Vibration Monitoring
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Basic Vibration Analysis – Indonesia
SKF Reliability Systems – IndonesiaJaka Rusdianto
Slide 123-04-15 ©SKF
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23-04-15 ©SKF
SKF Reliability Systems – IndonesiaJaka Rusdianto
Slide 2
Vibration Analysis
Conducted by:
Anis LutfiCondition Monitoring, SKF Reliability Systems
PT. Skefindo Primatama - INDONESIA
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23-04-15 ©SKF Slide 3
SKF Reliability Systems – Asia PacificCondition Monitoring Products
1SKF PLATFORM
Basic Vibration Analysis – Indonesia
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Basic Vibration Analysis – Indonesia
SKF Reliability Systems – IndonesiaJaka Rusdianto
Slide 423-04-15 ©SKF
SKF GROUP
FACTORY UNIT
• 80 Factories
• 1 in Indonesia
• 45,000 employees
• ISO 14001
SALES UNIT
SKF SALES ASIA PACIFIC
SKF VIETNAM
SKF THAILAND
SKF TAIWAN
SKF KOREA
SKF PHILIPINA
SKF MALAYSIA
SKF SINGAPORE
SKF INDONESIA (PT.SKEFINDO) etc.
• 130 COUNTRY• 7,000 DISTRIBUTOR
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Basic Vibration Analysis – Indonesia
SKF Reliability Systems – IndonesiaJaka Rusdianto
Slide 523-04-15 ©SKF
SKF Network
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23-04-15 ©SKF Slide 6
SKF Reliability Systems – IndonesiaJaka Rusdianto
2MAINTENANCE PILOSOPHY
Basic Vibration Analysis – Indonesia
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Basic Vibration Analysis – Indonesia
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The evolution continues…
Not to fix failed machinery, but to prevent machinery failing.
• To maximize productivity.
• To ensure machinery operates satisfactorily and continuously for its rated life - or longer.
• To provide the highest machine availability, with minimum downtime due to maintenance and service.
• To continuously improve the production process.
• To optimize machine performance.
• Smoother, efficient running machinery costs less to operate, and produces a higher quality product.
• To provide a safe environment.
Slide 7
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Basic Vibration Analysis – Indonesia
SKF Reliability Systems – IndonesiaJaka Rusdianto
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Cost of Maintenance
$17–18 US
$11–13 US
$7–9 US
Type of Maintenance Program
Run to Failure
Maintenance
Predictive Maintenance
PreventiveMaintenance
Cost of MaintenanceUS $/HP/Year
Customer : Cevron Oil USA
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Basic Vibration Analysis – Indonesia
SKF Reliability Systems – IndonesiaJaka Rusdianto
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How Do Predictive Maintenance Programs
Work?
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SKF Reliability Systems – IndonesiaJaka Rusdianto
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The Predictive Maintenance Cycle
Measurement exceeds
alarm limit
Measurement exceeds
alarm limit
Periodic MonitoringPeriodic
MonitoringAnalyze problem
Repair Equipment
Schedule repair(s)
No
Yes
Increase meas. intervals
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Basic Vibration Analysis – Indonesia
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Work FlowWork Flow
PRISM4MICROLOG
ROUTE
SCHEDULE(CMMS)
WORK REQUEST(CMMS)
C.MONITORINGPLAN
DAILY REPORT
MONTHLY REPORT
DATA ANALYSIS
RELIABILITY(Keandalan)
MAINTENANCE(Perawatan)
PRODUCTION(Produksi)
Management
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Basic Vibration Analysis – Indonesia
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How are Measurements Performed?
