VIBRATION I

Vibrasi Mekanis dan Analisa Vibrasi

Mengapa Vibrasi ?

Main source of sound

and vibration
Vibration Analysis

"Of all the parameters that can be measured

non-intrusively in industry today,
the one containing the most information
is the vibration signature."

Art Crawford
Basic Terminology: Vibration

 Vibration is a continuous,
random or periodic motion
of an object
 or transient “impact” event of
short time duration

 Caused by either a man-

made, natural excitation of a
structure, and mechanical
faults .
– Vibration institute
 Sekarang kita coba untuk
menjelaskan vibrasi dengan
memakai beberapa parameter
dasar….
 Amplitudo & Frekuensi
Consider a mass moving up …. Plotting its movement over
And down on a spring ….. Time yields its time domain signal
B

B A C E
A C E
D
D
AMPLITUDO FREQUENCY
Acceleration (max) at B & D
CPM =cycles per minute
Velocity (max) at A, C & E
Hertz = cycles per second
Displacement (peak to peak) B-D
Order = once per revolution
distance
 Grafik simpangan getaran
sederhana terhadap waktu

amplitude

1 period, T
Frequency (f) = 1 / T
Simple Case of Steady Vibration
Simple Case of Steady Vibration
Vibrational Displacement
Vibrational Velocity
Vibrational Acceleration
Vibrational Movement Related to
Vibration Waveform
Vibrational Movement Related to
Vibration Waveform
Vibrational Movement Related to
Vibration Waveform
Vibrational Movement Related to
Vibration Waveform
Different Ways of Describing the
Amplitude of the Waveform.1.
Zero
To
Zero
Peak Peak
to
Peak To Peak
peak to
Peak

Peak-to-Peak (P- P) = 2 x (Zero-to-Peak (Peak))

Caution! This is "true peak" and may not be
measured by all instruments
Different Ways of Describing the Amplitude
of a Waveform. 2.

Root
Mean Average
Square

Root Mean Square (RMS) = 0.707 x (Zero-to-Peak)

Average = 0.637 x (Zero-to-Peak)
Caution! This only applies to the "simple" vibration
shown here, not for complex waveforms
How Vibration is measured &
described
 Amplitudo
– Displacement (mils, micron)
– Velocity (ips, mm/s)
– Acceleration (g, mm/s2, Inch/s2)
• 1 g =9.807m/ s2 = 386.4 in/s2

 Frekuensi
– Cycle per second (Hz) atau Rotation per minute
(RPM)
 Fasa
– Derajat, dimana 1 putaran = 360°
How vibration is measured &
described
 Peak – to – Peak
– Umumnya dipakai untuk pengukuran
displacement
– Equal to 2x Peak
 Peak (zero to peak)
– Dapat dipakai untuk Velocity & Acceleration (US)
 RMS (root mean square)
– Equal to 0.707 x peak
– Dapat dipakai untuk Velocity & Acceleration
(Europe)
Hubungan antara Displacement,
Velocity, Acceleration
 Velocity
– V = 2 pf D
 Acceleration
– A = 2 pf V
– A = (2 pf)² D

 Note:
– Semua satuan harus
sama.
 Displacement, Velocity and Acceleration –
on a Same Vibrating Machine
 Peaks of graphs are at
increments of 30Hz
(i.e.. 0, 30Hz, 60Hz,
90Hz…)
– Displacement (mm)
• Proximity Probe

– Velocity (mm/s)
• Velocity Pickup

– Acceleration (m/s2)
• Accelerometer
Workshop

 Ubah displacement 40 micron p-p

pada 1450 RPM menjadi velocity peak
dalam mm/s
 Ubah velocity 3 mm/s peak pada 2950
RPM menjadi acceleration dalam g-s
RMS
– Jawaban
1. 3 mm/s Peak
2. 0.07 g - rms
Signal Acquisition
Transducer Waveform

