Case Study: Vibration Analysis Reveals Coupling Damage in Crude Oil Pump

Prepared by: Sharath Vunnam, Certified Level 3 Engineer
Company: Technomax
Service: Vibration Analysis
Industry: Oil & Gas (Offshore Operations)
Equipment: Crude Oil Stripper Pump

Objective

With industries shifting from preventive to predictive maintenance, vibration analysis has become one of the most powerful tools for monitoring equipment health. This case study highlights how Technomax’s advanced vibration analysis services helped detect a critical fault in a crude oil pump, preventing potential downtime and costly equipment failure.

Background

Technomax has a long-standing presence in providing condition monitoring services—including vibration analysis, thermography testing, ultrasound Analysis, and oil analysis—to offshore facilities. During a routine vibration monitoring session at one of our client’s offshore crude oil facilities, unusually high vibration levels were detected in a critical crude oil stripper pump.

Equipment Details

• Machine Name: Crude Oil Stripper Pump

• Configuration: Motor – Coupling – Pump

• Rated Speed: 2956 RPM

• Motor Power: 110 kW

• Coupling Type: Shim Packed Coupling

Instruments & Software Used

• Vibration Analyzer: Scout 140 Advanced 4-Channel

• Manufacturer: GE Bently Nevada

• Software: Ascent Level-II

Initial Findings

Using high-resolution spectral data, our engineers observed dominant vibration peaks at 2X and 3X the rotational frequency on both motor and pump bearings—an indication of coupling-related anomalies. Cross-channel phase analysis further confirmed significant misalignment between the motor and pump.

Fig 1 & 2: Velocity spectrum analysis at the Pump Drive End and Motor Drive End revealed consistently elevated vibration levels.

Recommendations

• Inspect and assess the condition of the coupling

• Replace damaged components

• Perform precision laser alignment after component replacement

Maintenance Action Taken

• The unit was shut down for inspection

• The coupling was found broken and heavily worn

• The coupling set was replaced

• The pump was swapped with a refurbished unit

• Precise alignment was performed between motor and pump

Post-Maintenance Results

Following maintenance, vibration levels dropped dramatically, confirming successful diagnosis and corrective action. The vibration amplitude was reduced by up to 89%, restoring equipment stability.

Figure: 2X and 3X vibration peaks observed before maintenance were completely eliminated after replacing the coupling.

Conclusion

This case study demonstrates how in-depth vibration analysis can identify specific mechanical faults, such as coupling damage, by interpreting vibration patterns. Through accurate diagnostics and timely maintenance, significant risks and costly downtime were avoided.

Regular condition-based monitoring is crucial in identifying such issues early—especially in critical systems operating under demanding conditions. Technomax offers expert condition monitoring services across UAE and Middle East, backed by certified engineers and advanced diagnostic tools, helping industries maintain reliability and performance.

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