Vibration: Integrated Reliability Technology

INTEGRATED RELIABILITY TECHNOLOGY
VIBRATION
- Sarafian Salleh
- diagnoveritas@gmail.com
DiagnoVeritas Pte Ltd.
• Vibration
• Noise
• Infrared Thermography
• Engineering Diagnostics
• Consultancy
BAD VIBRATIONS
 UNBALANCED WHEEL OF A CAR
 VIBRATING PIPES
 STRUCTURES AND PLATFORMS
 HVAC
GOOD VIBRATIONS
 ORGAN PIPES
 GUITAR STRINGS
 JACK HAMMER
 SHAKER CONVEYOR
BAD VIBRATIONS
 UNBALANCED WHEEL OF A CAR
 VIBRATING PIPES
 STRUCTURES AND PLATFORMS
 HVAC
GOOD VIBRATIONS
 ORGAN PIPES
 GUITAR STRINGS
 JACK HAMMER
 SHAKER CONVEYOR
 OSIM MASSAGE CHAIR
VIBRATION
•Dynamic Unbalance
•Mechanical Looseness
•Gear meshing forces
•Misalignment
•Flow induced vibration
•Bearing faults
•Structural Resonance
•Structural Defect
Corrective Maintenance
•Insitu Dynamic Balancing
•Laser Alignment
•Dynamic Analysis
Sarafian Salleh
VIBRATION – Baseline Survey
COMMON INDUSTRIAL FAULTS SURVEYED BY

PREDICTNDT
VIBRATION - Faults
LEGEND
Dynamic Unbalanced 35 %
Misalignment 18 %
PREDICTNDT
Mechanical Looseness 15 %
Resonance 9%
Bearings 9%
Gear mesh Faults 5%
Motor Vibration 2%
Mech. Looseness 2%
Rubbing 2%
Soft Foot 1%
Isolator Degradation 1%
Others 1%
VIBRATION - Faults
LEGEND Dynamic Unbalanced

•Dirt Accumulation
Dynamic Unbalanced 35 % •Corrossion
Misalignment 18 % •Rotor Bar Crack
Mechanical Looseness 15 % •Thermal Deformation
Resonance 9% •Coupling Compatibility
•Pulley Compatibility
Bearings 9%
Gear mesh Faults 5%
Motor Vibration 2%
Mech. Looseness 2% PREDICTNDT
Rubbing 2%
Soft Foot 1%
Others 1%
VIBRATION - Faults
LEGEND Misalignment
Dynamic Unbalanced 35 % Generally any machinery
Misalignment 18 % installed at structure, sensitive
Mechanical Looseness 15 % to different Ballast Conditions.
Resonance 9%
Misalignment will lead to
Bearings 9%
premature bearing wear.
Gear mesh Faults 5%
Motor Vibration 2%
Rubbing 2%
Soft Foot 1%
Others 1%
VIBRATION - Faults
LEGEND Mechanical Looseness

Dynamic Unbalanced 35 % A result of Poor Assembly after an
Misalignment 18 % overhaul.
Mechanical Looseness 15 % Preventive Maintenance exercise i.e.
Resonance 9% replacement of bearings has also
appeared to be the Root Cause of
Bearings 9%
Machine Failure.
Gear mesh Faults 5%
Motor Vibration 2%
Rubbing 2%
Soft Foot 1%
Others 1%
VIBRATION - Faults
LEGEND Resonance
Dynamic Unbalanced 35 % Design Fault
Misalignment 18 % Corrosion
Mechanical Looseness 15 % Piping Modification
Resonance 9% Torsion Response
Speed Change
Bearings 9%
Isolator
Gear mesh Faults 5%
Motor Vibration 2%
Rubbing 2%
Soft Foot 1%
Others 1%
VIBRATION - Faults
LEGEND Bearing Faults

Dynamic Unbalanced 35 % As a result of:
Misalignment 18 % Dynamic Unbalance
Mechanical Looseness 15 % Misalignment
Resonance 9% Poor Assembly
Resonance
Bearings 9%
Over Greasing !!
Gear mesh Faults 5%
Motor Vibration 2%
Piping Stress 2% PREDICTNDT
Rubbing 2%
Soft Foot 1%
Others 1%
SCOPE
THE VIBRATION ANALYZER & SOFTWARE
VIBRATION ANALYZER
Sarafian Salleh
VIBRATION
Measurement Locations
V - VERTICAL
H - HORIZONTAL
A – AXIAL
Data Collection
5 minutes per Machine
MOTOR MOTOR PUMP PUMP
NDE DE DE NDE
H
MOTOR PUMP
A
VIBRATION CRITERIA
VIBRATION ANALYSIS – MARINE HULL VIBRATION, ISO 6954
Guidelines for the
overall evaluation of
vibration in merchant
ships and the effect of
vibration exposure on
humans
Sarafian Salleh
VIBRATION ANALYSIS – Vibration Effect on Humans
& Sensitive Equipment
VIBRATION ANALYSIS – OTHER CRITERIA
V
MOTOR
NDE H
MOTOR
DE
PUMP
DE
PUMP
NDE
A
MOTOR PUMP
Vibration
Sensors
COOLING TOWER DYNAMIC BALANCING

