Dear all, We are currently dealing with high levels of vibration in a screw compressor at a 660MW thermal power plant. The compressor's vibration reached 22mm/s RMS on January 25th. Despite cleaning the air and oil filters, the vibration remains elevated. After these maintenance actions, the vibration has decreased to 19mm/s RMS. I have attached various spectrum and trend analyses for reference. Unfortunately, I do not have any additional information to provide at this time. Attachment(s): - New Microsoft Word Document (2).pdf (64 KB) - 1 version trend.pdf (30 KB)
Hello Mr. Vishal, thank you for your recent post. I would appreciate more information regarding the compressor rating speed, whether it is belt driven or direct, the motor speed, power, and pulley ratio. Additionally, we are interested in the Orders of 1X. The peaks observed seem to be non-synchronous and do not indicate any unique components of the compressor. It would be beneficial to obtain the DE and NDE triaxial FFT for a more detailed analysis. According to your observation, cleaning the filters on the Air and Oil side resulted in a reduction of vibration levels from 22 to 19 mm/s RMS. I recommend checking the oil condition, belt condition, pulley tightness, and grooves to ensure optimal performance. Thank you for your attention to these matters. Best regards, Chary
When examining the motor RPM of 1500 in a direct couple drive system, despite cleaning the oil filter and air filter, high levels of vibration persist. Attached is the axial spectrum of the compressor drive and NDE side for further analysis. Download the PDF file "compressor.pdf" (59 KB) for detailed information.
From the data you’ve shared, I suspect there could be possible issues with the alignment or balance of the compressor which may not be rectified only by cleaning filters. The persistently high vibration levels indicate there may be mechanical issues to look more closely into. Be sure to check for any misalignment, bearing wear, or damaged parts. Additionally, performing an operational deflection shape (ODS) test could help pinpoint the source of the vibration.
It's great that you've been able to slightly reduce the vibrations by cleaning the air and oil filters, however, the levels are still quite high. I suggest checking the alignment and coupling of the screw compressor, as the problem might be mechanical. Also, consider conducting a detailed vibration analysis to identify particularly problematic frequencies which could point you towards an imbalance in your system. Regular temperature monitoring might also be helpful as overheating could lead to increased vibration levels.
This indeed sounds like a tricky problem. The maintenance efforts seem to be having some effect, given that the vibration levels decreased slightly after cleaning the filters. However, it's possible that there might be an issue with the bearings or rotor balance that's causing these persistent vibrations. I'd recommend conducting a thorough mechanical inspection if that hasn't been done yet. Moreover, understanding the exact frequency components of the vibration might help identify the source. Do you happen to have the vibration spectra showing peak frequencies?
It sounds like you’ve already taken some solid steps by cleaning the filters, but those vibration levels are still concerning. Have you considered checking for alignment issues or any signs of imbalance in the rotating components? Sometimes even a small misalignment can cause significant vibration. Additionally, examining the foundation and supports for any weaknesses could also help, as these can transmit vibration issues. Let us know how it goes!
It sounds like you're doing a thorough job tackling the vibration issue, but it’s concerning that the levels are still elevated even after maintenance. Have you considered checking the alignment and balancing of the compressor, as misalignment is a common cause of high vibration? Also, reviewing the installation and foundation integrity might reveal underlying issues. It might be beneficial to look into the frequency spectrum to identify any specific fault patterns that could guide your next steps. Good luck, and I hope you find a resolution soon!
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Answer: - Possible causes of high vibration levels in a screw compressor can include misalignment, unbalanced rotor, worn bearings, damaged seals, or issues with the lubrication system.
Answer: - The maintenance team has cleaned the air and oil filters in an attempt to reduce vibration levels. They have also conducted spectrum and trend analyses to monitor the situation.
Answer: - The initial vibration level in the compressor was 22mm/s RMS, which decreased to 19mm/s RMS after cleaning the filters. Further details may be available in the attached analyses.
Answer: - The attached spectrum and trend analyses may reveal patterns such as frequency peaks or trends over time that could provide insights into the root cause of the high vibration levels in the screw compressor.
Answer: - Additional information such as historical maintenance records, operating conditions, temperature data, and any recent changes in the operation of the compressor could be valuable for diagnosing and resolving the vibration problem effectively.
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