Amplitude
Overall
Energy Time

FFT
Spectrum

Amplitude

On-line Frequency
Off-line
 Vibration Transducers
Vibration transducers (or sensors) adalah alat
untuk mengkonversi vibrasi mekanik menjadi
signal elektris ekivalen agar dapat di analisa
Jenis sensor yang umum dipakai:
1. Displacement Transducer
– Mengukur jarak pergerakan relatif dari poros relative
terhadap bantalan
2. Velocity Transducer
– Mengukur kecepatan vibrasi pada casing
3. Accelerometer
– Mengukur akselerasi vibrasi pada casing
4. Piezo-velocity transducer
– Akselerometer dengan signal keluaran velocity
Applications of Vibration
Transducers
 Displacement transducers:
– typically used for shaft relative
movement at low frequencies
 Velocity transducers
– commonly used for low to intermediate
frequency applications, where velocity
believed to give best guide to vibration
severity
– best to measure velocity with an
accelerometer using electronic
integration
Applications of Vibration
Transducers
 Accelerometers:
– best for high frequency, such as
bearing impacting, high speed gear
& blading problems
– transducer of choice for industrial
applications
 Which Units to use ?
Amplitude
Frequency
Measurements English Metric

1. Hz or CPS
Displacement Mils Microns
(Cycles / sec)
2. CPM
(Cycles / minute)
3. Orders
Velocity IPS mm/s

Acceleration G’s G’s

 Displacement Transducer
 Measures relative displacement
between probe tip and rotating
shaft
 Useful on machines with high
case to rotor weight ratio (e.g.
steam turbines)
 May be already installed as OEM
equipment
 Usually permanently installed -
may be difficult
 Limited frequency range due to
run-out
 0 to 1000 Hz (0 to 60,000 CPM)
typical
 Requires special power
Radial X & Y Installation supply/signal conditioner and
cables
 Application & Data Representation
Displacement Transducer
Displacement
Probe

CL
Driver
Shaft

Probe Tip Near Shaft

Bias or DC
-9V DC Gap Voltage AC Signal plus the
DC gap voltage for
machine spin-up
-18V DC

-24V DC Displacement transducer, also known as an

eddy current probe, has both AC and DC signal
Probe Tip Far Away From Shaft components. AC signal represents vibration;
DC average clearance, plus offset.
 How it works ?
Displacement Transducer

Radial X & Y Eddy Current Probe

 Gap Voltage
Displacement Transducer
The gap voltage (“DC Bias”)

Desired Gap Voltage Settings is the voltage which
represents the nominal
distance between the eddy
current probe tip and the
Voltage Output

AC Signal
measured surface.
 This may be either a positive
DC Gap
Desired Volt or negative polarity.
Desired Gap

Gap Offset
Velocity Transducer
 Seismic transducer works well where there is
significant casing vibration.
 Gives velocity signal directly.
 Self-generating, no power required.
 May have good signal-to-noise ratio, but limited
frequency range (10 - 2000 Hz).
 Tend to be relatively large, heavy & expensive.
 Transducers must be mounted horizontally to
obtain the best results.
 Calibration may shift due to wear and
temperature fluctuations (due to damping).
Velocity Transducer
Cable connector

Casing
Spring
Coils
Magnet

Damping fluid
Accelerometer Transducer
 The transducer of choice in industry today
 Very wide frequency range possible
– from 0 to 20,000 Hz (different transducers!)
– typically 2 to 15 kHz (120 to 900,000 CPM)
 Extremely rugged, no moving parts
 Relatively small and lightweight
 Easy mount for permanent or intermittent use
(stud, adhesive, magnet, hand-held)
 Requires constant current power supply for
built-in amplifier (some need external amps)
 Signal output is acceleration
Accelerometer Transducer
Acceleration Transducer Mounting
Stud mounting, up to
10000 Hz

2-pole magnet, up to
2000 Hz

Hand held stinger, up to 500 Hz

 Acceleration Sensor Locations
Measure as close as possible to bearing housing
Data acquisition

 Analog recorder
 Digital data logger

 Single Channel
 Multi Channel

 On-line
 Off-line
 Analog data logging

Sensors
Analog data recorder

Signal
Conditioner
Off-line portable data collector

Vibration Sensor

Data Collector
Rentang frekuensi
Komponen Rentang frekuensi
Shaft vibration 10 x RPM
Gearbox 3 x GMf
RE Bearing 10 x BPFI
Pump 3 x VP
Electric Motors 3 x 2 LF
Fans 3 x BP
Sleeve Bearing 10 x RPM
Digital Sampling

