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Predictive Maintenance untuk Mesin-mesin Rotasi
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Predictive Maintenance (PdM)
! Langkah-langkah Penerapan PdM
! Teknologi Pendukung PdM
! Case Studies
! Keuntungan Penerapan PdM
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Langkah-langkah Penerapan PdM
! Database setup! Pengambilan data di lapangan! Analisis data! Diagnosis permasalahan! Penilaian kondisi mesin! Corrective Action : Balancing & Alignment! Performance Improvement
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Vibration
Tribology
IR-Thermography
On-line Monitoring
Motor Current
CorrectiveBalancing & Alignment
Predictive Technology
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Vibration Analysis
Vibration Sensor
Data Collector
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Vibration Analysis
SOURCE OF PROBLEM
SEVERITY
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Vibration Analysis
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Machinery Vibration Diagnostic
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Tribology – Oil Analysis
Wear
Contamination Chemistry
Extreme
Bad
Marginal
Fair
Good
ABRAS WEAR - Abrasive Wear ExampleP3 - Mobil DTE hydraulic fluidSample Date: 21-FEB-93
Wear - Bad Contamination - Extreme Chemistry - Good
Bad seal leaking coolant into hydraulicsSaw abrasive wear particles on grid 100x
Check - Viscosity, Breather, Contamination, Shop Mic, MechanicalAction - Remove Contaminants (water?) Estimated total water content 2.5089%In Solution 1% +Emulsified 72% +Free 27% = 100%
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Infrared Thermography
33.2
19.3
Diff. 1 13.9
*>33.0°C
*<11.4°C
12.0
14.0
16.0
18.0
20.0
22.0
24.0
26.0
28.0
30.0
32.0
Infrared Picture
Photo Visual
Spot 1 78.8
Spot 2 73.0
Spot 3 75.0
*>81.6°C
*<-6.6°C
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0This hot spot proves not enough coolingfrom the fan.
Hot spot reveal thesource of heat from the motor winding.
Note : 1.Average ampere of the motor = 112 A
2. Full load Ampere = 132 A
Spot 1 = 78.8 ºCSpot 2 = 73.0 ºCSpot 3 = 75.0 ºC
Courtesy of VICO Indonesia
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Motor Analysis
! Vibration Analysis " Mechanical faults
! Untuk mendeteksi electrical faults– Shaft Current / Voltage– Electric Current Analysis– Temperature
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Electric Current Analysis
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Shaft Voltage Measurement
Fluting with Spalling
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Pengukuran Temperatur
TBI TSI TSC
TSO TBO TTH TCP
TAF
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Electrical Faults
! Stator Eccentricity, Shorten Laminations or Loose Iron
! Uneven (variable) Air Gap! Eccentric Rotor! Broken / Cracked Rotor Bars or Shorting Rings! Bad / Loose Connection Rotor Bars/Shorting
Rings! Shorted Rotor Laminations
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Corrective Action - Balancing & Precision Alignment
Two Plane
Large/OverhungRotors or Rolls
Multi-Plane
ComplexEquipment
One Plane
Simple Rotors
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Corrective Action - Balancing & Precision Alignment
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Contoh Penerapan Multi-Teknologi
The Alignment parameter band(2 X RPM) was chosen to trend over time. A forecast of when the fault level would be exceeded with the current trending of values is also applied.
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Nspectr automated fault diagnostics was run on the spectrum and it came up with the Shaft misalignment at the coupling as the most probable fault.
2 x RPMVibration Analysis was requested to provide more insight
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Thermography indicated misalignment
Excessive heat at the couplingExcessive heat at the bearing from increased load.
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Alignment of the motor and pump shafts was performed. The graph at the right shows the before and after alignment condition.
The vibration trend of the alignment parameter band decreased back to normal levels after the shaft alignment job.
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Integrated report showing the Vibration and Infrared Data and an Explanation and Urgency of the problem.
Explanation
Vibration Trend
Urgency
IR Thermogram
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Analisis Multi-Teknologi
– Vibration• FFT, waveform, & phase analysis• Automated diagnostics
WAVEFORM DISPLAY
18-OCT-94 08:37:00
RMS = 4.38
PK(+) = 14.53
PK(-) = 11.78
CRESTF= 3.32
0 50 100 150 200 250 300 350
-15
-12
-9
-6
-3
0
3
6
9
12
15
Time in mSecs
Acc
eler
atio
n in
G-s
CF ALARM
CF ALARM
PK ALARM
PK ALARM
MA#7 - GEARBOX DRIVE-SUCTION ROLL
GBX-DSROLL-G3R G-BOX OUTPUT SHAFT - RADIAL
Label: Severe BPFO defect - need action
Priority: 4
ROUTE SPECTRUM
18-OCT-94 08:37:00
OVRALL= .6516 V-DG
PK = .6892
LOAD = 100.0
FPM = 3518.
