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Vibration of Rotating Machinery in Hawiyah Gas Plant

Vibration of Rotating Machinery in Hawiyah Gas Plant. Presented by : Ahmed Al-Jaafari 993714 Advisor : Dr. Meyasser Al-Haddad October 19,2004. King Fahd University of Petroleum and Minerals Mechanical Engineering Departments. Outline: . Plant Overview Hawiyah Gas Plant Processes

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Vibration of Rotating Machinery in Hawiyah Gas Plant

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  1. Vibration of Rotating Machinery in Hawiyah Gas Plant Presented by : Ahmed Al-Jaafari 993714 Advisor : Dr. Meyasser Al-Haddad October 19,2004 King Fahd University of Petroleum and Minerals Mechanical Engineering Departments

  2. Outline: • Plant Overview • Hawiyah Gas Plant Processes • Vibration Group • Case Study • Conclusion

  3. Hawiyah Gas Plant Overview: • One of the newest plant. • The first completely non-associated gas plant • Completed four months ahead of schedule and under budget • Designed and built from scratch to meet the increased local demand for sales gas

  4. Overview: • Feed gas of the plant: • Juaf 407 MMSCFD (sweet) • Khuff 1305 MMSCFD (sour) Plant production: • 1530 MMSCFD sweet gas • 50 MMSCFD sulfur • Increased the Kingdom's gas supply by 30 %. • Increase capacity 2,400 MMSCFD

  5. 50 MMSCFD Juaf 407 MMSCFD Khuff(Haw) 1305 MMSCFD 1225 MMSCFD Khuff(Har) 50 MMSCFD USES OF PLANT 1587 MMSCFD 1530 MMSCFD SALES GAS HAWIYAH GAS PLANTPROCESSES SULFUR RECOVERY DEHYDRATION & DEW POINT CONRTOL INLET AREA GAS TREAT SALES COMPRESSORS SCFD = Standard Cubic Feet per Day

  6. Maintenance Division Technical Support Unit Planers Work Shop Areas Maintenance Crew Preventive Maintenance Vibration Group Quality Assurance Engineers

  7. ADRE System (AutomatedDiagnosis for Rotating Equipments) VibrationGroup Devices and Software: Data Manager2000 (DM 2000) C.S.I. Machinery Analyzer(Computational SystemIncorporated)

  8. Y Y Y Y A A A A X X X X Vibration Readings MOTOR COMPRESSOR

  9. CASE STUDY Bearing Defect:

  10. Bearing Frequencies: BSF • Ball Pass Frequency of Outer race (BPFO) • Ball pass frequency of the Inner race (BPFI) • Fundamental Train Frequency (FTF) • Ball Spain Frequency (BSF) FTF BPFI BPFO

  11. Bearing Frequencies Calculations 1. Bearing Frequency Equations: RPM = revolutions per minuteS = speed, revolutions per secondBd = ball or roller diameterNb = number of balls or rollersPd = pitch diameterθ = contact angle

  12. Bearing Frequencies Calculations 2. Rule of Thumb: OR = 0.4 x (speed) x N IR = 0.6 x (speed ) x N FTF =0.4 x (speed) Where N is number of balls

  13. Bearing Frequencies Calculations 3. Bearing Frequency Calculator:

  14. 1. Bearing Frequency Equations: 2. Rule of Thumb: • BPFO = 142.125 Hz • BPFI = 217.85 Hz • FTF = 11.84 Hz • BSF = 52.19 Hz • OR = 0.4 (1800/60) 12= 144 Hz • IR = 0.6 (1800/ 60) 12 = 216 Hz • FTF = 0.4 (1800/60) = 12 Hz 3. Bearing Frequency Calculator: • (BPFO) = 146.27Hz • (BPFI) = 213.73 Hz • (FTF) =12.19 Hz • (BSF) = 59.17 Hz Bearing Frequencies Calculations Example: ( SKF 7311BECBJ) Since: S = 1800 RPM Bd = 0.9474 in Pd = 3.449 in θ = 40 0 Nb = 12 balls

  15. Zone A Zone B Zone C Zone D Failure Modes: Bearing defect frequency region Bearing component natural freq. region Spike energy 1X 2X 3X Stage 1: 500 2000 20-60 kHz Stage 2: Stage 3: Random high freq. Vibration Stage 4:

  16. Bearing Frequency Calculation: • (BPFO) = 146.27Hz • (BPFI) = 213.73 Hz • (FTF) =12.19 Hz • (BSF) = 59.17 Hz Example 1: Analysis: Findings: • Non- of the bearing frequency match. • Highlighted readings are the max.

  17. Example 1: Findings: Zone A Zone B Zone C • 2 BPFO & 2 BPFI. • Bearing natural components freq. • Side band freq. around the bearing natural freq. Natural freq. & Side Band freq. 2BPFI Recommendation: The bearing is defective in the third stage of failure and has to be replaced. 2BPFO Note: harmonic means 1x(freq), 2x(freq), 3x(freq)

  18. Replacing the bearing:

  19. Example 2: Analysis: Bearing Frequency Calculation: • Inner race defect frequency (BPFI) = 332.6 Hz • Outer race defect frequency (BPFO) = 207.41 Hz • Cage defect frequency (FTF) = 23.05 Hz • Ball spin frequency (BSF) = 122.45 Hz • Findings: • side-bands freq. around the highest amplitude. • the highest amplitude (prime spike vib.) • = 6xBPFO

  20. Example 2: Findings: • None of the bearing freq. match. • The harmonic freq of BPFI do not match. • The harmonic freq. of BPFO match with the readings. Recommendation: The bearing outer race is in the third stage of failure and has to be replaced. Note: harmonic means 1x(freq), 2x(freq), 3x(freq)

  21. Conclusion: • I have been exposed to different types of rotating equipments. • I have gained good experience in analyzing the vibration readings and recommend the proper action. • I have given the opportunity to work in the Aramco Shadgham shop and dealing with different types of rotating machines during maintenance and overhauling. • I have been allowed to make studies and suggestions which improve the performance and reliability of the vibration group.

  22. Thank You

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