 Sampling rate
– Harus cukup tinggi untuk mencegah efek
ALIASING
– Instrumen sebaiknya sudah dilengkapi
dengan anti-aliasing filter
Windowing

 Ada dua jenis window yang umumnya

tersedia pada instrumen vibrasi
– Hanning Window
• Untuk fault analysis
• Window factor (WF) = 1.5
• Amplitude uncertainity = 18.8%
– Uniform Window
• Untuk impact test
• Window factor (WF) = 1
• Amplitude uncertainity = 56.5%
Resolusi, jumlah garis & waktu
pengambilan data
 Resolusi (bandwidth) adalah kemampuan
terendah untuk membedakan 2 frekuensi

 Resolusi = 2 x Freq. Span x WF

number of lines
 Data acquisition time = no. of lines
rentang frekuensi

 Number of lines yg tersedia:

– 100, 200, 400, 800, 1600, 3200, 6400
 FFT Signal Processing

T
im
e
Amplitude Amplitude
T
im
e e
u
q
e
r
Fy
c
n
Amplitude
Standard Waveform of Bad Bearing

Standard Waveform

• Some level of
impacting visible
• Difficult to determine the
problem
Standard FFT of Bad Bearing

Standard FFT
Workshop
 Akan dilakukan pengambilan data vibrasi pada dua
fan yang dipasang berdekatan, tapi mempunyai
kecepatan 965 RPM & 970 RPM. Berapa Number of
Lines yang harus dipakai untuk dapat membedakan
sumber getaran? Dipakai metoda Hanning Window
dan rentang frekuensi 10 x shaft speed.
 Berapa waktu pengambilan data?

– Jawab: 3200 lines

– Jawab: 16 seconds
Machine Fault Diagnosis

Single Channel Vibration

Three Rules of Diagnosis

 Tiap gejala kerusakan mekanis memberikan

pola vibrasi yang berbeda.

 Nilai frekuensi getaran ditentukan oleh

geometris mesin dan kecepatan putar.

 Sebuah pengukuran vibrasi memberikan

informasi tentang berbagai komponen mesin
A Typical FFT Spectrum

Many distinct peaks

A Typical FFT Spectrum

Specific peaks typically correlate to

Specific machine faults
Related to machine speed
Typical Machinery Problems
 Unbalance 40%
 Misalignment 20%
 Resonance 20%
 RE Bearing
 Sleeve Bearing
 Gear Problem 20%
 Motor Electrical
Ralph T Buscarello
 Cavitations Update International

 Vane pass
 Etc.
Unbalance
Imbalance typically appears at
the turning speed of the machine
Only in Radial Direction

Imbalance
Misalignment
Misalignment typically shows up
at either 1 or 2 x turning speeds
On Axial and Horizontal direction

Misalignment
Looseness

Looseness shows up as
multiples of turning speed

Looseness
Gear Mesh Fault

Sidebands Many distinct peaks

increase with
gear wear

Gear Wear
A Typical FFT Spectrum

Bearing wear shows up at

specific peaks related to the
geometry of the bearing

Bearing Wear
Roller Bearing Faults
Four different bearing frequencies

Ball Spin Frequency

(BSF)

Fundamental Train
Frequency
(FTF)

Ball Pass Frequency

Inner Race
(BPFI)

Ball Pass Frequency

Outer Race
(BPFO)
How Bearing Faults Generate Vibration

Outer Race
Impacting

Inner Race
Impacting
How Bearing Faults Generate Vibration

Outer Race
Impacting

Inner Race
Impacting

Inner race signal

with modulation
Actual Outer Race Defect

Advanced bearing wear shows

up clearly in spectrum
Onset of Outer Race Defect

Early bearing wear frequently

can’t be detected with
standard vibration measurements
Demodulation vs. PeakVue
Demodulation