RPM = 381.
0 400 800 1200 1600
0
0.1
0.2
0.3
0.4
0.5
0.6
Frequency in Hz
PK
Vel
oci
ty in
In/S
ec
Freq:
Ordr:
Spec:
79.29
12.50
.04412
>FAG 61896
G=BPFO
G G G G G G G G G G
BPFO harmonics show severe race defect
– Tribology• Trivector wear, chemistry, &
contamination analysis
– Alignment & Balancing• Tolerance plots by the job
– Motor Monitoring• Automated rotor & stator
diagnostics with current & flux
– Thermography• Palette & plot annotation tools• Temp profile & histogram analysis
MTR - Forced Draft w/ Broken Bars
450 HP MTR-RB1 Current Rotor Bar Analysis Ph=1
Label: MOTOR WITH 4 BROKEN ROTOR BARS
Spectrum Display
07-DEC-90 09:25
AMPS = 43.32
LOAD = 65%
RPM = 711.
RPS = 11.85
50 52 54 56 58 60 62 64 66 68 70
0
10
20
30
40
50
60
70
Frequency in Hz
dB
AM
PS
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CASE HISTORIES
! BEARING DEFECT ON NASH VACUUM PUMP
! FIELD BALANCING
! HIGH VIBRATION ON VERTICAL PUMP
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Kerusakan Bearing Pompa
MIVMIHMIA
PIVPIHPIA
POVPOHPOA
MOVMOH
#1 #3#2 #4
•Pompa vacuum di PTA Plant•Critical Equipment•Vibrasi tinggi
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Kerusakan Bearing Pompa
PK
Vel
oci
ty in
mm
/Sec
Frequency in Hz
PT4 - NASH Vacuum Pump FJ-10NVP - PTS=POV POH POA (26-APR-00)
0 200 400 600 800 1000
Max Amp 5.30
Plot Scale
0
3
NVP -POV
NVP -POH
NVP -POA
Spektrum pada Pump Outboard Bearing, frekuensi bearing muncul
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Kerusakan Bearing PompaPT4 - NASH Vacuum Pump FJ-10
NVP -POV Pump Outboard Vertical
Route Spectrum 26-APR-00 16:14:04
OVRALL= 12.94 V-DG PK = 12.96 LOAD = 100.0 RPM = 742. RPS = 12.36
0 20 40 60 80 100
0
1
2
3
4
5
6
7
Frequency in Order
PK
Vel
oci
ty in
mm
/Sec
>TMK 71450 CONE C=BPFO
C C C C C C C
ANALYZE WAVEFORM 26-APR-00 16:09:13 (PkVue-HP 1000 Hz) RMS = 11.73 PK(+) = 102.51 PK(-) = 13.21 CRESTF= 8.74
0 50 100 150 200 250 300 350 400
-20
0
20
40
60
80
100
120
Time in mSecs
Acc
eler
atio
n in
G-s
PT4 - NASH Vacuum Pump FJ-10NVP -POH Pump Outboard Horizontal
ANALYZE SPECTRUM 26-APR-00 16:09:13 (PkVue-HP 1000 Hz) RMS = 11.91 LOAD = 100.0 RPM = 740. RPS = 12.33
0 20 40 60 80 100
0
1
2
3
4
5
6
7
Frequency in Order
RM
S A
ccel
erat
ion
in G
-s
>TMK 71450 CONE D=BPFI
D D D D D D
Inner race defect !!
Outer race defect !!
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Field Balancing
GENERATOR
GOVGOHGOA
R4VR4HR4A
R3VR3HR3A
TOVTOHTOA
R1VR1HR1A
R2VR2HR2A
TURBINEGEARBOX
Gearbox outboard
Gearbox inboard
Generatoroutboard
Turbineinboard
Figure.1 Machine diagram of DGT-7
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Equipment Description
! GE Gas turbine coupled with generator ! Capacity 25 MW! Turbine speed = 5100 RPM! Generator speed = 3600 RPM! Configuration : Turbine – Gearbox – Generator! Bearing type : journal bearing
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Before & After Balancing
PK
Vel
oci
ty in
In/S
ec
Frequency in kCPM
PGTD - Duri Gas Turbine 7DGT-7 - PTS=GOV GOH
0 20 40 60 80 100 120
Max Amp .53
Plot Scale
0
1.2
16-DEC-99 09:18DGT-7 -GOV
21-DEC-99 15:01DGT-7 -GOV
16-DEC-99 09:20DGT-7 -GOH
21-DEC-99 14:58DGT-7 -GOH
before balancing
after balancing
before balancing
after balancing
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Keuntungan PdM
! Menghindari unschedule breakdown
! Menjamin Reliability & Availability
! Inventory control
! Menjaga kelangsungan proses produksi
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