teori dasar analisa vibrasi
DESCRIPTION
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TEORI DASAR ANALISA VIBRASI
DARYANTO
Predictive Maintenance - CRM
PT KRAKATAU STEEL
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Tujuan training : Bisa Membaca Spectrum Getaran
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PREDICTIVE MAINTENACE PROGRAM
1. Data Collection – Monitoring schedule :
monthly, weekly, daily
2. Detection & Analysis
• Trends
• Alarms
• Spectral Analysis
3. Problem Correction
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TUJUAN PENGUKURAN 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.
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Vibration is a "back and forth" movement of a structure. It
can also be referred to as a "cyclical" movement
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What Is Vibration Caused By ?
Imperfections in the Machine:
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
Design Assembly
Manufacture Operation
Installation Maintenance
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What Are Some Common Machine Problems
That Amplify Mechanical Vibration
(But Don't Cause It):
• Resonance
• Looseness
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PROGRAM KERJASAMA HUMAN CAPITAL DEVELOPMENT CENTER (PT.KRAKATAU STEEL)
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PROGRAM KERJASAMA HUMAN CAPITAL DEVELOPMENT CENTER (PT.KRAKATAU STEEL)
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PROGRAM KERJASAMA HUMAN CAPITAL DEVELOPMENT CENTER (PT.KRAKATAU STEEL)
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F = 1/T
T = The period of the wave
F = The Frequency of the wave
where d = instantaneous displacement,
D = maximum, or peak, Displacement = angular frequency, = 2f
t = time
where v = instantaneous velocity
where a = instantaneous acceleration
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Displacement, Velocity and Acceleration
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
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Example #1:
A Bearing Vibrates 100 Mils Pk-Pk @ 30 cpm
Displacement @ 1x rpm = 100 mils Displacement @ 1x rpm = 2540 um
English Units:
Velocity = 0.000052 x D x F
V = 0.000052 x 100 mils x 30 cpm
Metric Units:
Velocity = 0.000052 x D x F
V = 0.000052 x 2540 um x 30 cpm
V = 0.16 ips V = 4 mm/sec
Acceleration = 0.00027 x V x F
A = 0.00027 x 0.16 x 30
Acceleration = 0.0000107 x V x F
A = 0.0000107 x 4 x 30
A = 0.0013 g's A = 0.0013 g's
Example #2:
A Bearing Vibrates 10 Mils Pk-Pk At 1000 cpm
Displacement @ 1x rpm = 10 mils Displacement @ 1x rpm = 250 um
English Units:
Velocity = 0.000052 x D x F
V = 0.000052 x 10 mils x 1000 cpm
Metric Units:
Velocity = 0.000052 x D x F
V = 0.000052 x 250 um x 1000 cpm
V = 0.52 ips V = 13 mm/sec
Acceleration = 0.00027 x V x F
A = 0.00027 x 0.52 x 1000
Acceleration = 0.0000107 x V x F
A = 0.0000107 x 13 x 1000
A = 0.14 g's A = 0.14 g's
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Example #3:
A Bearing Vibrates 3 Mils Pk-Pk At 9,000 cpm
Displacement @ 9,000 cpm = 3 mils Displacement @ 9,000 cpm = 75 um
English Units:
Velocity = 0.000052 x D x F
V = 0.000052 x 3 mils x 9,000 cpm
Metric Units:
Velocity = 0.000052 x D x F
V = 0.000052 x 75 um x 9,000 cpm
V = 1.404 ips V = 35.1 mm/sec
Acceleration = 0.00027 x V x F
A = 0.00027 x 1.404 x 9,000
Acceleration = 0.0000107 x V x F
A = 0.0000107 x 35.1 x 9,000
A = 3.41 g's A = 3.41 g's
Example #4:
A High Speed Compressor Rotor Shaft
Vibrates 0.003 Mils Pk-Pk At 1,080,000 cpm
Displacement @ 1,080,000 cpm = 0.003 mils
(3 millionths of an inch)
Displacement @ 1,080,000 cpm = 0.077 um
(7.7 millionths of a centimeter)
English Units:
Velocity = 0.000052 x D x F
V = 0.000052 x 0.003 mils x 1,080,000 cpm
Metric Units:
Velocity = 0.000052 x D x F
V = 0.000052 x 0.077 um x 1,080,000 cpm
V = 0.17 ips V = 4.32 mm/sec
Acceleration = 0.00027 x V x F
A = 0.00027 x 0.17 x 1,080,000
Acceleration = 0.0000107 x V x F
A = 0.0000107 x 4.33 x 1,080,000
A = 50 g's A = 50 g's
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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
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Lines of Resolution: 200, 400, 800,1600, 3200, 6400, 12800
Spectrum Resolution = Max Frequency (Fmax)
# of Lines of Resolution Fmax = # Lines / Time Sample
Fmax [Hertz] = 800 / 0.1 seconds = 8000 Hz Fmax [CPM] = 8,000 Hz x 60 = 480,000 cpm
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The Resulting FFT
The Raw Signal
The Actual Signals
Used To Generate
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1x rpm w/ amplitude of 1.8 (pk-pk), '+'
peak on y-axis
2x rpm w/ amplitude of 0.45 (pk-pk)
3x rpm w/ amplitude of 0.05 (pk-pk), '-'
peak on y-axis
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Beats
'
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Linear Amplitude Scaling
Logarithmic Amplitude Scaling
The Decibel
The decibel (dB) is defined by the following expression:
where: LdB = The signal level in dB L1 = Vibration level in Acceleration, Velocity, or Displacement
Lref = Reference level, equivalent to 0 dB
The vibration velocity level in dB is abbreviated VdB, and is defined as:
or
Amplitude Scales
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ISO 10816-3
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The Velocity Probe
Velocity Transducer The Accelerometer
Piezo-Electric Accelerometer
The Proximity Probe
VIBRATION TRANSDUCERS
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Konfigurasi daripada meteran tingkat getaran
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SENSITIFITAS SENSOR VIBRASI
Recommended Frequency Ranges for Different Amplitude Units
Displacement Units: < 600 cpm (< 10 Hz)
Velocity Units: 300 - 120,000 cpm (5 - 2,000 Hz)
Acceleration Units: > 60,000 cpm (> 1,000 Hz)
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PENGAMBILAN DATA VIBRASI
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RUANG LINGKUP PENGUKURAN GETARAN
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.