Demodulation and
Amplitude 0.003 g
PeakVue each
detect early
bearing wear

PeakVue

Amplitude 0.05 g PeakVue shows:

 fault more clearly
 less signal noise
 actual amplitude
PeakVue Waveform of Bad Bearing

PeakVue Waveform

•focuses on
bearing impacting
•clear indication
of bearing wear
 PeakVue FFT of Bad Bearing

PeakVue Spectrum

• high frequency signals

brought to low
frequency
• clear indication of
bearing fault
Detecting Faults Automatically

Vibration Alarming Methods

Overall Alarm
Total vibration on machine

A
L
A
RM
L
E
VE
L
=
0.
1
1I
N/
S
EC

P
E
AK
-
RM
S
O
V
E
R
AL
L
VA
LU
E

May detect imbalance vibration (typically higher amplitudes)

Overall Alarm
Total vibration on machine

A
L
A
RM
L
E
VE
L
=
0.
1
1I
N/
S
EC

P
E
AK
-
RM
S
O
V
E
R
AL
L
VA
LU
E

Not sensitive enough for even advanced bearing faults

(typically low amplitude signals)
Frequency Bands
Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1
XImbalance

2
XMisalignment
3
X-6 X
Looseness
BEA RIN G
BearingB AND
Band 11B
EA
R
I
N
GBA
N
D
2 Bearing Band 2

9
-
3
0X
RP
M
3
0
-
5
0X
RP
M
Frequency Bands
Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1
XImbalance

2
XMisalignment
3
X-6 X
Looseness
BEA RIN G
BearingB AND
Band 11B
EA
R
I
N
GBA
N
D
2 Bearing Band 2

9
-
3
0X
RP
M
3
0
-
5
0X
RP
M
Frequency Bands
Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1
XImbalance

2
XMisalignment
3
X-6 X
Looseness
BEA RIN G
BearingB AND
Band 11B
EA
R
I
N
GBA
N
D
2 Bearing Band 2

9
-
3
0X
RP
M
3
0
-
5
0X
RP
M
Frequency Bands
Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1
XImbalance

2
XMisalignment
3
X-6 X
Looseness
BEA RIN G
BearingB AND
Band 11B
EA
R
I
N
GBA
N
D
2 Bearing Band 2

9
-
3
0X
RP
M
3
0
-
5
0X
RP
M
Frequency Bands
Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1
XImbalance

2
XMisalignment
3
X-6 X
Looseness
BEA RIN G
BearingB AND
Band 11B
EA
R
I
N
GBA
N
D
2 Bearing Band 2

9
-
3
0X
RP
M
3
0
-
5
0X
RP
M
Frequency Bands
Divide spectrum in frequency bands based on the
types of mechanical faults that might appear on the machine

1
XImbalance

2
XMisalignment
3
X-6 X
Looseness
BEA RIN G
BearingB AND
Band 11B
EA
R
I
N
GBA
N
D
2 Bearing Band 2

9
-
3
0X
RP
M
3
0
-
5
0X
RP
M
Typical Vibration Parameters
 Sub-synchronous  DC Gap Voltages from
Region Displacement Probes
 1 X Run Speed  Gearmesh Frequency
 2 X Run Speed  Belt Pass Frequency
 3 to 5 X Run Speed  Synchronous Peak
 6 to 20 X Run Speed Amplitudes
(Bearing Band 1)  Synchronous Phase
 20 to 50 X Run Speed Measurements
(Bearing Band 2)  Blade Pass Frequency
 VHFD or HFB, (1 kHz  Resonant Frequency
to 20 kHz, 60,000 to Ranges
1,200,000 CPM)
 Relation between Faults and
Parameter Bands – Exp.1.
Oil Whirl

Imbalance

General Sleeve Bearing Setup

Misalignment

Looseness

Parameter Freq. Range Alarm Level Units

Overall 0 - 15 X RPM .350 ips (pk)
Subsynchr. 0 - 0.8 X RPM .100 ips (pk)
1 X RPM 0.8-1.5 X RPM .300 ips (pk)
2 X RPM 1.5-2.5 X RPM .175 ips (pk)
3-5 X RPM 2.5-5.5 X RPM .150 ips (pk)
6-15 X RPM 5.5-15.5 X RPM .100 ips (pk)
Phase at N/A 20 from deg
1 X RPM baseline
Dispt. Probe N/A 1 from DC volts
Gap baseline
 Relation between Faults and
Parameter Bands – Exp.2.
Imbalance

