A02.12_Attachment B to PWS 23-Ton Maint..pdf

Vibration Analysis Report

For

CRREL/ERDC,

Hanover, NH.

April 5, 2023

RRBBMM RReeppoorrtt IInnttrroodduuccttiioonn

Data was collected recently at your facility and the analysis of this data is presented in the following report.

Each piece of equipment in your facility will fall into one of three categories.

1. No problems detected – equipment operating normally.

2. Data analysis indicates attention is needed or a potential problem exists – minor maintenance may be required, equipment must be watched more closely for any increase in vibration amplitude or an anomaly has been detected. An anomaly does not necessarily indicate a problem but it does indicate something in the spectrum that is not present in a normal spectrum. The color yellow in the bearing area will depict this problem category.

3. Equipment defect has been confirmed – repair work must be performed at some point in the near future. The color red in the bearing area will depict this problem category.

The contents of this report will highlight the equipment that poses potential problems and equipment that require repair work.

Keywords:

Certainty: This indicates how well the data indicating equipment defect follows accepted analysis rules. This is based on a numerical value from 1-5, where 5 is 100% certain.

Urgency: This is a rating that combines the Certainty and Operational Significance into a weighted value. The following is the description of each weighted value:

1. Normal - Equipment has no known defects – Operate equipment normally

2. Attention – Data analysis indicates an anomaly – Please follow recommended guidance to avoid future equipment damage.

3. Caution - Data analysis indicates a low priority problem exists – additional data may be required, equipment must be watched more closely for any increase in vibration amplitude.

4. Serious - Data analysis confirms equipment defect - Repair work must be scheduled and performed at some point in the near future.

5. Emergency – Data analysis confirms high priority equipment defect – Equipment should be shut down and repair work must be performed as soon as possible. Continued operation will result in a safety risk and/or serious damage to equipment.

The Four Stages of Bearing Failure

Stage 1

Stage 2

STAGE 1: Earliest indications of bearing problems appear in ultrasonic frequencies ranging from about 250,000 - 350,000 Hz; later, as wear increases, usually drops to approximately 20,000 - 60,000 Hz (1,200,000 - 3,600,000 CPM). These are frequencies evaluated by Spike Energy (gSE), HFD(g) and Shock Pulse (dB). For example, spike energy may first appear at about .25 gSE in Stage 1 (actual value depending on measurement location and machine speed). Acquiring high frequency enveloped spectra confirms whether or not bearing is in Failure Stage 1.

STAGE 2: Slight bearing defects begin to "ring" bearing component natural frequencies (fn) which predominantly occur in 30K - 120K CPM range. Such natural frequencies may also be resonances of bearing support structures. Sideband frequencies appear above and below natural frequency peak at end of Stage 2. Overall spike energy grows (for example, from .25 to .50 gSE).

Stage 3

Stage 4

STAGE 3: Bearing defect frequencies and harmonics appear. When wear progresses, more defect frequency harmonics appear and number of sidebands grows, both around these and bearing component natural frequencies. Overall spike energy continues to increase (for example, from .5 to over 1 gSE). Wear is now usually visible and may extend throughout periphery of bearing, particularly when many well-formed sidebands accompany bearing defect frequency harmonics. High frequency demodulated and enveloped spectra help confirm Stage III. Schedule the bearings for replacement, (independent of bearing defect frequency amplitudes in vibration spectra).

STAGE 4: Towards the end, amplitude of 1X RPM is even effected. It grows, and normally causes growth of many running speed harmonics. Discrete bearing defect and component natural frequencies actually begin to "disappear" and are replaced by random, broadband high frequency "noise floor". In addition, amplitudes of both high frequency noise floor and spike energy may in fact decrease; but just prior to failure, spike energy and HFD will usually grow to excessive amplitudes.

Spectral Analysis Scan Report CRREL/ERDC, Hanover, NH.

April 5, 2023

GEA Model 85GMX S/N G1560 MT Chiller 1 CT# 0147000610103 Problems Detected

GEA Model 85GMX S/N G1561 MT Chiller 2 CT# 0147000610102 Problems Detected

GEA Model 125GMX S/N L2746 LT Chiller 1 CT# 0147000610101 No Data Collected

Vibration Survey Problem Detail

Area: CRREL/ERDC, Hanover, NH.

Urgency:

Serious Equipment: MT Chiller 1, GEA Model 85GMX, S/N G1560

Title: Bearing Fault, AC Induction Motor, M1, M2 Contract: 01470-006-1-01-03

Survey: 04-Apr-23

Fault:

BPFO Fault Certainty: 4

Analyst: James Gable

Explanation: The bearing fundamental defect frequency BPFO “Ball Pass

Frequency Outer Race” and its harmonics are appearing in the spectrum. Moderate impacting from the defects in the outer race of the bearing can be seen in the time waveform. The bearing is in stage 3 of the 4-part bearing failure scenario.

