect coupling internals & achieve precision alignment between motor to fan.

 Provide the stiffeners between Fan bases to system channels.

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 6

 Re-assess the health condition of equipment after above correction.

NOTE:

Immediate actions are required at present condition to avoid further deterioration of the equipment.

Overall M/C Condition

2. KILEN FEEDER BLOWER NORMAL

Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 3.63 NORMAL

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 3.08 3.63 0.97
MOTOR DE 2.63 2.77 1.43

MACHINE CONDITION REPORT

OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor both bearings are in
Normal condition
 In spectrum analysis indicates dominant frequency 49.95 Hz at motor both bearings.

RECOMMENDATION:

 Tighten the entire system base bolts.

NOTE:

Action to be taken on priority basis.

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 7

 3.PRE-HEATER (8TH FLOOR) Overall M/C Condition
NORMAL
BAG FILTER FAN Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 2.66 NORMAL

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 1.43 1.15 0.74
MOTOR DE 2.66 1.25 0.79

MACHINE CONDITION REPORT

OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor bearings are in Normal
condition
 Non-synchronous frequencies were observed in the spectrum at motor bearings.

RECOMMENDATION:

 Lubricate motor both bearings on regular intervals.

 Re-assess the health condition of equipment.

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 8

NOTE:

Immediate actions are not required at present condition. Equipment runs as usual.

Overall M/C Condition

4. BAG FILTER FAN ALERT

Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 3.14 ALERT
FAN 4.39 ALERT

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 3.14 0.91 0.84
MOTOR DE 1.24 0.82 1.05
FAN DE 0.19 2.69 1.90
FAN NDE 2.74 4.39 2.28
MACHINE CONDITION REPORT
OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & fan both bearings are in
alert condition
 Non-synchronous frequencies were observed in the spectrum at motor & fan both bearings.
 Severe bearing looseness is indicated at fan both bearings.

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 9

 Abnormal sound was observed at motor NDE bearings.

RECOMMENDATION:

 Inspect the motor & fan both bearings and if required replace them on priority.

 Inspect coupling internals & achieve precision alignment between motor to fan.

 Re-assess the health condition of equipment after above correction.

NOTE:

Immediate actions are required at present condition to avoid further deterioration of the equipment.

5. CSP TOP BAG FILTER Overall M/C Condition

NORMAL
FAN (155 LM) Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 4.98 NORMAL
FAN 3.99 NORMAL

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 4.98 2.83 2.70
MOTOR DE 4.96 2.36 2.20
FAN DE 3.84 2.88 4.77
FAN NDE 3.35 3.99 4.12
MACHINE CONDITION REPORT
OBSERVATION & ANALYSIS:

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 10

 As per ISO standards 10816 present vibration readings recorded at motor & fan both bearings are in
Normal condition
 In spectrum analysis indicates dominant frequency 74.75 Hz at motor & fans both bearings.
 Coupling wear/looseness symptoms between motor to fan.

RECOMMENDATION:

 Inspect the fan NDE bearings for increased bearing clearances.

 Inspect coupling internals & achieve precision alignment between motor to fan.

 Re-assess the health condition of equipment after above correction.

NOTE:

Action to be taken on Available opportunity.

6. CSP TOP BAG FILTER Overall M/C Condition

NORMAL
FAN (156 LM) Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 1.39 NORMAL
FAN 1.29 NORMAL

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 1.20 1.16 1.36
MOTOR DE 1.38 1.22 1.39
FAN DE 1.17 1.23 1.24
FAN NDE 1.23 1.29 1.16

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 11

 MACHINE CONDITION REPORT
OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & fan both bearings are in
alarm condition
 In spectrum analysis indicates dominant frequency 12.5 Hz at entire system bearings.

RECOMMENDATION:

 Tighten the entire system base bolts.

 Monitor the vibration trend levels.

NOTE:

Immediate Corrections are not required at present condition.

Overall M/C Condition

7. COOLER FAN-1 NORMAL

Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 1.26 NORMAL
FAN 1.57 NORMAL

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 0.99 0.44 0.74
MOTOR DE 1.26 0.45 0.58

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 12

 FAN DE 1.16 0.68 1.57
FAN NDE 1.18 1.41 1.55
MACHINE CONDITION REPORT
OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & fan both bearings are in
Normal condition
 Non-synchronous frequencies were observed in the spectrum at motor both bearings.

RECOMMENDATION:

 Lubricate motor both bearings on regular intervals.

NOTE:

Action to be taken on next available opportunity.

Overall M/C Condition

8. COOLER FAN-4 NORMAL

Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 2.10 NORMAL
FAN 2.60 NORMAL

DATA SHEET:
VELOCITY RMS IN MM/SEC:

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 13

 LOCATION HORIZONTAL VERTICAL AXIAL
MOTOR NDE 1.30 1.72 1.79
MOTOR DE 1.69 1.23 2.10
FAN DE 0.96 1.17 2.60
FAN NDE 1.29 1.31 1.20
MACHINE CONDITION REPORT
OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & fan both bearings are in
Normal condition
 Non-synchronous frequencies were observed in the spectrum at fan both bearings.

RECOMMENDATION:

 Inspect the fan both bearings for increased bearing clearances.

 Lubricate fan both bearings on regular intervals.

NOTE:

Action to be taken on next available opportunity.

