Vibration Monitoring
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The document discusses vibration analysis techniques used for predictive maintenance. It begins with an introduction to SKF Reliability Systems and their network in Asia Pacific. It then covers maintenance philosophies focused on prevention rather than failure. Key concepts of vibration analysis are explained, including how measurements are performed, common measurement types and units, and analyzing vibration spectra. The document provides examples of vibration data and outlines how spectra are used to identify common machine faults.
Vibration Monitoring
- 1. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 115-07-08 ©SKF
- 2. 15-07-08 ©SKF SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 2 Vibration Analysis Conducted by: Anis Lutfi Condition Monitoring, SKF Reliability Systems PT. Skefindo Primatama - INDONESIA
- 3. 15-07-08 ©SKF Slide 3 SKF Reliability Systems – Asia Pacific Condition Monitoring Products 1SKF PLATFORM BasicVibrationAnalysis– Indonesia
- 4. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 415-07-08 ©SKF SKF GROUP FACTORY UNIT • 80 Factories • 1 in Indonesia • 45,000 employees • ISO 14001 SALES UNIT SKF SALES ASIA PACIFIC SKF VIETNAM SKF THAILAND SKF TAIWAN SKF KOREA SKF PHILIPINA SKF MALAYSIA SKF SINGAPORE SKF INDONESIA (PT.SKEFINDO) etc. • 130 COUNTRY • 7,000 DISTRIBUTOR
- 5. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 515-07-08 ©SKF SKF Network
- 6. 15-07-08 ©SKF Slide 6 SKF Reliability Systems – Indonesia Jaka Rusdianto 2MAINTENANCE PILOSOPHY BasicVibrationAnalysis– Indonesia
- 7. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 715-07-08 ©SKF The evolution continues… Not to fix failed machinery, but to prevent machinery failing. • To maximize productivity. • To ensure machinery operates satisfactorily and continuously for its rated life - or longer. • To provide the highest machine availability, with minimum downtime due to maintenance and service. • To continuously improve the production process. • To optimize machine performance. • Smoother, efficient running machinery costs less to operate, and produces a higher quality product. • To provide a safe environment. Slide 7
- 8. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 815-07-08 ©SKF Cost of Maintenance $17–18 US $11–13 US $7–9 US Type of Maintenance Program Run to Failure Maintenance Predictive Maintenance Preventive Maintenance Cost of Maintenance US $/HP/Year Customer : Cevron Oil USA
- 9. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 915-07-08 ©SKF How Do Predictive Maintenance Programs Work?
- 10. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 1015-07-08 ©SKF The Predictive Maintenance Cycle Measurement exceeds alarm limit Periodic Monitoring Analyze problem Repair Equipment Schedule repair(s) No Yes Increase meas. intervals
- 11. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 1115-07-08 ©SKF WorkFlowWorkFlow PRISM4 MICROLOG ROUTE SCHEDULE (CMMS) WORK REQUEST (CMMS) C.MONITORING PLAN DAILY REPORT MONTHLY REPORT DATA ANALYSIS RELIABILITY (Keandalan) MAINTENANCE (Perawatan) PRODUCTION (Produksi) Management
- 12. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 1215-07-08 ©SKF How are Measurements Performed? Sensors ... Sense and Convert Mechanical Energy Into An Electrical Signal
- 13. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 1315-07-08 ©SKF Buffered Outputs Internet/ Modem SKFLAN Enhanced RS485 Ethernet DCS/PAS/PLCorother RelayOutputs 4-20ma/0-10V RS485 RS232/TCP/IP VM600 MCT CMU Microlog Pens MARLIN RS485/TCP/IP-OPC RS232 RS232 P4Only CMMS Interface /RemoteView/TrendOil /HMI OurIntegrated PlatformforCondition Monitoring
- 14. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 1415-07-08 ©SKF Predictive Maintenance Measurements Vibration Temperature Lube Oil Process –Pressure –Flow –Speed
- 15. 15-07-08 ©SKF Slide 15 SKF Reliability Systems – Asia Pacific Condition Monitoring Products 3Basic Vibration Philosophy BasicVibrationAnalysis– Indonesia
- 16. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 1615-07-08 ©SKF Measuring Vibration Vibration is considered one of the most effective measurements for monitoring the condition of rotating machinery
- 17. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 1715-07-08 ©SKF Measurable Vibration Characteristics Frequency - What is vibrating? Amplitude - How much is it vibrating? Phase Angle - How is it vibrating?