Recommendation: Overhaul the motor at your first opportunity.

Vibration Survey Points Motor Problem Spectra

Route Waveform

04-Apr-23 17:34:24

PK = 3.00

PK(+/-) = 8.55/7.45

CRESTF= 3.95

0 1 2 3 4 5

-15

-10

-5

Revolution Number

A c c e le ra ti o n i n G

-s

CEHN - GEA Model 85GMX, S/N G1560 MT Chil 1 -M1V Motor Outboard Vertical

Route Spectrum

04-Apr-23 17:34:24

OVERALL= .1276 V-DG

PK = .1257

LOAD = 100.0

RPM = 3572. (59.53 Hz)

0 50 100 150 200

0.01

0.02

0.03

0.04

0.05

0.06

Frequency in kCPM

P K

V e lo c it y i n

I n

/S e c

Freq:

Ordr:

Spec:

11.07 3.098 .00350

>SKF 6314

V=BPFO -IO

V V V V V V V V V V V V V V V

Red Boxes=BPFO & Harmonics

Moderate Impacting at the BPFO Freq.

Vibration Survey Problem Detail

Area: CRREL/ERDC, Hanover, NH.

Urgency:

Serious Equipment: MT Chiller 2, GEA Model 85GMX, S/N G1561

Title: Bearing Fault, AC Induction Motor, M1, M2 Contract: 01470-006-1-01-02

Survey: 05-Apr-23

Fault:

BPFO Fault Certainty: 4

Analyst: James Gable

Explanation: The bearing fundamental defect frequency BPFO “Ball Pass

Frequency Outer Race” and its harmonics are appearing in the spectrum. Moderate impacting from the defects in the outer race of the bearing can be seen in the time waveform. The bearing is in stage 3 of the 4-part bearing failure scenario.

Recommendation: Overhaul the motor at your first opportunity.

Vibration Survey Points Motor Problem Spectra

Route Waveform 05-Apr-23 17:22:54

PK = 3.72

PK(+/-) = 8.54/7.96

CRESTF= 3.25

0 1 2 3 4 5 6 7

-20

-15

-10

-5

Revolution Number

A c c e le ra ti o n i n

G -s

CEHN - GEA Model 85GMX, S/N G1561 MT Chil 2 -M1V Motor Outboard Vertical

Route Spectrum 05-Apr-23 17:22:54

OVERALL= .1595 V-DG

PK = .1589

LOAD =3925.0

RPM = 3570. (59.50 Hz)

0 30 60 90 120 150 180

0.01

0.02

0.03

0.04

0.05

0.06

0.07

Frequency in kCPM

P K

V e lo c it y i n

I n

/S e c

Freq:

Ordr:

Spec:

11.05 3.095 .01005

>SKF 6314

V=BPFO -IO

V V V V V V V V V V V V V V V

Red Boxes=BPFO & Harmonics

Moderate Impacting at the BPFO Freq.

Abbreviated Last Measurement Summary

Database: GEA.rbm Area: CRREL/ERDC, Hanover, NH Report Date: 17-Apr-23 15:31

MEASUREMENT POINT OVERALL LEVEL HFD / VHFD

MT Chil 1 - GEA Model 85GMX, S/N G1560 (04-Apr-23) HRS - Run Hours 4197.0 STANDARD M1H - Motor Outboard Horizontal .090 In/Sec .542 G-s M1V - Motor Outboard Vertical .128 In/Sec .807 G-s M1A - Motor Outboard Axial .218 In/Sec 1.352 G-s M2H - Motor Inboard Horizontal .080 In/Sec .236 G-s M2L - Mot. Inboard Horiz./2X Line Freq .035 In/Sec M2V - Motor Inboard Vertical .099 In/Sec .179 G-s M2A - Motor Inboard Axial .087 In/Sec .181 G-s C1H - Compressor Inboard Horizontal .031 In/Sec .129 G-s C1V - Compressor Inboard Vertical .090 In/Sec .239 G-s C1A - Compressor Inboard Axial .035 In/Sec .074 G-s C2H - Compressor Outboard Horizontal .085 In/Sec .098 G-s C2V - Compressor Outboard Vertical .146 In/Sec .261 G-s C2A - Compressor Outboard Axial .074 In/Sec .134 G-s C3H - Compressor Inboard Horizontal .031 In/Sec .145 G-s C3V - Compressor Inboard Vertical .116 In/Sec .219 G-s C3A - Compressor Inboard Axial .049 In/Sec .212 G-s C4H - Compressor Outboard Horizontal .094 In/Sec .217 G-s C4V - Compressor Outboard Vertical .061 In/Sec .408 G-s C4A - Compressor Outboard Axial .049 In/Sec .121 G-s