Misalignment

Looseness

Bearing Defect Frequencies

Antifriction Bearing Setup

Parameter Freq. Range Alarm Level Units
Overall 0 - 50 X RPM .350 ips (pk)
Sub & 0 -1.5 X RPM .300 ips (pk)
1 X RPM
2 X RPM 1.5-2.5 X RPM .175 ips (pk)
3-5 X RPM 2.5-5.5 X RPM .150 ips (pk)
Bearing Band 15.5 - 30 X RPM .080 ips (pk)
1
Bearing Band 30 - 50 X RPM .08 ips (pk)
2
High Freq. 1000 - 20,000 Hz 1.414 g (RMS)
Band
Frequency Bands with Trend
Sub- 1X 2X Bearing Bearing Gears Bearing
Harmonic
Amplitude

1xRPM 2xRPM 10-20xRPM

Trend of Trend of
.3 Imbalance Bearing Wear
in/sec Alarm
.1
Time in/sec Time
(Days) (Days)
Finally: Estimating Time to Alarm
Trend Display
of
1xRPM
Baseline Value
.240 in/sec (pk)
Date: 08-JAN-87

240 270 300 330

"Line of best fit"

is drawn thru last
3 points...
240 270 300 330
... to "predict"
240 270 300 330 time until alert
level is reached... ... estimate is 60
days until alert level
240 270 300 330 is exceeded
240 270 300 330

240 270 300 330

240 270 300 330
 Establishing a Vibration Program

 TECHNICAL
Define program focusSTEPS
Determine collection method(s)

Create database
BUSINESS
Collect data
STEPS
Detect developing faults

Diagnose nature and extent of fault

Document business and maintenance implications

Step 1: Define program focus

 Identify Critical Machines

– Effect on production
– Availability of back-up machine
– Cost to repair
– Time to repair
Step 2: Determine Collection Method(s)

 Route-based  Online monitoring

periodic
– general plant equipment
– walk around survey
– manual measurement
– monthly reading typical
– readily accessible
– critical equipment
– installed sensors
– automatic monitoring
– define measurement
interval
– inaccessible or
hazardous area
Single vs. Dual Channel Analysis

Single Channel Dual Channel

Analysis Analysis

Implementation Lower cost, reduced Higher cost,

training Increased training

Focus Detect developing Analyze machine

machine faults structure

Purpose Identify component Indentify wear

wear (fault type) mechanism (root cause)

Application General application Typically only for

across most equipment problem machines
On-line vs. Off-line Monitoring

Periodic measurement Continuous

(route-based survey) (on-line monitoring)
Implementation Lower capital cost, Higher capital cost,
increased labor cost minimal labor cost

Focus Monthly measurement Continuous update

(Detect prior to failure) (Detect at on-set)

Purpose Maximize plant Protect assets, ensure

availability safety & availability

Application General application Most applicable to

across most equipment critical plant equipment
Step 3: Create database

 Enter machines information

• Machine ID (asset code)
• Description
• Operating speed (RPM)

 Define measurement points

• Point ID (identification)
• Description
• Sensor type (accelerometer)
• Analysis Parameters (how to analyze signal)
• Alarm Limits (allowable amount of vibration)
Measurement Point Locations

MOH MIH PIH POH

MOV MIV PIV POV

POA
MOA

2 per bearing + 1 axial measurement per shaft

Automated Database Set-up

Automatically assigns
measurement points,
parameters and alarm limits

Selection of
component types
Step 4: Collect Data

1) Periodic walk-
around survey

2) Smart sensor
with periodic
data transfer

3) Continuous
and on-line
Step 5: Detect Developing Faults
Step 5: Detect Developing Faults
Measurement Point List showing
alarm conditions

