Teori Dasar Analisa Vibrasi

PROGRAM KERJASAMA HUMAN CAPITAL DEVELOPMENT CENTER (PT.KRAKATAU STEEL) DENGAN JURUSAN TEKNIK MESIN UNIV.
SULTAN AGENG TIRTAYASA
TEORI DASAR ANALISA VIBRASI
DARYANTO
Predictive Maintenance - CRM

PT KRAKATAU STEEL
PROGRAM KERJASAMA HUMAN CAPITAL DEVELOPMENT CENTER (PT.KRAKATAU STEEL) DENGAN JURUSAN TEKNIK MESIN UNIV.SULTAN AGENG TIRTAYASA
Tujuan training : Bisa Membaca Spectrum Getaran
PREDICTIVE MAINTENACE PROGRAM

1. Data Collection Monitoring schedule : monthly, weekly, daily 2. Detection & Analysis Trends Alarms Spectral Analysis
3. Problem Correction
TUJUAN PENGUKURAN GETARAN 1. Menentukan kondisi mekanis mesin. 2. Merencanakan jadwal pemeliharaan. 3. Memeriksa hasil repair/overhaul. 4. Menghentikan mesin untuk mencegah gangguan serius. 5. Lokalisasi gangguan. 6. Pengesahan aspek keselamatan.
Vibration is a "back and forth" movement of a structure. It can also be referred to as a "cyclical" movement
What Is Vibration Caused By ? Imperfections in the Machine:

Design
Manufacture Installation
Assembly
Operation Maintenance
What Are Some Common Machine Problems? That Generate Mechanical Vibration: Misalignment Unbalance Worn belts & pulleys Bearing Defects Hydraulic Forces Aerodynamic Forces Reaction Forces Reciprocating Forces Bent Shafts Rubbing Gear Problems Housing Distortion Certain Electrical Problems Frictional Forces
What Are Some Common Machine Problems That Amplify Mechanical Vibration (But Don't Cause It):
Resonance Looseness
F = 1/T T = The period of the wave F = The Frequency of the wave

where d = instantaneous displacement, D = maximum, or peak, Displacement = angular frequency, = 2f t = time
where v = instantaneous velocity
where a = instantaneous acceleration
Displacement, Velocity and Acceleration
Displacement = mils Velocity = in/sec Acceleration = g's Frequency = cycles/min Displacement = (19,231 x V) / F
English Units:
Displacement = um Velocity = mm/sec Acceleration = g's Frequency = cycles/min Displacement = (19,231 x V) / F
Metric Units:
Velocity = 0.000052 x D x F
Acceleration = 0.00027 x V x F
Velocity = 0.000052 x D x F
Acceleration = 0.0000107 x V x F
Example #1: A Bearing Vibrates 100 Mils Pk-Pk @ 30 cpm

Displacement @ 1x rpm = 100 mils English Units: Velocity = 0.000052 x D x F V = 0.000052 x 100 mils x 30 cpm Displacement @ 1x rpm = 2540 um Metric Units: Velocity = 0.000052 x D x F V = 0.000052 x 2540 um x 30 cpm
V = 0.16 ips
Acceleration = 0.00027 x V x F A = 0.00027 x 0.16 x 30 A = 0.0013 g's
V = 4 mm/sec
Acceleration = 0.0000107 x V x F A = 0.0000107 x 4 x 30 A = 0.0013 g's
Example #2: A Bearing Vibrates 10 Mils Pk-Pk At 1000 cpm

Displacement @ 1x rpm = 10 mils English Units: Velocity = 0.000052 x D x F V = 0.000052 x 10 mils x 1000 cpm V = 0.52 ips Acceleration = 0.00027 x V x F A = 0.00027 x 0.52 x 1000 A = 0.14 g's Displacement @ 1x rpm = 250 um Metric Units: Velocity = 0.000052 x D x F V = 0.000052 x 250 um x 1000 cpm V = 13 mm/sec Acceleration = 0.0000107 x V x F A = 0.0000107 x 13 x 1000 A = 0.14 g's
Example #3: A Bearing Vibrates 3 Mils Pk-Pk At 9,000 cpm