Sensors ... Sense and Convert Mechanical Energy Into
An Electrical Signal
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BufferedOutputs
Internet / Modem
SKF LANEnhanced
RS485
Ethernet
DCS / PAS / PLC or other Relay Outputs
4-20ma / 0-10VRS485
RS232 / TCP/IP
VM600
MCT
CMU
Microlog
Pens
MARLIN
RS485 / TCP/IP - OPC
RS232
RS232
P4 Only
CMMSInterface
/ RemoteView/ TrendOil
/HMI
Our Integrated Platform for Condition Monitoring
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Basic Vibration Analysis – Indonesia
SKF Reliability Systems – IndonesiaJaka Rusdianto
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Predictive Maintenance Measurements
Vibration
Temperature
Lube Oil
Process
–Pressure
–Flow
–Speed
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23-04-15 ©SKF Slide 15
SKF Reliability Systems – Asia PacificCondition Monitoring Products
3Basic Vibration Philosophy
Basic Vibration Analysis – Indonesia
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Basic Vibration Analysis – Indonesia
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Measuring Vibration
Vibration is considered one of the most effective measurements for monitoring thecondition ofrotating machinery
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Measurable Vibration Characteristics
Frequency - What is vibrating?
Amplitude - How much is it vibrating?
Phase Angle - How is it vibrating?
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Vibration FrequencyMeasurements & Units
• RPM (Revolutions Per Minute)• CPM (Cycles Per Minute)• CPS/Hz (Cycles Per Second/Hertz)• Orders of Running Speed (how
many times event occurs per shaft revolution)
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SKF Reliability Systems – IndonesiaJaka Rusdianto
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Vibration AmplitudeMeasurements & Units
Displacement (Distance)
Mils or Microns
Velocity (Speed - Rate of change of displcmt)
In./Sec. or mm/Sec.
Acceleration (Rate of change of velocity)
G’s - In./Sec.2 or Meter/Sec.2
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Amplitude vs. Frequency
When analyzing vibration we look at two components of the vibration signal, its amplitude and its frequency.
Vibration amplitude indicates the severity of the problem.
Vibration frequency indicates the source of the problem.
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Displacement Probe/Eddy Probe
• Measure Relative Distance Between Two (2) Surfaces
• Accurate Low Frequency Response• Limited High Frequency Sensitivity
• Require External Power Source
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Velocity Sensors
• Often Measure Bearing Housings or Machinery Casing Vibration
• Effective in Low to Mid Frequency Range (10 Hz to around 1,500 Hz)
• Self Generating Devices
• Are Electro-Mechanical Devices With Moving Parts That Can Stick or Fail
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Accelerometers
• Rugged Devices
• Operate in Wide Frequency Range (Near 0 to above 400 kHz)
• Good High Frequency Response
• Some Models Suitable For High Temperature
• Require Additional Electronics
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Sensor Relationships
10 100 1,000 10,000
Frequency (Hz)
10
1.0
0.1
1
0.01
100
Displacement (mils)Acceleration(g's)
Velocity (in/sec)
Common Machinery Operating Range
Amplitude(mils, in/sec, g’s)
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Basic Vibration Analysis – Indonesia
SKF Reliability Systems – IndonesiaJaka Rusdianto
Slide 2523-04-15 ©SKF
Same Data in Velocity and Acceleration
VelocitySpectru
m
Acceleration
Spectrum
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23-04-15 ©SKF Slide 26
SKF Reliability Systems – Asia PacificCondition Monitoring Products
4Vibration Analysis
Basic Vibration Analysis – Indonesia
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Basic Vibration Analysis – Indonesia
SKF Reliability Systems – IndonesiaJaka Rusdianto
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Detection vs. Analysis
Detection
Alarm limits are established for each measurement. When the measurement’s value exceeds its programmed alarm limits, the predictive maintenance software or data collector notifies the analyst of a problem.
Analysis
Once detected, analyzing exceptional measurements provides insight to the problem itself, and to its root cause.
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Types of Alarms
Overall Vibration Limits
Spectral Enveloping
Spectral Bands
Phase Alarms
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ISO Standard
Vibration StandardISO 2372-1974
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ISO Vibration Severity Chart
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Overall Vib. Alarm
Assessing OverallVibration Severity
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23-04-15 ©SKF Slide 32
SKF Reliability Systems – Asia PacificCondition Monitoring Products
5Vibration Spectrum
Basic Vibration Analysis – Indonesia
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What is Vibration Analysis ?
