4. TUJUAN MONITORING 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.
5.
6. What Is Vibration Caused By ?
Imperfections in the Machine:
Design Assembly
Manufacture Operation
Installation 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
22. AMPLITUDE – How Much movement Occurs
FREQUENCY – How Often The Movement Occurs
How many “cycle” in a period of time:
a second or a minute
PHASE - In What Direction Is The Movement
Relative To Other Locations On The Machine
At A Given Moment In Time
What Vibration "Characteristics" Do We Measure ?
24. English Units:
Displacement = mils
Velocity = in/sec
Acceleration = g's
Frequency = cycles/min
Metric Units:
Displacement = um
Velocity = mm/sec
Acceleration = g's
Frequency = cycles/min
Displacement = (19,231 x V) / F Displacement = (19,231 x V) / F
Velocity = 0.000052 x D x F Velocity = 0.000052 x D x F
Acceleration = 0.00027 x V x F Acceleration = 0.0000107 x V x F
Displacement, Velocity and Acceleration
25. 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
Average = 0.637 Peak Amp.
36. The Velocity Probe
Velocity Transducer
The Accelerometer
Piezo-Electric Accelerometer
The Proximity Probe
VIBRATION TRANSDUCERS
37. Accelerometer Tranduser
Prinsip Kerja
Gambar diagram sederhana dari tipe accelerometer dengan sebuah penguat didalamnya. Apabila tranduser ini
ditempelkan pada bagian mesin yang bergetar, maka getaran mekanis tersebut diteruskan melalui Case insulator ke
bahan piezoeletric, sehingga bahan tersebut mengalami tekanan sebanding dengan getarannya
Bahan piezoelectric tersebut mempunyai kemampuan untuk menimbulkan muatan listrik sebagai respon terhadap
gaya mekanis yang bekerja terhadapnya. Getaran mekanis yang menghasilkan gaya akan mengenai bahan
piezoeletric dan bahan tersebut akan menimbulkan muatan listrik yang seband¬ing dengan besarnya percepatan dari
getaran tersebut. Muatan listrik yang ditimbulkan oleh bahan piezoelectric tersebut sangat kecil jika dibandingkan
dengan output velocity tranduser. Karena muatan listrik yang ditimbulkan langsung oleh bahan piezoelectric begitu
kecil, maka di dalam tranduser ini dibuat rangkaian penguat electronik untuk memperkuat muatan listrik yang
dihasilkan oleh bahan piezoelectric, tersebut. Besarnya muatan yang dihasilkan langsung oleh bahan piezoelectric
biasanya dalam picocoulombs per g. Sedangkan besarnya sinyal yang dihasilkan setelah melalui penguat,
mempunyai sensitivitas 50 mv per g
39. RUANG LINGKUP PENGUKURAN VIBRASI
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.
41. 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)
46. 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:
Machine
Component
Elements of
Component
Number of
Elements
Motor Cooling Fan Fan Blades 11
Motor Rotor Rotor Bars 42
Drive Pinion Gear Teeth 36
Driven Gear Gear Teeth 100
Fan Fan Blades 9
47. 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 Elements Forcing Frequency,
CPM
Rotation 1 1,780
Motor Cooling Fan 11 19,580
Motor Rotor 42 74,760
Drive Pinion 36 64,080
Fan Shaft Elements Forcing Frequency
CPM
Rotation 1 640.8
Driven Gear 100 64,080
Fan 9 5,767.2
48. 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
49.
50.
51. 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
52. Typical Radial FFT Generated By Unbalance Single Plane Unbalance
Unbalance
Two-Plane Unbalance
Typical Radial FFT Generated By Unbalance
53. Typical Axial FFT Generated By Unbalance
Overhung Rotor Unbalance
Typical Radial FFT Generated By Unbalance
56. Typical FFT Generated By Angular Misalignment
Definition: Shaft Centerlines Intersect But Are Not Parallel
Typical FFT Generated By Offset Misalignment
Definition: Shaft Centerlines Are Parallel But Do Not Intersect
Angular Misalignment
Offset Misalignment
Misalignment
57. Belt-Drive Problems
Pulley Misalignment
FFT Typical Of Pulley Misalignment
This Condition Often Results
In High Axial Vibration At Both Components 1x RPM.
Belt/Pulley Wear, Improper Tension & Belt Resonance
Typical FFT Showing Belt/Pulley Wear Problems
58. Pulley Eccentricity / Bent Shaft (Near Pulley)
Typical FFT Showing Pulley Eccentricity / Bent Shaft Near Pulley
Eccentricity Causes High Vibration
At 1x RPM Of The Problem Component.