- 18. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 1815-07-08 ©SKF Vibration Frequency Measurements & Units • RPM(Revolutions PerMinute) • CPM(Cycles PerMinute) • CPS/Hz (Cycles PerSecond/Hertz) • Orders of Running Speed (how many times event occurs pershaft revolution)
- 19. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 1915-07-08 ©SKF Vibration Amplitude Measurements & Units Displacement (Distance) Mils orMicrons Velocity (Speed - Rate of change of displcmt) In./Sec. ormm/Sec. Acceleration (Rate of change of velocity) G’s - In./Sec.2 orMeter/Sec.2
- 20. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 2015-07-08 ©SKF Amplitude vs. Frequency When analyzing vibration we lookat two components of the vibration signal, its amplitude and its frequency. Vibration amplitude indicates the severity of the problem. Vibration frequency indicates the source of the problem.
- 21. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 2115-07-08 ©SKF Displacement Probe/Eddy Probe • Measure Relative Distance Between Two (2) Surfaces • Accurate Low Frequency Response • Limited High Frequency Sensitivity • Require External PowerSource
- 22. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 2215-07-08 ©SKF Velocity Sensors • Often Measure Bearing Housings orMachinery Casing Vibration • Effective in Low to Mid Frequency Range (10 Hz to around 1,500 Hz) • Self Generating Devices • Are Electro-Mechanical Devices With Moving Parts That Can StickorFail
- 23. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 2315-07-08 ©SKF Accelerometers • Rugged Devices • Operate in Wide Frequency Range (Near0 to above 400 kHz) • Good High Frequency Response • Some Models Suitable ForHigh Temperature • Require Additional Electronics
- 24. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 2415-07-08 ©SKF SensorRelationships 10 100 1,000 10,000 Frequency (Hz) 10 1.0 0.1 1 0.01 100 Displacement (mils) Acceleration (g's) Velocity (in/sec) Common Machinery Operating Range Amplitude (mils, in/sec, g’s)
- 25. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 2515-07-08 ©SKF Same Data in Velocity and Acceleration Velocity Spectrum Acceleration Spectrum
- 26. 15-07-08 ©SKF Slide 26 SKF Reliability Systems – Asia Pacific Condition Monitoring Products 4Vibration Analysis BasicVibrationAnalysis– Indonesia
- 27. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 2715-07-08 ©SKF Detection vs. Analysis Detection Alarmlimits are established foreach measurement. When the measurement’s value exceeds its programmed alarmlimits, the predictive maintenance software ordata collectornotifies the analyst of a problem. Analysis Once detected, analyzing exceptional measurements provides insight to the problemitself, and to its root cause.
- 28. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 2815-07-08 ©SKF Types of Alarms Overall Vibration Limits Spectral Enveloping Spectral Bands Phase Alarms
- 29. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 2915-07-08 ©SKF ISO Standard Vibration Standard ISO 2372-1974
- 30. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 3015-07-08 ©SKF ISO Vibration Severity Chart
- 31. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 3115-07-08 ©SKF Overall Vib. Alarm Assessing Overall Vibration Severity
- 32. 15-07-08 ©SKF Slide 32 SKF Reliability Systems – Asia Pacific Condition Monitoring Products 5Vibration Spectrum BasicVibrationAnalysis– Indonesia
- 33. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 3315-07-08 ©SKF What is Vibration Analysis ? Vibration Analysis is a measure of the energy being emitted froma surface due to forced and natural oscillatory movement. The energy is captured as vibrations and displayed in two common form: 1. Time vs Magnitude - known as time wafe form 2. Magnitude vs frequency - known as FFT
- 34. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 3415-07-08 ©SKF Typical Vibration Analysis Display Formats Overall Vibration (Trending) FFT Spectrum(Trending/Analysis) Time Waveform(Trending/Analysis) OtherProcessing Methods – Acceleration Enveloping – SEE
- 35. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 3515-07-08 ©SKF FFT SpectrumAnalysis FFT Spectrum shows component vibration signals at theirrespective frequencies low freq. high freq. frequency amplitude frequency
- 36. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 3615-07-08 ©SKF Spectral Pattern Recognition (velocity spectrum) 1X 2X 3X 4X frequency amplitude < 1X low frequency rotational events and harmonics (i.e. imbalance, misalignment, looseness, etc.) high frequency events (i.e. bearing or gear-mesh) 10X
- 37. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 3715-07-08 ©SKF Spectral Example 1 2 3 baseline spectrum (norm) higher than normal 1X vibration signal 1X 2X 3X bearing freq.. gearmesh freq. higher than normal 1X and bearing vibration signals Known good measurement collected when machine was known to be in good running order. 1X running speed peak is significantly higher than normal. Indicates a vibration signal occurring once per shaft revolution. Typically caused by misalignment or imbalance. Higher than normal 1X running speed peak and bearing fault frequency peaks indicate that 1X rotational problem has caused bearing damage.