****************************

* SUSPECT MACHINE LIST *

****************************

MEASUREMENT ANALYSIS PARAMETER ALARM/FAULT ALARM DAYS TO

POINT PARAMETER VALUE LEVELS CODE ALARM
---------------------- ---------------- --------------- ----------- ----- -------

Alignment Fault ( 11-DEC-96 )

ALIGNMENT - (RPM = 3550.) (LOAD = 100.0)
M1H --- 2xTS .055 In/Sec . 035 .081 C 62
M1H 36-65xTS .0067 In/Sec .0050 .024 Br 78
M1V --- 36-65xTS .012 In/Sec .010 .024 C 26
M1V 1. - 10. kHz .328 G-s .394 .773 A 66
M2H --- 2xTS .041 In/Sec .035 .081 C 121
M2H 36-65xTS .015 In/Sec .010 .024 C 280
M2V --- 36-65xTS .013 In/Sec .010 .024 C 25
M2V 1. - 10. kHz .432 G-s .394 .773 C 64
M2A --- 36-65xTS .012 In/Sec .010 .024 C 68
M2A 1. - 10. kHz .326 G-s .301 .773 Br 234
P2A --- 3-8xTS .083 In/Sec .080 .300 Br 257
P2A 36-65xTS .023 In/Sec .021 .175 Br 198
P2A 1. - 10. kHz 1.289 G- s 1.149 5.414 Br 123
P2H --- 9-35xTS .035 In/Sec .027 .150 Br 310
Step 5: Detect Developing Faults
Visual detection using
color and shape

Vibration
divided
into
frequency
Entire Machine Train bands
on one screen

Motor Gearbox Pump

Step 5: Detect Faults On-line

Point
Color coding statistics
at machine level

Color coding by frequency

band identifies specific
developing fault types

On-line trend indicates

rate of change
Advantages of On-line Approach

 Continuous monitoring of critical equipment

 Automatic scan for developing machine faults

 Immediate notification of alarm conditions

 Extensive data history available for diagnosis

Screening Vibration Data
500 Total
Machines

200 From
Screening
Step 6: Diagnose Nature of Fault
Expert System Program Documentation

Multiple
Multiple Analysis
Plot Options
Options

Report
Link

Fault frequencies
to identify specific
nature of fault
Fast
Indexing
Step 6: Diagnose Nature of Fault

Trend shows
rate of
advancement
for fault
in question
Individual
trend
parameter
covering
suspect
frequency
range
 Step 6: Automated Diagnosis

Automatically Statistical Flag Suspect

Determine RPM Analysis Readings
across machine train of RPM
 Step 6: Automated Diagnosis
Calculates Overall Severity

Diagnosis
Across
Entire
Machine
Train

Calculates Calculates
Problem Certainty
Multiple Severity
Diagnoses
Step 6: Automated Diagnosis

View Logic Tree for Diagnosis in Tutorial Mode

Step 6: Automated Diagnosis

 Purpose of Expert System is:

• NOT to replace analyst, but…

• to screen data to identify developing problems

Step 6: Automated Diagnosis
500 Total
Machines

200 From
Screening

100 From
Expert System
Need more Input?

 Periodic and on-line systems should provide the

ability
to collect additional diagnostic data:

• increased resolution and/or frequency range

• peak/phase measurement

• order based analysis

• time synchronous averaging

Advanced Analysis

 Transient Analysis

 Dual Channel Analysis

 Cross Channel Analysis

 Structural Analysis
Step 6: Getting to the Real Problem
500 Total
Machines

200 From
Screening

100 From
Expert System

50 Real
Problems
7) Document
Business & Maintenance Implications

Document:

•diagnoses
•recommendations
•accuracy
•reoccurring faults
•production gains
•cost savings
•financial impact
Vibration System Checklist
 Periodic  On-line
– Fast data collection – Parameter band alarming

– Analysis on Demand – Analysis on Demand

– Dual channel capability – Dual channel capability

– Advanced gearbox & – Connectivity - across

bearing analysis network & other systems

– Expandability – Expandability

– Expert System Software – Expert System Software

Integration of On-line & off-line system

Continue to: Vibration 2