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ANALISA VIBRASI
TUJUAN MONITORING GETARAN 1. Menentukan kondisi mekanis mesin. 2. Merencanakan jadwal pemeliharaan. 3. Memeriksa hasil repair/overhaul.
What Is Vibration Caused By ? Imperfections in the Machine: Design Manufacture Assembly 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
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
FFT Analysis
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
AMPLITUDO
v rms [inch/ s] 0,80 0,78 0,76 0,74 0,72 0,70 0,68 0,66 0,64 0,62 0,60 0,58 0,56 0,54 0,52 0,50 0,48 0,46 0,44 0,42 0,40 0,38 0,36 0,34 0,32 0,30 0,28 0,26 0,24 0,22 0,20 0,18 0,16 0,14 0,12 0,10 0,08 0,06 0,04 0,02 0,00 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000 f [cpm] (2955,00 / 0,43) M RPM : 2953 (49,22Hz) M(x) : 2955,00 cpm (1,00 Orders) M(y) : 0,43 inch/ s Fan/ blower No.21 - ARP\ Fan/ blower # 21\ BH4\ 103 Mac h. spec tr. >600 22/ 11/ 2011 9:10:07
a rms [g] 0,80 0,78 0,76 0,74 0,72 0,70 0,68 0,66 0,64 0,62 0,60 0,58 0,56 0,54 0,52 0,50 0,48 0,46 0,44 0,42 0,40 0,38 0,36 0,34 0,32 (2955,00 / 0,342) M RPM : 2953 (49,22Hz) M(x) : 2955,00 cpm (1,00 Orders) M(y) : 0,342 g Fan/ blower No.21 - ARP\ Fan/ blower # 21\ BH4\ 103 Mac h. spec tr. >600 22/ 11/ 2011 9:10:07
English or "Imperial": Inches per Second (ips -or- in/sec) Metric: Millimeters per Second (mm/sec) Conversion::1 ips = 25.4 mm/sec
0,30 0,28 0,26 0,24 0,22 0,20 0,18 0,16 0,14 0,12 0,10 0,08 0,06 0,04 0,02 0,00 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000 f [cpm]
s rms [mils] 1,60 1,55 1,50 1,45 1,40 1,35 1,30 1,25 1,20 1,15 1,10 1,05 1,00 0,95 0,90 0,85 0,80 0,75 0,70 0,65 0,60 0,55 0,50 0,45 0,40 0,35 0,30 0,25 0,20 0,15 0,10 0,05 0,00 0
Fan/ blower No.21 - ARP\ Fan/ blower # 21\ BH4\ 103 Mac h. spec tr. >600 22/ 11/ 2011 9:10:07
(2955,00 / 1,378) M
RPM : 2953 (49,22Hz) M(x) : 2955,00 cpm (1,00 Orders) M(y) : 1,378 mils
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Displacement = mils Velocity = in/sec Acceleration = g's Frequency = cycles/min Displacement = (19,231 x V) / F
English Units:
Metric Units:
Velocity = 0.000052 x D x F
Acceleration = 0.00027 x V x F
Velocity = 0.000052 x D x F
Acceleration = 0.0000107 x V x F
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
FREQUENCY
v rms [inch/ s] 0,50 0,48 0,46 0,44 0,42 0,40 0,38 0,36 0,34 0,32 0,30 0,28 0,26 0,24 0,22 0,20 0,18 0,16 0,14 0,12 0,10 0,08 0,06 0,04 0,02 0,00 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000 f [cpm] (2955,00 / 0,43) M RPM : 2953 (49,22Hz) M(x) : 2955,00 cpm (1,00 Orders) M(y) : 0,43 inch/ s Fan/ blower No.21 - ARP\ Fan/ blower # 21\ BH4\ 103 Mac h. spec tr. >600 22/ 11/ 2011 9:10:07
v rms [inch/ s] 0,50 0,48 0,46 0,44 0,42 0,40 0,38 0,36 0,34 0,32 0,30 0,28 0,26 0,24 0,22 0,20 0,18 0,16 0,14 0,12 0,10 0,08 0,06 0,04 0,02 0,00 0,0 0,2
Fan/ blower No.21 - ARP\ Fan/ blower # 21\ BH4\ 103 Mac h. spec tr. >600 22/ 11/ 2011 9:10:07
(1,00 / 0,43) M
RPM : 2953 (49,22Hz) M(x) : 1,00 - (2955,00 cpm) M(y) : 0,43 inch/ s
0,4
0,6
0,8
1,0
1,2
1,4
1,6
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2,0
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2,4
2,6
2,8
3,0
3,2
3,4
3,6
3,8
4,0
4,2
4,4
4,6
4,8
5,0
5,2
5,4
5,6
5,8
6,0
6,2
6,4
6,6
6,8
7,0
7,2
7,4
7,6
v rms [inch/ s] 0,50 0,48 0,46 0,44 0,42 0,40 0,38 0,36 0,34 0,32 0,30 0,28 0,26 0,24 0,22 0,20 0,18 0,16 0,14 0,12 0,10 0,08 0,06 0,04 0,02 0,00 0
Fan/ blower No.21 - ARP\ Fan/ blower # 21\ BH4\ 103 Mac h. spec tr. >600 22/ 11/ 2011 9:10:07
