Case Studies
Case Study: Water Supply Pump Optimization for a Major City
Client Challenge
A major city's water supply facility was experiencing repeated bearing failures and excessive noise in critical well water pumps, especially those driven by Variable Frequency Drives (VFDs).
GiTReal's Approach & Diagnosis
Our vibration analysis experts conducted a comprehensive assessment using advanced techniques to pinpoint the root cause: a complex torsional resonance within the pump's motor/shaft/impeller assembly, amplified by the VFD's pulse signals.
Solutions Explored
- VFD parameter adjustments provided minor improvements.
- Costly VFD modifications were not feasible.
- VFD frequency skipping caused unacceptable water pressure fluctuations.
Innovative Solution & Results
We designed and implemented a custom inertia wheel (harmonic balancer) on the pump shaft to counteract torsional vibrations. This significantly reduced resonant vibrations, normalized overall vibration levels, improved pump reliability and efficiency, and saved the city from costly replacements and downtime.
Key Takeaways
This case study demonstrates our expertise in vibration analysis and customized solutions. Our approach resolved the immediate issue and delivered long-term benefits in reliability and cost savings for the city's critical water supply.
Case Study: Resolving Complex Vibration Issues in Industrial Fans
Client Challenge
A client installed new industrial furnace fans that exhibited excessive axial vibration and labyrinth seal rubs, exceeding specified tolerances. The issue was aggravated by high operating temperatures.
GiTReal's Approach & Diagnosis
We conducted a comprehensive investigation using advanced vibration analysis techniques, identifying three key problems:
- High axial vibration due to pedestal resonance excited by fan turbulence.
- Labyrinth seal rubs caused by insufficient clearance and frame misalignment.
- Unpredictable and temperature-sensitive balancing due to rotor distortion and tight shaft-to-hub fit.
Solutions Implemented
- Installed outriggers for pedestal support to address axial vibration.
- Optimized bearing offset to further mitigate vibration issues.
- Machined housings to proper clearances and corrected frame misalignment to eliminate labyrinth seal rubs.
- Performed meticulous hot balancing, adjusting for thermal rotor distortion, to achieve acceptable vibration levels at operating temperature.
Results
- Significantly reduced axial vibration to meet client specifications.
- Eliminated labyrinth seal rubs.
- Achieved stable and predictable fan balancing across operating temperatures.
- Improved overall fan reliability and performance.
- Saved the client from costly equipment replacements and downtime.
Key Takeaways
This case study demonstrates our expertise in complex vibration analysis and our commitment to finding innovative, customized solutions. Our multi-faceted approach resolved multiple interconnected issues, delivering long-term benefits to the client's operations.
Case Study: Resonance and Unbalance Resolution in Industrial Centrifuges
Client Challenge
A chemical processing facility was experiencing excessive vibrations in their decanting centrifuges. The vibrations were causing operational issues and posing a risk to equipment reliability. The problem was particularly severe at the centrifuges' operating speed.
GiTReal's Approach & Diagnosis
Our vibration analysis experts conducted a comprehensive assessment, including vibration data collection and bump tests on the centrifuges, framework, and surrounding structure. Our analysis revealed:
- Resonance issues in both the centrifuge framework and the surrounding floor structure.
- Excessive unbalance in the centrifuge bowl and screw assembly, exacerbated by the attached planetary gear.
Solutions Implemented
We recommended a three-pronged approach to address the issues:
- Increase the mass and stiffness of resonant components in the centrifuge base and surrounding structure.
- Improve the balance quality of the bowl and screw assembly, targeting a tighter balance specification (G-1).
- Investigate and correct the influence of the planetary gear on the balance condition.
Results
By implementing our recommendations, the client was able to:
- Significantly reduce vibration levels to acceptable limits.
- Improve the reliability and operational stability of the centrifuges.
- Minimize the risk of equipment failure and associated downtime.
Key Takeaways
This case study demonstrates our expertise in diagnosing and resolving complex vibration issues in industrial settings. Our thorough analysis and targeted solutions led to a substantial improvement in equipment performance and reliability, resulting in significant cost savings for the client.
Case Study: Alignment Optimization for High-Speed Canning Line
Client Challenge
A beverage manufacturing facility installed a new seamer onto an existing filler on their can production line. Concerns arose about the alignment between the two machines, potentially impacting operational efficiency and reliability.
GiTReal's Approach
Our alignment specialists were engaged to assess the alignment between the seamer and filler, and provide recommendations for correction. We utilized precision laser alignment tools to measure both vertical and horizontal alignment.
Diagnosis
Our initial measurements revealed misalignment in both the vertical and horizontal planes. The filler was found to be out of level, which was corrected. However, angular misalignment persisted between the seamer spindle and the worm drive of the filler.
Solutions Implemented
To achieve optimal alignment, we recommended:
- Adjusting the seamer spindle drive to correct vertical offset.
- Enlarging bolt holes in the spindle drive for greater flexibility in offset adjustment.
While horizontal angular misalignment remained a concern, immediate correction was not feasible due to time constraints. We provided a detailed plan for future correction, including cutting welds from support pads and relocating the seamer feet.
Results
- Vertical alignment was successfully corrected, ensuring proper machine operation.
- Recommendations were provided for addressing remaining horizontal misalignment in the future.
- The client gained a clear understanding of the alignment issues and a roadmap for complete resolution.
Key Takeaways
This case study demonstrates our expertise in precision alignment and problem-solving in manufacturing environments. By addressing the immediate vertical alignment issue and providing a plan for future corrections, we helped the client optimize their canning line's performance and mitigate potential reliability problems.