Displacement @ 9,000 cpm = 3 mils Displacement @ 9,000 cpm = 75 um
English Units: Velocity = 0.000052 x D x F V = 0.000052 x 3 mils x 9,000 cpm

V = 1.404 ips Acceleration = 0.00027 x V x F A = 0.00027 x 1.404 x 9,000 A = 3.41 g's
Metric Units: Velocity = 0.000052 x D x F V = 0.000052 x 75 um x 9,000 cpm

V = 35.1 mm/sec Acceleration = 0.0000107 x V x F A = 0.0000107 x 35.1 x 9,000 A = 3.41 g's
Example #4: A High Speed Compressor Rotor Shaft Vibrates 0.003 Mils Pk-Pk At 1,080,000 cpm
Displacement @ 1,080,000 cpm = 0.003 mils (3 millionths of an inch) English Units: Velocity = 0.000052 x D x F V = 0.000052 x 0.003 mils x 1,080,000 cpm V = 0.17 ips Acceleration = 0.00027 x V x F A = 0.00027 x 0.17 x 1,080,000 A = 50 g's Displacement @ 1,080,000 cpm = 0.077 um (7.7 millionths of a centimeter) Metric Units: Velocity = 0.000052 x D x F V = 0.000052 x 0.077 um x 1,080,000 cpm V = 4.32 mm/sec Acceleration = 0.0000107 x V x F A = 0.0000107 x 4.33 x 1,080,000 A = 50 g's
Vibration Amplitude Measurement

The following definitions apply to the measurement of mechanical vibration amplitude.
Root Mean Square Amplitude (RMS) is the square root of the average of the squared values of the waveform. In the case of the sine wave, the RMS value is 0.707 times the peak value
Spectrum Resolution =
Max Frequency (Fmax) # of Lines of Resolution
Lines of Resolution: 200, 400, 800,1600, 3200, 6400, 12800
Fmax = # Lines / Time Sample Fmax [Hertz] = 800 / 0.1 seconds = 8000 Hz Fmax [CPM] = 8,000 Hz x 60 = 480,000 cpm
The Raw Signal
The Actual Signals Used To Generate
The Resulting FFT
1x rpm w/ amplitude of 1.8 (pk-pk), '+' peak on y-axis 2x rpm w/ amplitude of 0.45 (pk-pk) 3x rpm w/ amplitude of 0.05 (pk-pk), '-' peak on y-axis
Beats
'
Amplitude Scales
Linear Amplitude Scaling
Logarithmic Amplitude Scaling
The decibel (dB) is defined by the following expression:
The Decibel
where: LdB = The signal level in dB L1 = Vibration level in Acceleration, Velocity, or Displacement Lref = Reference level, equivalent to 0 dB The vibration velocity level in dB is abbreviated VdB, and is defined as:
or
ISO 10816-3
VIBRATION TRANSDUCERS
The Proximity Probe
The Velocity Probe
Velocity Transducer
The Accelerometer
Piezo-Electric Accelerometer
Konfigurasi daripada meteran tingkat getaran
SENSITIFITAS SENSOR VIBRASI
Recommended Frequency Ranges for Different Amplitude Units

Displacement Units: < 600 cpm (< 10 Hz)
Velocity Units: 300 - 120,000 cpm (5 - 2,000 Hz)

Acceleration Units: > 60,000 cpm (> 1,000 Hz)
PENGAMBILAN DATA VIBRASI
RUANG LINGKUP PENGUKURAN GETARAN

