VIBRASI - Level 1

Condition Monitoring
& Vibration Fundamentals
Copyright 2004- PT. Putranata Adi Mandiri sole agent Prftechnik AG, Germany
Kenapa perlu condition monitoring ?
Biaya maintenance setelah pengenalan condition monitoring
Penyebab dari breakdown mesin
Apakah itu, Condition Monitoring ?

Monitoring Parameters
Temperature
Output
Phase
Motor Current
Casing Expansion
Eccentricity
Valve position
Suara !
Apa lagi ?
Pressure
Speed
Vibration
Oil Quality & Condition
Differential Expansion
Rotor position
Tipe Monitoring
Kerusakan pada mesin Penyebab utama kerusakan
Unbalance
Misalignment
Temperature
X
Lubrication
Oil contam
Gear mesh
defect
Blade
defects
Stator
defect
Component
resonance
Belt
vibrations
Bearing
defect
Rotordefect
Oil Analysis
X
Vibration

Suara
X
Pengukuran vibrasi
Kondisi bearing : lokasi & persiapan
Pengukuran kavitasi
Pengukuran RPM
Pengukuran temperatur
10
Contoh alat - 1
11
Contoh alat - 2
12
Contoh alat - 3
13
Apakah vibrasi itu ?
Vibration is a mechanical oscillation around a reference position.

In a machine, vibration is the result of internal dynamic forces created
by the rotating elements.
Reference : Introduction to Machinery Analysis and Monitoring Second Edition - by John S. Mitchell
14
Parameter-parameter vibrasi
A = Amplitudo, T = Perioda waktu, f = 1/T = frekuensi
= Phase
Harmonic motion is the simplest form of vibration, when plotted as a

function of time, it is represented by a sinusoidal curve.
15
Frekuensi rotasi
16
Parameter umum pengukur vibrasi
Rms = Root Mean Square

M = mean (rata-rata)
P = Peak (puncak)
x (t ) = x p sin t
= 2 f
1
f =
T
1
xm =
T
x rms
1
=
T
x (t ) dt
x 2 (t )dt
peak
rms
K factor = peak rms
rms
Form factor =
mean
Crest factor =
17
Faktor-faktor konversi untuk gelombang sinus

Conversion
ke :
Peak-to-Peak
value
Peak value
Mean value
Effective / RMS
value
Peak-to-Peak value
0.5
0.32 = 1/
0.35 = 1/22
Peak value
0.64 = 2/
0.71 =1/2
3.14 =
1.57 =
1.11 = /22
2.83 = 22
1.41 = 2
0.90 = 22/
Dari :
Faktor
Median value
Effective/RMS value
18
Nilai Peak dan RMS
19
Layar VIBROTIP
20
Lokasi penempatan transducer yang cocok
21
Typical Uses of Vibration Transducers

Radial Shaft
Vibration & Position
Radial Casing
Vibration
Axial Shaft
Vibration & Position
22
Contoh alat - 1
23
Displacement, velocity & acceleration
x (t ) = x p sin t
v (t ) = x p cos t = v p sin t +
2
a (t ) = 2 x p sin t = a p sin ( t + )
x p = 1 x pp
2
v p = 2 f x p = 6.28 f x p
a p = 4 2 f 2 x p = 39.47 f 2 x p
24
Bagaimana mengukur amplitudo vibrasi ?
x (t ) = x p sin t
v (t ) = x p cos t = v p sin t +
2
a (t ) = 2 x p sin t = a p sin ( t + )
25
Transducer Vibrasi
SensorTransducerProbeApakah ini ?
.Pada dasarnya peralatan ini merubah vibrasi

mekanis ke signal electric
Accelerometer
Charge Type &
Line Drive
Constant Voltage &
Constant Current
Velocity
Transducer
Displacement
Shaft Riders
Proximity Probes
(Eddy Current Probes)
26
Tipe transducer vibrasi
27
28
Fundamental Vibrasi
Seberapa besar vibrasi diijinkan ?

1. Gunakan Batas Vibrasi Absolut
- diberikan oleh pembuat mesin
- gunakan Standard Vibrasi
Internasional, misalnya ISO
2372, VDI 2056, BS 4675
(Canadian Government Vibration Limit for
Maintenance)
2. Gunakan Batas Vibrasi Relatif
- gunakan histori mesin
- gunakan batas dari
pengalaman sendiri
- lihat kondisi baru
29
Formula umur bearing

3
16667
H=
x
L + Konst M V N N
H = umur bearing (jam)
C = kapasitas bearing (kg) (dari spesifikasi manufacturer)
L = beban bearing in - service (kg)
Konst = 2.6674 10-6
M = berat (kg)
V = vibrasi (mm/s)
N = speed (RPM)
(Jika V dalam inch/s dan C, L, M dalam lbs, maka Konst
berubah menjadi : Konst = 6.7753 10-5 )
30
Contoh menggunakan formula umur bearing