MT Chil 2 - GEA Model 85GMX, S/N G1561 (05-Apr-23) HRS - Run Hours 3925.0 STANDARD M1H - Motor Outboard Horizontal .070 In/Sec .253 G-s M1V - Motor Outboard Vertical .160 In/Sec .139 G-s M1A - Motor Outboard Axial .154 In/Sec .321 G-s M2H - Motor Inboard Horizontal .064 In/Sec .130 G-s M2L - Mot. Inboard Horiz./2X Line Freq .077 In/Sec M2V - Motor Inboard Vertical .122 In/Sec .241 G-s M2A - Motor Inboard Axial .069 In/Sec .183 G-s C1H - Compressor Inboard Horizontal .036 In/Sec .069 G-s C1V - Compressor Inboard Vertical .145 In/Sec .323 G-s C1A - Compressor Inboard Axial .046 In/Sec .089 G-s C2H - Compressor Outboard Horizontal .067 In/Sec .342 G-s C2V - Compressor Outboard Vertical .123 In/Sec .269 G-s C2A - Compressor Outboard Axial .071 In/Sec .275 G-s C3H - Compressor Inboard Horizontal .036 In/Sec .180 G-s C3V - Compressor Inboard Vertical .058 In/Sec .092 G-s C3A - Compressor Inboard Axial .055 In/Sec .048 G-s C4H - Compressor Outboard Horizontal .092 In/Sec .243 G-s C4V - Compressor Outboard Vertical .086 In/Sec .168 G-s C4A - Compressor Outboard Axial .080 In/Sec .134 G-s

Clarification Of Vibration Units:

Vel --> In/Sec PK HFD --> G-s PK

Lubricant Analysis Report North America: +1-877-808-3750

Overall report severity based on comments.

Account Information Account Number: 401110-0040-0000 Company Name: MILLER REFRIGERATION

COMP INC

Contact: NANCY MILLER Address: 93 LEWISTON PO BOX 1165

GRAY, ME 04039 US

Phone Number: 207-657-3691

Component Information Component ID: MT CHILLER 1

Secondary ID: CRREL Ferf Component Type: ROTARY SCREW

COMPRESSOR

Manufacturer: GEA

Model: 85GS Application: TEST CELL

Sump Capacity: 35 gal

Sample Information Tracking Number: 21141R96651

Lab Number: I-319582 Lab Location: Indianapolis Data Analyst: AC

Sampled: 05-Apr-2023 Submitted: 11-Apr-2023

Received: 14-Apr-2023 Completed: 18-Apr-2023

Filter Information Filter Type: CARTRIDGE

Micron Rating: 0

Miscellaneous Information Product Information

Product Manufacturer: CPI ENGINEERING

SERVICES

Product Name: SOLEST 120 Viscosity Grade: CUSTOM GRADE

Comments Flagged data does not indicate an immediate need for maintenance action. Continue to observe the trend and monitor equipment and fluid conditions. Lead is at a MINOR LEVEL; Tin is at a MINOR LEVEL; Possible bearing/bushing metal; Filter change acknowledged.

Sample Approver

Comments

18-Apr-2023 No immediate maintenance requirements.

Wear Metals (ppm) Contaminant Metals (ppm) Multi-Source Metals (ppm) Additive Metals (ppm)

Sa m pl e

Ir on

Ch ro m iu m

N ic ke l

Al um in um

Co pp er

Le ad

Ti n

Ca dm iu m

Si lv er

Va na di um

Si lic on

So di um

Po ta ss iu m

Ti ta ni um

M ol yb de nu m

An tim on y

M an ga ne se

Li th iu m

Bo ro n

M ag ne si um

Ca lc iu m

Ba riu m

Ph os ph or us

Zi nc

1 2 0 0 1 0 2 2 0 0 0 2 1 0 0 0 1 0 0 0 2 3 0 3 2

Sample Information Contaminants Fluid Properties

Sa m pl e

D at e Sa m pl ed

D at e R ec ei ve d

Lu be

T im e h

U ni t T im e h Lu be

C ha ng e

Lu be

Ad de d gal Fi lte r C ha ng e

Fu el

D ilu tio n

So ot

W at er

Vi sc os ity

°C cSt

Vi sc os ity

°C cSt Ac id N um be r mg KOH / g

Ba se

N o.

D mg KOH / g

O xi da tio n abs / cm

N itr at io n abs / 0.1mm

1 05-Apr-2023 14-Apr-2023 4198 4198 No 0 Yes .01 - mo. 6304C 90.3 0.01

Particle Count (particles/mL) Additional Testing

Sa m pl e

IS

O

C od e

Based On 4/6/14 particles / mL particles / mL particles / mL particles / mL particles / mL particles / mL particles / mL particles / mL

Te st

M et ho d

1 / /

Comments are advisory only and are based on the assumption that the sample and data submitted are valid. Results relate only to the items tested. Missing fluid or component information limits the evaluation. No warranty is expressed or implied. Measurement uncertainty available upon request.

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