(49,25 / 0,43) M
RPM : 2953 (49,22Hz) M(x) : 49,25 Hz (1,00 Orders) M(y) : 0,43 inch/ s
Frequency Unit Cycles / Second (Hertz) Hertz x 60 = Cycles / Minute (CPM) Order
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f [Hz]
400
Displacement Units: < 600 cpm (< 10 Hz) Velocity Units: 300 - 120,000 cpm (5 - 2,000 Hz) Acceleration Units: > 60,000 cpm (> 1,000 Hz)
Spectrum Resolution =
Fmax = # Lines / Time Sample Fmax [Hertz] = 800 / 0.1 seconds = 8000 Hz Fmax [CPM] = 8,000 Hz x 60 = 480,000 cpm
Frequency Name 4-Lobe Rotor Speed 4-Lobe Pass Frequency 6-Lobe Rotor Speed 6-Lobe Pass Frequency Bull Gear Mesh Freq: Pinion GMF 2x GMF 3x GMF
Calculation 3580 x 48T/36T 4773 x 4 4773 x 4T/6T 3182 x 6 3580 rpm x 48T 4773 x 36T 2 x GMF
Frequency 4773 rpm 19092 cpm 3182 rpm 19092 cpm 171,840 cpm 171840 cpm 343,680 cpm 515,520 cpm
VIBRATION TRANSDUCERS
The Proximity Probe
The Velocity Probe
Velocity Transducer
The Accelerometer
Piezo-Electric Accelerometer
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 sebanding 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
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)
Horizontal machines
Vertical machines
Let us assume that the motor/gear/fan components have the following element counts: Elements of Component
Fan Blades Rotor Bars Gear Teeth Gear Teeth
Machine Component
Motor Cooling Fan Motor Rotor Drive Pinion Driven Gear
Number of Elements
11 42 36 100
Fan
Fan Blades
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
Rotation Motor Cooling Fan Motor Rotor Drive Pinion
Elements
1 11 42 36
Fan Shaft
Rotation Driven Gear Fan
Elements
1 100 9
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
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:
Unbalance
Two-Plane Unbalance
MISALIGNMENT
Misalignment
Typical FFT Generated By Angular Misalignment Definition: Shaft Centerlines Intersect But Are Not Parallel
Angular Misalignment
Typical FFT Generated By Offset Misalignment Definition: Shaft Centerlines Are Parallel But Do Not Intersect
Offset Misalignment
FFT Typical Of Pulley Misalignment This Condition Often Results In High Axial Vibration At Both Components 1x RPM.
Eccentricity Causes High Vibration At 1x RPM Of The Problem Component. Bent Shaft Near Pulley Causes Same Symptom
Mechanical Looseness
- Bearing / Shaft (Bearing Looseness) - Bearing / Housing (Bearing Looseness) - Internal bearing clearances (Bearing Looseness) - Adjacent, fastened surfaces (Structural) - Areas of the base (Structural)
Soft Foot Or Other Housing Distortion Such As Pipe Stress Can Cause Bearings Within A Component To Misalign And Can Throw Off Normal Clearances
Structural Looseness
Bearing Looseness
Bearing Looseness
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
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
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
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
Typical Spectrum Showing Indications Of Variation In Air Gap, Winding Shorts, Stator Weakness
Motor Construction
Winding Construction
Elliptical Rotor
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
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
Phasing Problems
One 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)
Another Possible Spectrum Caused By A Problem With A Short In One Of The Phases Or Feeder Cables
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
DC Drives Problem
DC Drives Problem
Gear Problems:
3. Diagnosis