1. Kelompok penggerak mula (prime mover) mesin-mesin yang mampu mengolah daya sendiri. Contohnya: Elektric Motor, Steamturbin, Gasturbin, Hydraulic & Pneumatic Motor dll. 2. Kelompok sistem transmisi peralatan untuk memindahkan daya. Contohnya : Gearbox, Coupling, V-Belts dll. 3. Kelompok mesin bukan penggerak mula peralatan produksi yang harus digerakkan oleh penggerak mula. Contohnya : Compressor, Centrifugal Pump, Hydraulic Pump, Fans, Reciprocating Pump, Cooling Tower Fans, Rolling Machines dll.
MACHINE DATA SHEET

1. Plant Name 2. Train Name 3. Machine Name 4. Machine Description 5. Machine Sketch 6. Position 7. Direction 8. Measurement Units 9. Point Identification 10. Coupling Type 11. RPM 12. Number of Gear Teeth 13. Bearings (Type, manufacture, Number of balls/Series Number)
Horizontal machines
Vertical machines
MENENTUKAN ARAH PENGUKURAN
ANALISA DATA VIBRASI
Following is an example of forcing frequency calculation for a gear-driven machine:
Let us assume that the motor/gear/fan components have the following element counts: Elements of Component
Fan Blades
Rotor Bars Gear Teeth Gear Teeth Fan Blades
Machine Component
Motor Cooling Fan
Motor Rotor Drive Pinion Driven Gear Fan
Number of Elements
11
42 36 100 9
Let us assume that the motor is again running at 1780 RPM.

Divide the drive pinion tooth count by the driven gear tooth count:
or
Next, multiply this ratio by the motor shaft RPM to find the fan shaft RPM;
We would now say that the fundamental frequency of the motor is 1780 CPM and the fundamental frequency of the fan is 640.8 CPM.
Motor Shaft
Rotation Motor Cooling Fan Motor Rotor Drive Pinion
Elements
1 11 42 36
Forcing Frequency, CPM

1,780 19,580 74,760 64,080
Fan Shaft
Rotation Driven Gear Fan
Elements
1 100 9
Forcing Frequency,CPM
640.8 64,080 5,767.2
Formulas for Calculating Belt Frequencies: You can calculate belt RPM with the following: 3.14 x PS1 x PD1/BL = Belt RPM - or 3.14 x PS2 x PD2/BL = Belt RPM Belt Length = 1.57 x (PD1 + PD2) + 2(SD) PS = Pulley rpm (PS1 = Driver Pulley Speed, PS2 = Driven Pulley Speed) PD = Pulley diameter (PD1 = Driver Pulley Dia., PD2 = Driven Pulley Dia) SD = Distance between shaft centers BL = Belt Length
Deep Groove Ball Bearing