3
9,000
16667
H=
= 9,971 jam
x
-6
450 + 2.6674 10 5,850 15.24 1,800 1,800
9,971
=
= 1.13 tahun
(24 365)
H = umur bearing (jam)
C = kapasitas bearing = 9,000 (kg)
L = beban bearing in - service = 450 (kg)
Konst = 2.6674 10-6
M = berat = 5,850 (kg)
V = vibrasi = 15.24 (mm/s)
N = speed = 1,800 (RPM)
31
Monitoring Vibrasi
Mana mesin yang bagus ?
Batas
Bahaya
Batas
Bahaya
Batas
Peringatan
Batas
Peringatan
Ref
Ref
Mesin A
Mesin B
32
Monitoring Vibrasi
Tingkat
Vibrasi
Batas Bahaya
Mesin A
Batas
Peringatan
Mesin B
Waktu
33
Monitoring Vibrasi

Tingkat
Vibrasi
Batas Bahaya
Batas
Peringatan
Mesin A
Mesin B
Waktu
34
Overall Measurement
Vibration
um
mils
mm/s
Danger
Limit
xx
x x
x
x
x x
Alert
Limit
Vibration
um
mils
mm/s
Ref
Lead Time
Time
35
Manual & Automatic Trending
Trending with a Difference

Vib
Danger Limit
Danger Limit
Alert Limit
Alert Limit
* *
* *
*
* *
* *
** * *
*
* *
** * *
*
* *
Time
Time
Poor Trend accuracy with no control
(Takes all data & makes trend)
Vib
Improve Trend accuracy with Manual

& Automatic Trending
(User define trend conditions)
36
Trending Vibration RMS velocity
37
Trending shock pulse method

ShockPulsedBn
50
Path of Location : PT. Caltex\Water Plant\Fresh Water

Pump\Centrifugal Pump\Impeller Side\shock pulse m. >120
45
Number of Meas. Values : 6

Meas. Task : Bearing
40
AlarmM
ax
Meas. Type : Sum
35
Unit: dBn
30
W
arningM
ax
dBc
dBa
(mm)
9:21:40 PM 9
20
0
80.00
6/2/98
8:46:42 PM 9
20
0
80.00
dBm
7/2/98
8:21:40 PM 11
20
0
80.00
dBc
8/8/98
6:03:53 PM 9
1500
20
3
0
80.00
9/18/98
1:18:12 AM 11
1500
20
4
0
80.00
3/23/99
11:48:27 PM -3
1500
20
-10
0
80.00
25
20
AlarmCarpet
15
SIM Date
Time
RPM
5/3/98
W
arningCarpet
10
5
0
-5
-10
5/25/98 6/22/98 7/20/98 8/17/98 9/14/98 10/12/98 11/9/98 12/7/98 1/4/99 2/1/99 3/1/99 3/29/99
date
dBm
dBia
38
Trending bearing condition
39
Standar ISO 2372
Amplitudo velocity RMS (mm/s)
Daya < 15 kW
atau < 20 HP
15 kW - 75 kW
atau 20 100 HP
Daya > 75 kW
atau > 100 HP
Turbomachinery
(Turbine/Comp dll)
40
Standar ISO 10816-3
41
Standard ISO 10816-3
42
Persiapan untuk pengukuran vibrasi
43
VIBCODE: pengenalan lokasi dengan cara otomatis
44
Sistem VIBCODE
45
Vibrasi dominan vertikal
MOTOR/DR
POMPA/DN
Penyebab Utama :
1. Pondasi (karatan, dudukan lemah, melengkung, baut kendor)
46
Vibrasi dominan horizontal
MOTOR
BLOWER
Penyebab Utama :
1. Unbalance
2. Housing bearing
3. Gaya aerodinamik
47
Vibrasi dominan aksial
MOTOR
BLOWER
Penyebab Utama :
1. Misalignment
2. Sleeve bearing
3. Housing bearing
48
Vibrasi dominan vertikal, horizontal, aksial
MOTOR
BLOWER
Penyebab Utama :
1. Antifriction bearing
2. Shaft bengkok
3. Pondasi melengkung
49
Fase
50
Contoh fase - 2
51
Contoh fase - 3
52
Vibrasi gabungan
1+2
Amplitudo(1) = 10, Amplitudo(2) = 5, Amplitudo(1+2) = ???
53
Vibrasi gabungan 1 frekuensi
54
Vibrasi gabungan 1 frekuensi beda fase
55
Machine Vibration Signal
Time Signal
S1 + S2 + S3
+
S1
S2
S3
56
Spectrum frekuensi dari gelombang sinus
Frekuensi = 1 / T
57
Time signal & Spectrum frekuensi
58
59
60
61
Vibration Fundamentals
Machine Vibration Signal
Time Signal
Freq. Spectrum
Hz
62
FFT Analysis
FAST
FOURIER
TRANSFORMATION
T
Eg.
1x = 1/T
Converting
time signal to
freq. spectrum
1X
5 kHz
63
Spectrum Analysis
64
FFT - Fast Fourier Transformation
Sample 1
Sample 2
Filtering
Filtering
Window Function
Window Function
Detectors
Detectors
FFT
FFT
=
Avg
FFT Spectrum 1
FFT Spectrum
FFT Spectrum 2
65
Time vs FFT
Time Signal:
FFT
Fast Fourier
Transformation
transient signals, repeat