- 38. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 3815-07-08 ©SKF Sources of Vibration Specific patterns in the spectral signatures are recognized as being related to specific machine problems. • Misalignment 1x or 2x shaft speed • Imbalance 1x • Bent shaft 1x or 2x Axial • Looseness 2x to 10x • Gearmesh # of teeth x RPM • Bearing Defects bearing defect frequencies
- 39. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 3915-07-08 ©SKF Misalignment Angular Misalignment Parallel Misalignment
- 40. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 4015-07-08 ©SKF Velocity Measurement Showing Misalignment
- 41. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 4115-07-08 ©SKF Imbalance - Diagnosis static imbalance - vibration across machine “in phase” couple imbalance - vibration across machine “180 degrees out of phase”
- 42. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 4215-07-08 ©SKF Velocity measurement Showing Imbalance
- 43. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 4315-07-08 ©SKF Bent Shaft
- 44. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 4415-07-08 ©SKF Bent Shaft - Diagnosis 1 - axial measurements across machine typically 180 degrees out of phase, and ... 2 - radial measurements across machine are typically in phase
- 45. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 4515-07-08 ©SKF Velocity measurement Showing Bent Shaft Problem
- 46. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 4615-07-08 ©SKF Mechanical Looseness
- 47. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 4715-07-08 ©SKF Enveloping measurement showing Mechanical Looseness Problem Journal bearing on 600 MWSteamTurbine
- 48. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 4815-07-08 ©SKF Gear-mesh Frequencies GMF = # of teeth x RPM
- 49. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 4915-07-08 ©SKF GearDefects • The gear mesh frequency is equal to the gear shaft rotating speed times the number of teeth on that gear. • The amplitude will vary with the load. • Two equal gearboxes can have very different amplitudes under the same loads. • ALWAYS collect a time domain spectrum on each gear shaft bearing.
- 50. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 5015-07-08 ©SKF Acceleration Measurement Showing Gear-mesh Frequencies
- 51. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 5115-07-08 ©SKF Mining Gearbox Time Domain 208 RPM
- 52. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 5215-07-08 ©SKF Why Do Bearings Fail? inadequate lubrication - too much - too little - contaminated excessive load caused by: - misalignment - imbalance - bent shaft - etc..... improperhandling or installation ageflaw on outer race
- 53. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 5315-07-08 ©SKF Enveloping Band Pass Filter is specified according to defect harmonic frequencies of interest low frequency events filtered out, high frequency defect harmonics emphasized due to low signal to noise ratio, these high frequency harmonics are then summed and folded back to the defect’s fundamental frequency resulting enveloped signal, measured in gE defect fundamental frequency fundamental frequency harmonics
- 54. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 5415-07-08 ©SKF Bearing Defect Frequencies BPFO Ball Pass Frequency Outer Race BPFI Ball Pass Frequency Inner Race BSF Ball Spin Frequency FTF Cage Frequency or Fundamental Train Frequency
- 55. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 5515-07-08 ©SKF Acceleration Enveloping on bearing with Outerrace defect
- 56. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 5615-07-08 ©SKF Acceleration Enveloping on bearing with Innerrace defect
- 57. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 5715-07-08 ©SKF Acceleration Enveloping on bearing with Cage defect
- 58. BasicVibrationAnalysis– Indonesia SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 5815-07-08 ©SKF Enveloping Severity Chart ISO 10816
- 59. 15-07-08 ©SKF SKF Reliability Systems – Indonesia Jaka Rusdianto Slide 59 Pleasewriteyourquestion!