(BPFO) (BSF)
(BPFI) (FTF)
BPFO : Ball Pass Frequency Outer BPFI : Ball Pass Frequency Inner BSF : Ball Spin Frequency
FTF
: Foundation Train Frequency
Spectrum Interpretation (Troubleshooting chart) The following pages are designed to provide typical examples of the vibration spectrums that will result from different problems a machine might experience. They are probability based and field testing should always be performed regardless of how "sure" you are of the diagnosis. Remember:
EVERY diagnosis made from an FFT interpretation can be characterized as:
An ASSUMPTION based on an ESTIMATE
Troubleshooting chart
Typical Radial FFT Generated By Unbalance
Typical FFT Generated By Angular Misalignment Definition: Shaft Centerlines Intersect But Are Not Parallel
Typical Axial FFT Generated By Unbalance
Typical FFT Generated By Offset Misalignment Definition: Shaft Centerlines Are Parallel But Do Not Intersect
MISALIGNMENT
Typical FFT Generated By Cocked Bearing
Typical Radial FFT Generated By Mechanical (Structural) Looseness
Typical FFT Generated By Shaft Bent Through The Bearing
Typical Radial FFT Generated By Bearing Looseness
Typical Axial FFT Generated By Housing Distortion
Relatively High Amplitudes Will Be Generated.
Typical Radial FFT Generated By Housing Distortion
FFT Typical Of Pulley Misalignment
Typical FFT Showing Belt/Pulley Wear Problems
FFT Showing Sleeve Bearing Looseness
Typical FFT Showing Pulley Eccentricity / Bent Shaft Near Pulley
FFT Resulting From Oil Whirl
Typical Spectrum Showing High Vane Pass Frequency
Typical FFT Showing Flow Turbulence
Typical Spectrum Showing Cavitation
Typical Spectrum Showing Indications Of Variation In Air Gap, Winding Shorts, Stator Weakness
Typical Spectrum Showing Indications Of Eccentric Rotor
Spectrum Showing Pattern Of Peaks Separated By 2xLine Frequency (Sidebands) In High Frequency Range (3090xRPM)
One Possible Spectrum Caused By A Problem With A Short In One Of The Phases Or Feeder Cables
Another Possible Spectrum Caused By A Problem With A Short In One Of The Phases Or Feeder Cables
Loose in Winding Slots, Iron, End Turns And/Or Connections
Figure 1 - Full-Wave Rectified Velocity Spectrum w/ Drive
"Normal" FFT Taken On DC Drive
Problems
Figure 2 - Half-Wave Rectified Velocity Spectrum w/ Drive Problems
Figure 3 - Spectrum on DC Motor w/ Speed Fluctuations
Normal Gear Spectrum
Typical FFT For Eccentric Gear Or Gear On Bent Shaft
ANALISA DATA VIBRASI 1. Trends Data

v [mm/ s] 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 14/ 02/ 2009 14/ 03/ 2009 11/ 04/ 2009 09/ 05/ 2009 06/ 06/ 2009 04/ 07/ 2009 01/ 08/ 2009 29/ 08/ 2009 26/ 09/ 2009 24/ 10/ 2009 21/ 11/ 2009 19/ 12/ 2009 date Strip Dryer Fan No.1 - G1.420\ Fan/ blower Dryer # 1\ BH3\ 101 Ov erall v eloc ity >600
2. Waterfall Trends Data

v rms [mm/ s] St rip D ryer Fan N o. 1 - G1. 420\ Fan/ blow er D ryer # 1\ BH 3\ 103 Mac h. spec t r. >600 13/ 11/ 2009 8: 42: 18
10,0 9,5 9,0 8,5 8,0 7,5 7,0 6,5 6,0 5,5 5,0 4,5 4,0 3,5 3,0 2,5 2,0 1,5 1,0 0,5 0,0 0
06/ 10/ 2009 09/ 09/ 2009 25/ 08/ 2009 07/ 08/ 2009 10/ 07/ 2009 12/ 05/ 2009 15/ 04/ 2009 24/ 03/ 2009 M 24/ 02/ 2009 24/ 01/ 2009 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 f [cpm]
3. Single Spectra
v rms [mm/ s] 8,0 7,5 7,0 6,5 6,0 5,5 5,0 4,5 4,0 3,5 3,0 3 2,5 2,0 1,5 1,0 2 0,5 0,0 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 f [cpm] D Strip D ryer Fan N o.1 - G1.420\ Fan/ blow er D ryer # 1\ BH 3\ 103 Mac h. spec tr. >600 06/ 10/ 2009 9:02:35
Housing Bearing Gearbox Aus
KESIMPULAN
LOKASI / AREA MESIN MESIN & SPESIFIKASINYA POSISI & ARAH PENGUKURAN
A M P L I T U D O
PUTARAN POROS
PROGRAM PREDICTIVE MAINTENANCE

1. Data Collection
Pemantauan getaran terjadwal
2. Analysis (diperlukan Software) Domain frekuensi (harus tahu anatomi mesin) Domain waktu Frek. eksitasi getaran, database bantalan, gearbox dll
3. Diagnosis Prakiraan sumber masalah Dibantu oleh Software Human Interface (Tergantung pengalaman)
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PROGRAM KERJASAMA HUMAN CAPITAL DEVELOPMENT CENTER (PT.KRAKATAU STEEL) DENGAN JURUSAN TEKNIK MESIN UNIV.

