Cement Mill Gearbox Bearing Failure
Vibration readings revealed increased levels in the gearbox input, indicating a bearing defect. The bearing was replaced during the next scheduled stoppage, successfully reducing vibration levels to acceptable ranges.
Case study for Major Drive: earlier identified the bearing defect in the gearbox input and successfully rectified by the concerned team during opportunity stoppage.
Subject: - On 03.05.2025, vibration readings were taken at the rated RPM of the above equipment, and it was observed that the gearbox input vibration and acceleration levels had increased.
Analysis and Observations
1. The overall vibration level of the equipment is considered to be Un satisfactory.
2. The FFT analysis reveals the presence of bearing defect frequency (non-synchronized with near BPFI) along with gear mesh frequency with sidebands associated with the first intermediate shaft.
Recommendations:
3. 4. 5. It is recommended to proactively initiate the procurement of gearbox input bearings in order to replace them during the next scheduled opportunity stoppage, thereby preventing unexpected failures.
Additionally, Please inspect the 1st intermediate bearing clearances. Please Inspect the coupling with review the alignment from pinion to motor via gearbox.
Current/Final Status:
• Following the replacement of the affected bearing gearbox, acceleration levels have decreased from 8.5 to 5.91 mm/sec at the input, and acceleration has reduced from 3.5 to 0.37g.
• These levels are within the acceptable range, demonstrating that the corrective actions have been successful.
• Continuous monitoring will be maintained to ensure sustained equipment performance and to promptly identify any potential issues.
Final Results: Normal
We extend our sincere gratitude to the concerned team for their invaluable support.
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