Bent Shaft Near Pulley Causes Same Symptom
60. - Bearing / Shaft (Bearing Looseness)
- Bearing / Housing (Bearing Looseness)
- Internal bearing clearances (Bearing Looseness)
- Adjacent, fastened surfaces (Structural)
- Areas of the base (Structural)
Mechanical Looseness
61. Housing Distortion (Soft Foot, Pipe Stress, etc.)
Typical Axial FFT Generated By Housing Distortion
Typical Radial FFT Generated By Housing Distortion
Soft Foot Or Other Housing Distortion Such As
Pipe Stress Can Cause Bearings Within A
Component To Misalign And Can Throw Off
Normal Clearances
62. Structural Looseness
Typical Radial FFT Generated By Mechanical (Structural)
Looseness
Looseness Allows Movement In
The Direction Of The Looseness
Bearing Looseness
Typical Radial FFT Generated By Bearing Looseness Bearing Looseness
63.
64. Rolling Element Bearings
Earlier Failure Stage Symptoms
Typical Enveloping Plot Showing Impacts At Bearing Defect
Frequency
Typical Velocity FFT Showing Early Stage Bearing Defect
Defect Causes Impacts
At A Frequency Equal To The
Component Multiplier x RPM
Two Frequencies Are Produced. The Frequency Of The
Bearing Assembly Resonance Affects The FFT Plot While
The Frequency Of The Impacts Affects The Enveloping Plot
65. Rolling Element Bearings
Later Failure Stage Symptoms
Typical Enveloping Plot Showing Impacts At Bearing Defect
Frequency. Amplitudes May Actually Decrease As Bearings
Continue To Worsen
Typical Velocity FFT Showing Early Stage Bearing Defect.
Amplitudes Can Be Very Low In Early Stages. It Should Be
Noted That The Acceleration Spectrum Will Show The High
Frequency Peaks Far More Clearly Than The Velocity Spectrum
66.
67. Hydraulic Problems:
Recirculation & Flow Related Problems
Typical Spectrum Showing High Vane Pass Frequency ("VPF" = # of Vanes x RPM).
Symptoms normally in the radial directions but may also be seen axially
Cavitation
Typical Spectrum Showing Cavitation (Random, Very Broad Haystack-Like Appearance).
Symptoms normally in the radial directions but may also be seen axially.
Cavitation - occurs when there is insufficient flow into or pressure out of a pump.
This causes the fluid entering to literally be torn apart. Vacuum pockets are created and
then implode. This occurs in a random, unpredictable manner and can be extremely
destructive to the impeller and internal pump components
68. Flow Turbulence
Typical FFT Showing Flow Turbulence. Occurs In Compressors And High
Pressure Blowers When Surging Or Load Variations Occur That The Machine Is
Affected By. Often, A Reservoir Or Surge Suppressor Can Be Used To Eliminate
This Feedback
69.
70. AC Induction Motor Problems:
Elliptical Stator, Stator Weakness & Winding Shorts
Typical Spectrum Showing Indications Of Variation In Air Gap,
Winding Shorts, Stator Weakness
Elliptical Rotor
Typical Spectrum Showing Indications Of Eccentric Rotor. Similar
To Eccentric Stator. Some Cases May Exhibit The Sidebands
Seen Here; Others May Propagate Strictly At 2x Line Frequency
Motor Construction Winding Construction
FLine = Electrical line frequency - 60 Hz(3600 cpm) or 50 Hz(3000 cpm)
2 x FLine = Torque Pulse Frequency
P = # of poles on the motor
FSynch = Synchronous electrical speed = 2 x FLine / P
Fslip = Slip frequency = FSynch - rotor RPM (actual speed)
FPole = Pole pass frequency = P x FSlip
WSPF = # Winding Slots x RPM
RBPF = # Rotor Bars x RPM
71. Phasing Problems
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 Rotor Bars
Spectrum Showing Pattern Of Peaks Separated By 2xLine
Frequency (Sidebands) In High Frequency Range (30-90xRPM)
Winding Slot Pass Frequency or WSPF = # windings slot x RPM
72. Loose in Winding Slots, Iron, End Turns And/Or Connections
Velocity FFT Showing Pattern Of Peaks Separated By 2xLine Frequency
(Sidebands) In High Frequency Range (30-90xRPM)
Envelope Plot Showing 2xLine Peak And Harmonics.
This Indicates Impacts Occurring At 2xLine Frequency
RBPF = rotor bar pass frequency = #Rotor Bar x RPM
75. DC Drives Problem
"Normal" FFT Taken On DC Drive
Full-Wave Rectified Velocity Spectrum w/ Drive Problems
Half-Wave Rectified Velocity Spectrum w/ Drive Problems
Spectrum on DC Motor w/ Speed Fluctuations
FSCR : Freq. Silicon Controlled Rectifier