4. Langkah Perbaikan
0,90
0,85 RPM : 0 M(x) : 01/ 06/ 2011 19:06:29 M(y) : 0,51 inch/ s
0,80 0,75
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0,00 20/ 07/ 2009 07/ 09/ 2009 26/ 10/ 2009 14/ 12/ 2009 01/ 02/ 2010 22/ 03/ 2010 10/ 05/ 2010 28/ 06/ 2010 16/ 08/ 2010 04/ 10/ 2010 22/ 11/ 2010 10/ 01/ 2011 28/ 02/ 2011 18/ 04/ 2011 date
(2955,00 / 0,38) M RPM : 2953 (49,22Hz) M(x) : 2955,00 cpm (1,00 Orders) M(y) : 0,38 inch/ s
0,44 0,42 0,40 0,38 0,36 0,34 0,32 0,30 0,28 0,26 0,24 0,22 0,20 0,18 0,16 0,14 0,12 0,10 0,08 0,06 0,04 0,02 0,00 0 1000 2000 3000 4000 5000 6000 7000 8000 04/ 05/ 2010 16/ 04/ 2010 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000 21000 22000 23000 24000 f [cpm] 17/ 07/ 2010 02/ 06/ 2010 03/ 11/ 2010 19/ 09/ 2010 24/ 08/ 2010 01/ 06/ 2011
3. Single Spectrum
v rms [inch/ s] 0,44 0,42 0,40 0,38 0,36 0,34 0,32 0,30 0,28 0,26 0,24 0,22 0,20 0,18 0,16 0,14 0,12 0,10 0,08 0,06 0,04 0,02 0,00 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 f [cpm] (8865,00 / 0,14) 3 (2955,00 / 0,38) M RPM : 2953 (49,22Hz) M(x) : 2955,00 cpm (1,00 Orders) M(y) : 0,38 inch/ s D(x) : 20685,00 cpm (7,00 Orders) D(y) : 0,01 inch/ s Fan/ blower No.21 - ARP\ Fan/ blower # 21\ BA4\ 103 Mac h. spec tr. >600 01/ 06/ 2011 19:06:44
(5910,00 / 0,06) 2 (11820,00 / 0,04) 4 (14775,00 / 0,02) 5 (17730,00 / 0,01) 6 (20685,00 / 0,01) D
4. Kondisi Bearing
Enveloping Signal Processing(ESP) & High Frequency Domain(HFD)......SKF/DI Spike Energy(gSE) .............Entek/IRD Peakvue ..............................CSI Enveloping Spectrum .........Pruftechnik
a rms [g] 0,90 Fan/ blow er N o. 21 - AR P\ Fan/ blow er # 21\ BH 4\ 250 Env elope Spec t rum Ac c elerat ion 29/ 11/ 2011 16: 50: 04 0,85 (2952,00 / 0,797) 0,80 M RPM : 2953 (49,22Hz) M(x) : 2952,00 cpm (1,00 Orders) M(y) : 0,797 g D(x) : 20664,00 cpm (7,00 Orders) D(y) : 0,030 g
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(5904,00 / 0,264) 2
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0,20
0,15 (8856,00 / 0,094) 0,10 3 (17712,00 / 0,033) (14760,00 / 0,031) (20664,00 / 0,030) (11808,00 / 0,018) 6 5 D 4
0,05
0,00 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000 28000 30000 32000 34000 36000 f [cpm]
6. Orbit
Y2 [g] Strip Dryer - J1.470\ Fan/ blower Dryer \ BV3\ 285 Orbit 17/ 06/ 2009 18:35:06 90 0,040 0,038 0,036 0,034 0,032 0,030 0,028 0,026 (-0,04 / 0,021) M 0,024 0,022 0,020 0,018 0,016 0,014 0,012 0,010 0,008 0,006 0,004 0,002 -0,040 -0,035 -0,030 -0,025 -0,020 -0,015 -0,010 -0,005 0,000 0,000 0,005 -0,002 -0,004 -0,006 -0,008 -0,010 -0,012 -0,014 -0,016 -0,018 -0,020 -0,022 -0,024 -0,026 -0,028 -0,030 -0,032 -0,034 -0,036 -0,038 -0,040 270 Y1 [g] 0,010 0,015 0,020 0,025 0,030 0,035 0,040
a [g channel A] 0,050 0,045 0,040 0,035 0,030 0,025 0,020 0,015 0,010 0,005 0,000 -0,005 -0,010 -0,015 -0,020 -0,025 -0,030 -0,035 -0,040 -0,045 -0,050 0 10
Strip Dryer - J1.470\ Fan/ blower Dryer \ BV3\ 285 Orbit 17/ 06/ 2009 18:35:06 RPM : 47897 (798,29Hz) M(x) : 90,00 M(y) : -0,037 g
(90,00 / -0,037) M
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a [g channel B] 0,050 0,045 0,040 0,035 0,030 0,025 0,020 0,015 0,010 0,005 0,000 -0,005 -0,010 -0,015 -0,020 -0,025 -0,030 -0,035 -0,040 -0,045 -0,050 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 (90,00 / 0,021) M
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KESIMPULAN
LOKASI / AREA MESIN MESIN & SPESIFIKASINYA POSISI &
ARAH PENGUKURAN
A M P L I T U D O
Type Spectrum
PUTARAN POROS
TERIMA KASIH