PIPE VIBRATION & STRUCTURAL ANALYSIS

CENTRIFUGAL & AXIAL FANS

FLOOR VIBRATION INSTRUMENTATION

FLOOR VIBRATION INSTRUMENTATION

FLOOR VIBRATION PROFILE

1x Motor at 16.8Hz
Dynamic Transition
VIBRATION ‘EVENT’ MONITORING
Applicable for Quick-Changing condition – Cranes, Gearbox, Rolling Stock, Structures

VIBRATION ‘EVENT’ MONITORING FOR TRANSIENT CONDITION

Application – Explosive, Fracture, Production Equipment, etc
SCOPE
DATA COLLECTION TECHNIQUES
MEASUREMENT LOCATIONS – Rolling Stock

HP
TURBINE
LP
TURBINE
HP
TURBINE
LP
TURBINE
SCOPE
REPORT
FORMAT
SCOPE
MEASUREMENT LOCATIONS - Complex

VIBRATION – Condition Monitoring
30th Nov 2004
Deterioration of a
gearbox, with 15th Nov 2006
evidence of running
speed harmonics
PREDICTNDT
with rotational
sidebands.
VIBRATION – Resolving Resonance
Oil Cooler exhibited high vibration in the

radial direction
Impact test indicated equipment

experiencing resonance condition.
High vibration level of

13mm/sec at rotational
speed of the fan
VIBRATION – Baseline & Trend Analysis
Weights have been recommended

to detune the ‘Natural Frequency’
of the Oil Cooler structure.
Vibration level has reduced to

a low of 5 mm/sec rms
VIBRATION – Report
VIBRATION – Costs Savings
Vibration Baseline – 1000 Rotating Equipment
•Based on Vibration Survey, approximately 10% of

equipment will have severe bearing problems.
•High failure probability due to Dynamic Unbalance

& Misalignment will be detected and eliminated
(AHU,FD Fan & Cooling Tower).
•Vibration analysis will confirm serviceability of all

remaining shipboard equipment to ISO standards
till the next survey. COMMON INDUSTRIAL FAULTS SURVEYED BY
PREDICTNDT
Reliability = Availability
VIBRATION – Costs Savings
Vibration Baseline – 150 shipboard equipment
ChevronTexaco & ExxonMobil are one of our marine

clients that indicated maintenance cost-savings of
approximately 60% off the preventive maintenance
practices.
•Defer unnecessary replacement of parts.

•Revised insurance premiums for assets.
•Planned maintenance & inventory.
•Minimize unforeseen breakdown. COMMON INDUSTRIAL FAULTS SURVEYED BY
PREDICTNDT
•Timely charter and availability.

VIBRATION
APPLICATION OF VIBRATION TO MARINE AND OIL & GAS EQUIPMENT:
•Generator Exciter & Rectifier
•Main Generator
•Emergency Generator
•Shaft Generator
•Main Sea Water Pump
•Main Boiler Feed Water Pump
•General Service Pump
•Fire Pump
•Bilge & Ballast Pump
•Anchor Windlass Power Pack
•Power Pack Motor
•Bow Thruster
•Cargo Pump
•Force Draft Fan
•Main Engine
•Propeller Shaft
•Transfer Pump
•Axial Jet Fans
•Cooling Tower
VIBRATION APPLICATION
•MARINE
•OIL & GAS
•PETROCHEMICAL & REFINERY
•WAFER & MICROCHIP FABRICATION
•GEOLOGY
•BUILDING MANAGEMENT
•STRUCTURAL AND CIVIL
•MILITARY
•MANUFACTURING
•POWER GENERATION
•BIOTECH
•AEROSPACE
•EXPLOSIVE AND SHOCK
MISC
Sarafian Salleh TENAGA TIGA

Vibration: Integrated Reliability Technology

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Vibration: Integrated Reliability Technology

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INTEGRATED RELIABILITY TECHNOLOGY

DiagnoVeritas Pte Ltd.

COMMON INDUSTRIAL FAULTS SURVEYED BY

LEGEND Dynamic Unbalanced

Mech. Looseness 2% PREDICTNDT

Mech. Looseness 2% PREDICTNDT

LEGEND Mechanical Looseness

Mech. Looseness 2% PREDICTNDT

Mech. Looseness 2% PREDICTNDT

LEGEND Bearing Faults

Piping Stress 2% PREDICTNDT

COOLING TOWER DYNAMIC BALANCING

PIPE VIBRATION & STRUCTURAL ANALYSIS

CENTRIFUGAL & AXIAL FANS

FLOOR VIBRATION INSTRUMENTATION

FLOOR VIBRATION INSTRUMENTATION

FLOOR VIBRATION PROFILE

VIBRATION ‘EVENT’ MONITORING

Applicable for Quick-Changing condition – Cranes, Gearbox, Rolling Stock, Structures

VIBRATION ‘EVENT’ MONITORING FOR TRANSIENT CONDITION

MEASUREMENT LOCATIONS – Rolling Stock

MEASUREMENT LOCATIONS - Complex

30th Nov 2004

Oil Cooler exhibited high vibration in the

Impact test indicated equipment

High vibration level of

Weights have been recommended

Vibration level has reduced to

Vibration Baseline – 1000 Rotating Equipment

•Based on Vibration Survey, approximately 10% of

•High failure probability due to Dynamic Unbalance

•Vibration analysis will confirm serviceability of all

Vibration Baseline – 150 shipboard equipment

ChevronTexaco & ExxonMobil are one of our marine

•Defer unnecessary replacement of parts.

•Timely charter and availability.

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