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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)
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Horizontal machines Vertical machines
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MENENTUKAN ARAH PENGUKURAN
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ANALISA DATA VIBRASI
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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
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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
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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
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Deep Groove Ball Bearing
(BPFO)
(BPFI)
(BSF)
(FTF)
BPFO : Ball Pass Frequency Outer
BPFI : Ball Pass Frequency Inner
BSF : Ball Spin Frequency
FTF : Foundation Train Frequency
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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
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Typical Radial FFT Generated By Unbalance
Typical Axial FFT Generated By Unbalance
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
Troubleshooting chart
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MISALIGNMENT
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Typical FFT Generated By Cocked Bearing
Typical FFT Generated By Shaft Bent Through The Bearing
Typical Radial FFT Generated By Mechanical
(Structural) Looseness
Typical Radial FFT Generated By Bearing Looseness
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Typical Axial FFT Generated By Housing Distortion
Typical Radial FFT Generated By Housing Distortion
Relatively High Amplitudes Will Be Generated.
FFT Typical Of Pulley Misalignment
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Typical FFT Showing Belt/Pulley Wear Problems
Typical FFT Showing Pulley Eccentricity / Bent Shaft
Near Pulley
FFT Showing Sleeve Bearing Looseness
FFT Resulting From Oil Whirl
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Typical Spectrum Showing High Vane Pass Frequency
Typical Spectrum Showing Cavitation
Typical FFT Showing Flow Turbulence
Typical Spectrum Showing Indications Of
Variation In Air Gap, Winding Shorts, Stator
Weakness
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Typical Spectrum Showing Indications Of Eccentric Rotor
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
Spectrum Showing Pattern Of Peaks Separated By 2xLine
Frequency (Sidebands) In High Frequency Range (30-
90xRPM)
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Loose in Winding Slots, Iron, End Turns And/Or Connections
"Normal" FFT Taken On DC Drive Figure 1 - Full-Wave Rectified Velocity Spectrum w/ Drive
Problems
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Figure 2 - Half-Wave Rectified Velocity Spectrum w/
Drive Problems Figure 3 - Spectrum on DC Motor w/ Speed Fluctuations
Normal Gear Spectrum Typical FFT For Eccentric Gear Or Gear On Bent Shaft
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ANALISA DATA VIBRASI
1. Trends Data
14/ 02/ 2009 14/ 03/ 2009 11/ 04/ 2009 09/ 05/ 2009 06/ 06/ 2009 04/ 07/ 2009 01/ 08/ 2009 29/ 08/ 2009 26/ 09/ 2009 24/ 10/ 2009 21/ 11/ 2009 19/ 12/ 2009date
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
v [mm/ s] Strip Dryer Fan No.1 - G1.420\ Fan/ blower Dryer # 1\ BH3\ 101 Ov erall v eloc ity >600
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0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000f [cpm]
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
5,0
5,5
6,0
6,5
7,0
7,5
8,0
8,5
9,0
9,5
10,0
v rms [mm/ s] Strip Dryer Fan No.1 - G1.420\ Fan/ blower Dryer # 1\ BH3\ 103 Mac h. spec tr. >600 13/ 11/ 2009 8:42:18
M
06/ 10/ 2009
09/ 09/ 2009
25/ 08/ 2009
07/ 08/ 2009
10/ 07/ 2009
12/ 05/ 2009
15/ 04/ 2009
24/ 03/ 2009
24/ 02/ 2009
24/ 01/ 2009
2. Waterfall Trends Data
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0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000f [cpm]
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
5,0
5,5
6,0
6,5
7,0
7,5
8,0
v rms [mm/ s] Strip Dryer Fan No.1 - G1.420\ Fan/ blower Dryer # 1\ BH3\ 103 Mac h. spec tr. >600 06/ 10/ 2009 9:02:35
2
3
D
M
3. Single Spectra
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Housing Bearing Gearbox Aus
A
M
P
L
I
T
U
D
O
MESIN &
SPESIFIKASINYA
POSISI &
ARAH PENGUKURAN
LOKASI / AREA MESIN
PUTARAN
POROS
KESIMPULAN
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PROGRAM PREDICTIVE MAINTENANCE
1. Data Collection
• Pemantauan getaran terjadwal
2. Analysis (diperlukan Software)
• Domain frekuensi (harus tahu anatomi mesin)
• Domain waktu
• Frek. eksitasi getaran, database bantalan, gearbox dll
3. Diagnosis
• Prakiraan sumber masalah
• Dibantu oleh Software
• Human Interface (Tergantung pengalaman)
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TERIMA KASIH