Vibration Analysis is a measure of the energy being emitted from a surface due to forced and natural oscillatory movement. The energy is captured as vibrations and displayed in two common form:
1. Time vs Magnitude - known as time wafe form2. Magnitude vs frequency - known as FFT
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Typical Vibration Analysis Display Formats
Overall Vibration (Trending)FFT Spectrum (Trending/Analysis)Time Waveform (Trending/Analysis)Other Processing Methods
– Acceleration Enveloping– SEE
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FFT Spectrum Analysis
FFT Spectrumshows component vibrationsignals at their respectivefrequencies
low freq.
high fre
q.
frequency
amplitude
frequency
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Spectral Pattern Recognition(velocity spectrum)
1X
2X 3X
4X
frequency
amp
litu
de
< 1X
low frequency rotational events and harmonics(i.e. imbalance, misalignment, looseness, etc.)
high frequency events(i.e. bearing or gear-mesh)
10X
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Spectral Example
1
2
3
baseline spectrum (norm)
higher than normal1X vibration signal
1X
2X
3X
bearingfreq..
gearmeshfreq.
higher than normal1X and bearingvibration signals
Known good measurement collected whenmachine was known to be in good runningorder.
1X running speed peak is significantly higher than normal. Indicates a vibration signal occurring once per shaft revolution. Typically caused by misalignment or imbalance.
Higher than normal 1X running speed peak and bearing fault frequency peaks indicate that 1X rotational problem has caused bearing damage.
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Sources of Vibration
Specific patterns in the spectral signatures are recognized as being related to specific machine problems.• Misalignment 1x or 2x shaft speed
• Imbalance 1x
• Bent shaft 1x or 2x Axial
• Looseness 2x to 10x
• Gearmesh # of teeth x RPM
• Bearing Defects bearing defect frequencies
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Misalignment
AngularMisalignment
ParallelMisalignment
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Velocity Measurement Showing Misalignment
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Imbalance - Diagnosis
static imbalance - vibration across machine“in phase”
couple imbalance - vibration across machine“180 degrees out ofphase”
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Velocity measurement Showing Imbalance
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Bent Shaft
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Bent Shaft - Diagnosis
1 - axial measurements across machinetypically 180 degrees out of phase, and ...2 - radial measurements across machineare typically in phase
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Velocity measurement Showing Bent Shaft Problem
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Mechanical Looseness
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Enveloping measurement showing Mechanical Looseness
Problem
Journal bearing on 600 MW Steam Turbine
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Gear-mesh Frequencies
GMF = # of teeth x RPM
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Gear Defects
• The gear mesh frequency is equal to the gear shaft rotating speed times the number of teeth on that gear.
• The amplitude will vary with the load.
• Two equal gearboxes can have very different amplitudes under the same loads.
• ALWAYS collect a time domain spectrum on each gear shaft bearing.
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Acceleration Measurement Showing Gear-mesh Frequencies
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Mining Gearbox Time Domain 208 RPM
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Why Do Bearings Fail?
inadequate lubrication- too much- too little- contaminated
excessive load caused by:- misalignment- imbalance- bent shaft- etc.....
improper handling or installation
ageflaw on outer race
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Enveloping
Band Pass Filter is specifiedaccording to defect harmonicfrequencies of interest
low frequency events filtered out, high frequency defect harmonics emphasizeddue to low signal to noise ratio, these highfrequency harmonics are then summed andfolded back to the defect’s fundamental frequency
resulting enveloped signal,measured in gE
defect fundamentalfrequency
fundamentalfrequencyharmonics
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Bearing Defect Frequencies
BPFOBall Pass Frequency Outer Race
BPFIBall Pass Frequency Inner Race
BSFBall Spin Frequency
FTFCage Frequency orFundamental Train Frequency
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Acceleration Enveloping on bearing with Outer race defect
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Acceleration Enveloping on bearing with Inner race defect
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Acceleration Enveloping on bearing with Cage defect
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Enveloping Severity ChartISO 10816
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Slide 59
Please write your question !
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