Editor's Notes
- #4: Section divider 3 The section divider slide is a useful way of breaking up a presentation. Five section dividers have been included in this document, each with its own unique SKF Supergraphic. If you require more than five section dividers, then simply copy and paste the five that have been provided and re-number them following the original sequence that is shown in this document. The SKF Supergraphic is placed as a graphic element on this slide in a fixed position. The number of the section always appears on its own line, with the title text appearing beneath. The text is in a fixed position which is aligned with the typographic grid (Ctrl G). Note: This slide does not exist as a ‘slide master’ therefore it is recommended that you copy and paste this slide into your presentation.
- #7: Section divider 5 The section divider slide is a useful way of breaking up a presentation. Five section dividers have been included in this document, each with its own unique SKF Supergraphic. If you require more than five section dividers, then simply copy and paste the five that have been provided and re-number them following the original sequence that is shown in this document. The SKF Supergraphic is placed as a graphic element on this slide in a fixed position. The number of the section always appears on its own line, with the title text appearing beneath. The text is in a fixed position which is aligned with the typographic grid (Ctrl G). Note: This slide does not exist as a ‘slide master’ therefore it is recommended that you copy and paste this slide into your presentation.
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- #16: Section divider 5 The section divider slide is a useful way of breaking up a presentation. Five section dividers have been included in this document, each with its own unique SKF Supergraphic. If you require more than five section dividers, then simply copy and paste the five that have been provided and re-number them following the original sequence that is shown in this document. The SKF Supergraphic is placed as a graphic element on this slide in a fixed position. The number of the section always appears on its own line, with the title text appearing beneath. The text is in a fixed position which is aligned with the typographic grid (Ctrl G). Note: This slide does not exist as a ‘slide master’ therefore it is recommended that you copy and paste this slide into your presentation.
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- #27: Section divider 5 The section divider slide is a useful way of breaking up a presentation. Five section dividers have been included in this document, each with its own unique SKF Supergraphic. If you require more than five section dividers, then simply copy and paste the five that have been provided and re-number them following the original sequence that is shown in this document. The SKF Supergraphic is placed as a graphic element on this slide in a fixed position. The number of the section always appears on its own line, with the title text appearing beneath. The text is in a fixed position which is aligned with the typographic grid (Ctrl G). Note: This slide does not exist as a ‘slide master’ therefore it is recommended that you copy and paste this slide into your presentation.
- #28: Note: Cannot refer to products as Microlog MX & Microlog GX or Microlog MX series & Microlog GX series MX series, part of the Microlog family GX series, part of the Microlog family GX Image to be updated to one with Colour Screen or just use MX & GX
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- #33: Section divider 5 The section divider slide is a useful way of breaking up a presentation. Five section dividers have been included in this document, each with its own unique SKF Supergraphic. If you require more than five section dividers, then simply copy and paste the five that have been provided and re-number them following the original sequence that is shown in this document. The SKF Supergraphic is placed as a graphic element on this slide in a fixed position. The number of the section always appears on its own line, with the title text appearing beneath. The text is in a fixed position which is aligned with the typographic grid (Ctrl G). Note: This slide does not exist as a ‘slide master’ therefore it is recommended that you copy and paste this slide into your presentation.
- #34: Note: Cannot refer to products as Microlog MX & Microlog GX or Microlog MX series & Microlog GX series MX series, part of the Microlog family GX series, part of the Microlog family GX Image to be updated to one with Colour Screen or just use MX & GX
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- #56: Note: Cannot refer to products as Microlog MX & Microlog GX or Microlog MX series & Microlog GX series MX series, part of the Microlog family GX series, part of the Microlog family GX Image to be updated to one with Colour Screen or just use MX & GX
- #57: Note: Cannot refer to products as Microlog MX & Microlog GX or Microlog MX series & Microlog GX series MX series, part of the Microlog family GX series, part of the Microlog family GX Image to be updated to one with Colour Screen or just use MX & GX
- #58: Note: Cannot refer to products as Microlog MX & Microlog GX or Microlog MX series & Microlog GX series MX series, part of the Microlog family GX series, part of the Microlog family GX Image to be updated to one with Colour Screen or just use MX & GX
- #59: Note: Cannot refer to products as Microlog MX & Microlog GX or Microlog MX series & Microlog GX series MX series, part of the Microlog family GX series, part of the Microlog family GX Image to be updated to one with Colour Screen or just use MX & GX