frequencies, beats and sine
waveform good visible
but:
Individual Frequencies of the
Vibration Spectrum
almost not visible
Amplitude Spectrum:
good visibility of the dominant
frequencies of the vibration signal
but:
transient Signals, shocks with
repeat frequency and beat signals
almost not visible
66
Spectrum frekuensi dari signal yang kompleks
67
Contoh : Pompa centrifugal
68
Spectra untuk bentuk gelombang yang standard
69
Displacement, velocity & acceleration spectra
70
Fungsi window
71
Skala linear dan logaritmis
Logaritmis
72
Spectrum dengan alarmband
vmm/s
5.0
Location :PT. Caltex\Water Plant\Fresh Water

Pump\Centrifugal Pump\Impeller Side\mach.
4.5
spectr. >600 including band alarm

4.0
3.5
25.00
0.78
3.0
49.75
0.49
2.5
99.75
0.40
2.0
74.75
0.23
124.75
0.19
Alarm
97.25
0.15
Warning
10.25
0.09
9.00
0.09
122.00
0.09
11.75
0.07
1.5
1.0
0.5
0.0
10 15
20
25
30 35
40
45
50 55
60
65
70 75
80
85
90 95 100
f Hz
73
Vibrasi harmonis dan vibrasi resonan
Vibrasi
harmonis
Vibrasi
resonan
74

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Condition Monitoring

& Vibration Fundamentals

Kenapa perlu condition monitoring ?

Biaya maintenance setelah pengenalan condition monitoring

Penyebab dari breakdown mesin

Apakah itu, Condition Monitoring ?

Kondisi bearing : lokasi & persiapan

Apakah vibrasi itu ?

Vibration is a mechanical oscillation around a reference position.

Harmonic motion is the simplest form of vibration, when plotted as a

Parameter umum pengukur vibrasi

Rms = Root Mean Square

Faktor-faktor konversi untuk gelombang sinus

Nilai Peak dan RMS

Lokasi penempatan transducer yang cocok

Typical Uses of Vibration Transducers

Displacement, velocity & acceleration

Bagaimana mengukur amplitudo vibrasi ?

.Pada dasarnya peralatan ini merubah vibrasi

Tipe transducer vibrasi

Seberapa besar vibrasi diijinkan ?

Formula umur bearing

Contoh menggunakan formula umur bearing

Mana mesin yang bagus ?

Manual & Automatic Trending

Trending with a Difference

Improve Trend accuracy with Manual

Trending Vibration RMS velocity

Trending shock pulse method

Path of Location : PT. Caltex\Water Plant\Fresh Water

Number of Meas. Values : 6

Meas. Type : Sum

Trending bearing condition

Standar ISO 2372

Amplitudo velocity RMS (mm/s)

Standar ISO 10816-3

Standard ISO 10816-3

Persiapan untuk pengukuran vibrasi

VIBCODE: pengenalan lokasi dengan cara otomatis

Vibrasi dominan vertikal

Vibrasi dominan horizontal

Vibrasi dominan aksial

Vibrasi dominan vertikal, horizontal, aksial

Amplitudo(1) = 10, Amplitudo(2) = 5, Amplitudo(1+2) = ???

Vibrasi gabungan 1 frekuensi

Vibrasi gabungan 1 frekuensi beda fase

Machine Vibration Signal

Spectrum frekuensi dari gelombang sinus

Time signal & Spectrum frekuensi

FFT - Fast Fourier Transformation

transient signals, repeat

Spectrum frekuensi dari signal yang kompleks

Contoh : Pompa centrifugal

Spectra untuk bentuk gelombang yang standard

Displacement, velocity & acceleration spectra

Skala linear dan logaritmis

Spectrum dengan alarmband

Location :PT. Caltex\Water Plant\Fresh Water

spectr. >600 including band alarm

Vibrasi harmonis dan vibrasi resonan

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