Overall M/C Condition

9. COOLER FAN-6 NORMAL

Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 2.07 NORMAL
FAN 2.59 NORMAL

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 14

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 1.66 0.46 0.58
MOTOR DE 2.07 1.31 0.57
FAN DE 0.98 0.55 0.63
FAN NDE 2.59 0.55 0.60
MACHINE CONDITION REPORT
OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & fan both bearings are in
Normal condition
 Coupling wear/looseness symptoms between motor to fan.

RECOMMENDATION:

 Inspect coupling internals & achieve precision alignment between motor to fan.

 Re-assess the health condition of equipment after above correction.

NOTE:

Action to take on next available opportunity

Overall M/C Condition

10.FK PUMP-KC COAL ALERT

Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 15

 MOTOR 1.35 NORMAL
PUMP 3.73 ALERT

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 0.72 0.54 0.99
MOTOR DE 0.73 1.35 0.85
PUMP DE 1.00 1.37 0.85
PUMP NDE 3.73 0.75 0.96
MACHINE CONDITION REPORT
OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & pump both bearings are
in Normal condition
 Non-synchronous frequencies were observed in the spectrum at pump NDE bearings.
 Severe bearing Noise is indicated at pump NDE bearings

RECOMMENDATION:

 Inspect the Pump NDE bearings and if required replace them on priority.

 Re-assess the health condition of equipment after above correction.

NOTE:

Immediate actions are required at present condition to avoid further deterioration of the equipment.

Overall M/C Condition

11.FK PUMP-PC COAL ALERT

Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 16

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 1.10 NORMAL
PUMP 3.09 ALERT

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 0.40 0.46 1.10
MOTOR DE 0.46 0.49 0.61
PUMP DE 3.09 2.23 1.18
PUMP NDE 213 1.30 1.48
MACHINE CONDITION REPORT
OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & pump both bearings are
in Normal condition
 Non-synchronous frequencies were observed in the spectrum at pump both bearings.
 Abnormal sound was observed at Pump DE bearings.

RECOMMENDATION:

 Inspect the pump both bearings and if required replace them on priority.

 Re-assess the health condition of equipment after above correction.

NOTE:

Immediate actions are required at present condition to avoid further deterioration of the equipment.

12.KC/PC BINS BAG Overall M/C Condition

NORMAL
FILTER FAN Date of visit: 30-11-2019

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 17

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 5.90 NORMAL

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 5.60 4.95 5.90
MOTOR DE 5.51 3.96 4.08

MACHINE CONDITION REPORT

OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & fan both bearings are in
Normal condition
 In spectrum analysis indicates dominant frequency 48.75 Hz at motor both bearings.

RECOMMENDATION:

 Tighten the entire system base bolts.

 Re-assess the health condition of equipment after above correction.

NOTE:

Action to be take on Available opportunity.

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 18

 13.RAW MILL DISCHARGE Overall M/C Condition
NORMAL
AIR SLIDE BLOWER
Date of visit: 30-11-2019
(EM155)
EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 1.53 NORMAL

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 1.47 1.53 1.12
MOTOR DE 1.17 1.38 1.49

MACHINE CONDITION REPORT

OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & fan both bearings are in
Normal condition

RECOMMENDATION:

 Re-assess the health condition of equipment.

NOTE:

Immediate actions are not required at present condition. Equipment run as usual.

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 19

 14.RAW MILL DISCHARGE Overall M/C Condition
NORMAL
AIR SLIDE BLOWER
Date of visit: 30-11-2019
(EM161)
EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 3.76 NORMAL

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 3.76 3.50 2.30
MOTOR DE 2.75 2.41 1.83

MACHINE CONDITION REPORT

OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & fan both bearings are in
Normal condition
 In spectrum analysis indicates dominant frequency 48.95 Hz at motor both bearings.

RECOMMENDATION:

 Tighten the entire system base bolts.

 Re-assess the health condition of equipment.

NOTE:

Action to be taken on available opportunity.

MVS ACMEI TECHNOLOGIES PVT LTD PRIYA CEMENTS Page 20

 Overall M/C Condition

15.SEAL AIR FAN NORMAL

Date of visit: 30-11-2019

EQUIPMENT IMAGE:
Machine Class II

Normal <7.1 mm/s

Alert 7.2mm/s-11.2mm/s

Alarm 18.0>mm/s

Power KW
Speed RPM

HIGHEST AMPLITUDES AND HEALTH CONDITIONS:

LOCATION RMS VELOCITY(mm/sec) HEALTH CONDITION

MOTOR 1.27 NORMAL
FAN 0.89 NORMAL

DATA SHEET:
VELOCITY RMS IN MM/SEC:

LOCATION HORIZONTAL VERTICAL AXIAL

MOTOR NDE 1.25 1.18 0.41
MOTOR DE 1.27 0.44 0.34
FAN DE 0.89 0.30 0.24
FAN NDE 0.83 0.20 0.24

MACHINE CONDITION REPORT

OBSERVATION & ANALYSIS:

 As per ISO standards 10816 present vibration readings recorded at motor & fan both bearings are in
Normal condition
 Coupling wear/looseness symptoms between motor to fan.

RECOMMENDATION:

 Inspect coupling internals & achieve precision alignment between motor to fan.

 Re-assess the health condition of equipment after above correction.

NOTE:

Action to be take on Available opportunity.

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