SULTAN AGENG TIRTAYASA

TEORI DASAR ANALISA VIBRASI

Predictive Maintenance - CRM

Tujuan training : Bisa Membaca Spectrum Getaran

PREDICTIVE MAINTENACE PROGRAM

What Is Vibration Caused By ? Imperfections in the Machine:

F = 1/T T = The period of the wave F = The Frequency of the wave

where v = instantaneous velocity

where a = instantaneous acceleration

Displacement, Velocity and Acceleration

Displacement = um Velocity = mm/sec Acceleration = g's Frequency = cycles/min Displacement = (19,231 x V) / F

Example #1: A Bearing Vibrates 100 Mils Pk-Pk @ 30 cpm

Example #2: A Bearing Vibrates 10 Mils Pk-Pk At 1000 cpm

Example #3: A Bearing Vibrates 3 Mils Pk-Pk At 9,000 cpm

English Units: Velocity = 0.000052 x D x F V = 0.000052 x 3 mils x 9,000 cpm

Metric Units: Velocity = 0.000052 x D x F V = 0.000052 x 75 um x 9,000 cpm

Vibration Amplitude Measurement

Max Frequency (Fmax) # of Lines of Resolution

Lines of Resolution: 200, 400, 800,1600, 3200, 6400, 12800

The Raw Signal

The Actual Signals Used To Generate

The Resulting FFT

Logarithmic Amplitude Scaling

The decibel (dB) is defined by the following expression:

Konfigurasi daripada meteran tingkat getaran

SENSITIFITAS SENSOR VIBRASI

Recommended Frequency Ranges for Different Amplitude Units

Velocity Units: 300 - 120,000 cpm (5 - 2,000 Hz)

PENGAMBILAN DATA VIBRASI

RUANG LINGKUP PENGUKURAN GETARAN

MACHINE DATA SHEET

MENENTUKAN ARAH PENGUKURAN

ANALISA DATA VIBRASI

Following is an example of forcing frequency calculation for a gear-driven machine:

Let us assume that the motor is again running at 1780 RPM.

Forcing Frequency, CPM

Deep Groove Ball Bearing

: Foundation Train Frequency

An ASSUMPTION based on an ESTIMATE

Typical Radial FFT Generated By Unbalance

Typical Axial FFT Generated By Unbalance

Typical FFT Generated By Cocked Bearing

Typical Radial FFT Generated By Mechanical (Structural) Looseness

Typical FFT Generated By Shaft Bent Through The Bearing

Typical Radial FFT Generated By Bearing Looseness

Typical Axial FFT Generated By Housing Distortion

Relatively High Amplitudes Will Be Generated.

Typical Radial FFT Generated By Housing Distortion

FFT Typical Of Pulley Misalignment

Typical FFT Showing Belt/Pulley Wear Problems

FFT Showing Sleeve Bearing Looseness

Typical FFT Showing Pulley Eccentricity / Bent Shaft Near Pulley

FFT Resulting From Oil Whirl

Typical Spectrum Showing High Vane Pass Frequency

Typical FFT Showing Flow Turbulence

Typical Spectrum Showing Cavitation

Typical Spectrum Showing Indications Of Eccentric Rotor

Loose in Winding Slots, Iron, End Turns And/Or Connections

Figure 1 - Full-Wave Rectified Velocity Spectrum w/ Drive

"Normal" FFT Taken On DC Drive

Figure 2 - Half-Wave Rectified Velocity Spectrum w/ Drive Problems

Figure 3 - Spectrum on DC Motor w/ Speed Fluctuations

Normal Gear Spectrum