International Methanol Company, a SIPCHEM affiliate, KSA, has a Flue Gas FD Fan (DMW, 2725KW, 945RPM) driven by a steam turbine (Elliott, 4755RPM) through a step-down Gearbox (RENK, GR=5.03, Single Helical). Unit is monitored by BN 3500 Vibration Monitoring System with paired proximity probes on each bearing of Fan, Gearbox and Turbine. The proximity probe data was recorded using ADRE 408 system connected to the BN3500 monitor buffered outputs.

ID Fan experienced high shaft vibrations on DE bearing which were above alarm levels. At normal running condition (745RPM) maximum vibration level of 85um was observed at Fan DE. Full spectrum waterfall plots showed dominant 1X amplitude with high forward and significant reverse component at fan DE and NDE respectively. Step change in vibration was observed during steady state and vibrations were changed from 85um to 105um at Fan DE and 65um to 86um at Fan NDE. 1X amplitude change with slight phase angle deviations observed during the steady state. Orbit plot found with increase in amplitude with almost same pattern.

After detailed analysis, we concluded that high vibrations were due to high shaft run out values and presence of residual unbalance condition. According to API 670 run-out values should not be more than 25% of the maximum peak-to-peak allowable vibrations (OEM alarm set-point). Moreover, change in 1X amplitude vibrations at Fan DE/NDE bearing was due to change in dynamic stiffness condition of rotor/bearing during the event. Since the change in vibrations amplitude founds in both inboard and outboard bearings, process flue gas effect was also considered which initiated further investigation. Based on condition monitoring report, fan internals inspection was planned and the rotor was found with severely out of balance residue with 1KG out of tolerance in one plane and ½KG out of tolerance on the second plane.

Takeaways

1. Precision maintenance.
2. Machine diagnostic a better tool for failure analysis.
3. Advance vibration analysis.

Working as a Reliability Engineer (Rotating Equipment) in Saudi International Petrochemicals Company (SIPCHEM),KSA, I am an accomplished and self-driven mechanical engineer (CMRP) with the ability to lead multi-cultural teams. I have more than 08 years’ experience of core Rotating Equipment, Vibration Analysis, Machinery Diagnostics, Reliability Enhancement & Plant Maintenance mainly in Fertilizer and Petrochemical sector of various countries like KSA, UAE and Pakistan. Experience of renown vendors like BHGE, Nuovo Pignone, Sundyne, MAN Turbo, Dresser-Rand, Ingersoll Rand, Pacific, Burkhart, Elliot, Worthington, Kobelco, Flowserve etc. Key area of expertise includes; – Safe, uninterrupted and reliable operations of plant machinery which includes Process Compressors (Centrifugal / Reciprocating) & its driver Steam Turbines, Power generation Gas turbines, Fans, pumps (centrifugal & positive displacement) and Blowers.  – Vibration analysis thru BN-Adre, System-1 and CSI. – Condition Monitoring thru Lube Oil analysis, process parameters monitoring, Thermography etc. – Field Balancing (Single plane,Dual Plane) – Failure Root Cause Analysis (RCA) thru various techniques like Fish bone, Fault tree, 5 why etc. – Development and implementation of AIM services by utilizing techniques i.e. RCM, RAM, FMECA, RCA, Optimized PM strategies and other industry accepted practices. – Hands on experience of APM/CMMS software like Meridium, Isograph, SAP and Oracle.

Working as a Team Lead Condition Monitoring, in Saudi International Petrochemicals Company (SIPCHEM), KSA having 18+ years of experience in fertilizer and petrochemical sector. Core experience around condition monitoring, non-destructive testing techniques, standards and procedures development, turnaround planning and execution. Performed leadership role towards uptime of operating facility, safe and reliable maintenance practices and compliance of RAM/RCM/FMECA/RCA methodologies.

Professional Skills include:

–        HSQE focused initiatives.

–              Development and controlling of plant performance KPIs.

–              Decision Making.

–              Data Science (performance) analysis.

–              Uninterrupted and reliable operations of plant machinery which includes Process Compressors (Centrifugal / Reciprocating) & its driver Steam Turbines, Power generation Gas turbines, Fans, pumps (centrifugal & positive displacement) and gearboxes.

–              Vibration analysis through BN-Adre, System-1 and CSI.

–              Condition Monitoring thru Lube Oil analysis, process parameters monitoring, Thermography etc.

–              Failure Root Cause Analysis (RCA) thru various techniques like Fish bone, Fault tree, 5 why etc.

–              Development and implementation of AIM services by utilizing techniques i.e. RCM, RAM, FMECA, RCA, Optimized PM strategies and other industry accepted practices.

–              Hands on experience of APM/CMMS software like Meridium, Isograph, SAP and Oracle.

Core Experience:

–              Experience of renown vendors like BHGE, Nuovo Pignone, Sundyne, MAN Turbo, Dresser-Rand, Ingersoll Rand, Pacific, Burkhart, Elliot, Worthington, Kobelco, Flowserve etc.

Working as a Team Lead Condition Monitoring, in Saudi International Petrochemicals Company (SIPCHEM), KSA having 18+ years of experience in fertilizer and petrochemical sector. Core experience around condition monitoring, non-destructive testing techniques, standards and procedures development, turnaround planning and execution. Performed leadership role towards uptime of operating facility, safe and reliable maintenance practices and compliance of RAM/RCM/FMECA/RCA methodologies.

Professional Skills include:

–              HSQE focused initiatives.

–              Development and controlling of plant performance KPIs.

–              Decision Making.

–              Data Science (performance) analysis.

–              Uninterrupted and reliable operations of plant machinery which includes Process Compressors (Centrifugal / Reciprocating) & its driver Steam Turbines, Power generation Gas turbines, Fans, pumps (centrifugal & positive displacement) and gearboxes.

–              Vibration analysis through BN-Adre, System-1 and CSI.

–              Condition Monitoring thru Lube Oil analysis, process parameters monitoring, Thermography etc.

–              Failure Root Cause Analysis (RCA) thru various techniques like Fish bone, Fault tree, 5 why etc.

–              Development and implementation of AIM services by utilizing techniques i.e. RCM, RAM, FMECA, RCA, Optimized PM strategies and other industry accepted practices.

–              Hands on experience of APM/CMMS software like Meridium, Isograph, SAP and Oracle.

Core Experience:

–              Experience of renown vendors like BHGE, Nuovo Pignone, Sundyne, MAN Turbo, Dresser-Rand, Ingersoll Rand, Pacific, Burkhart, Elliot, Worthington, Kobelco, Flowserve etc.