VIBRASI - SE 3 (Level2)

Vibration Analysis Level 2
for assessing machine potential failure modes
Copyright 2005- PT. Putranata Adi Mandiri sole agent Prftechnik AG, Germany
ANALYSIS TECHNIQUES
Broad Band Vibration Analysis

Bearing Condition Analysis
Frequency Analysis (FFT)
Time Synchronous Averaging Analysis
Time Waveform Analysis
Multispectrum
Envelope Analysis
Constant Percentage Bandwidth Analysis
Cepstrum
Shaft Orbit
Tracking Analysis
Vector Analysis (Amp. & Phase)
Startup / Coastdown Analysis
Impact Test
Broad Band Vibration Analysis

Also know as Overall vibration measurement
Typically...
Velocity measurement
mm/s, RMS from 2 Hz to 1000 Hz
ISO 10816-3
Displacement measurement
um, RMS from 2 Hz to 1000 Hz
Can be overall acceleration measurement
eg. Gear box monitoring
Vibration Monitoring
v mm/s
0.45
0.40
Effect of Machine speed variation

on
Vibration measurement
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
0.05
0.10
v m m /s
0.15
4 .0
0.20
3 .8
0.25
3 .6
0.30
3 .4
0.35
3 .2
0.40
3 .0
0.45
2 .8
1500
2000
2500
3000
3500
Time Signal
4000
4500
5000
2 .6
5500
6000
6500
7000
t ms
2 .4
2 .2
2 .0
1 .8
1 .6
1 .4
1 .2
rms
1 .0
0 .8
0 .6
0 .4
0 .2
0 7 /0 2 /2 0 0 1
4 :5 9 :0 0 PM
0 7 /0 2 /2 0 0 1
4 : 5 9 : 1 0 PM
0 7 /0 2 /2 0 0 1
4 : 5 9 :2 0 PM
0 7 /0 2 /2 0 0 1
4 :5 9 :3 0 PM
0 7 / 0 2 /2 0 0 1
4 :5 9 :4 0 PM
d a te
Overall Vibration Level
Bandpass Measurement
Peak
RMS (0.707xPeak)
Avg (0.637xPeak)
Peak
to
Peak
Freq. = 1/Time
Freq. = Hz
= rev. per second
Always ask.... Are you measuring RMS or Peak , etc ??

What is the frequency range ??
How much averaging?
Machine Freq are function of RPM

ie. rev. per minute
Frequency Analysis
Machine Vibrations
Time Signal
Time, s = Frequency, Hz
Time = 1 / Frequency
Frequency Analysis
How to make a frequency analysis?
FFT - Fast Fourier Transform is merely an efficient means of calculating a
DFT (Discrete Fourier Transform). Basically, it transform a time signal into a
frequency spectrum.
Time
F (Hz)
T
Time = 1 / Frequency
Frequency Analysis
How to make a frequency analysis?

Frequency analysis can be made using frequency selective devices called filters
dB
dB
B = Bandwidth
f1
fc
f2
An ideal filter will only signals to pass within its bandwidth
-3
f1
fc
f2
Practical filter have roll-off, express as half-power (-3dB)

For good filters the two will be very similar.
In FFT analysis, the bandwidth = Frequency span / no. lines

Types of Bandwidth
Constant
Percentage
Bandwidth
(CPB)
Vibration
Amplitude
0.1 1
Constant
Bandwidth
(FFT)
frequency
a
x
a=b=c
10 kHz
c
z
x, y, z are constant % of their center frequency
10
Frequency Analysis
Types of filters:
f
High-Pass filters
- As the name imply, a high pass filter allows high

frequencies to pass. (lower frequency limit)
Low-Pass filters
- Allow low frequencies to pass through

(upper limit)
Bandpass filters
- Allows only frequencies within the band

f
Anti-aliasing filters
- Low pass filter at half the sampling frequencies
11
FFT (DFT) - Pitfalls

Discrete Fourier Transform (DFT) - Pitfalls
FFT - Fast Fourier Transform is an efficient means of calculating a DFT
(Discrete Fourier Transform). Basically, it transform a time signal into a
frequency spectrum.
1.
1. Aliasing
Aliasing-- high
highfrequencies
frequenciesappearing
appearingas
aslow
lowfrequencies
frequencies
2.
2. Leakage
Leakage-- Memory
Memorycontents
contentsforced
forcedto
tobe
beperiodic.
periodic.
Can
Cangive
givediscontinuities
discontinuitieswhen
whenends
endsjoined
joined
3.
3. Picket
Picketfence
fenceeffect
effectActual
Actualspectrum
spectrumsampled
sampledat
atdiscrete
discrete
frequencies.
frequencies.Peaks
Peaksmay
maybe
bemissing
missing
12
FFT pitfalls - Aliasing Effect
Sampling rate too slow

High frequency analysis results in false
low frequency signal
Solution: Use Anti-aliasing filter
Typically a 1K (1024 point) transform, 512 frequency components are calculated
and 400 lines displayed. Similarly a 2K transform 800 lines are displayed.
13
FFT pitfalls - Leakage

+ve
1st Sample
-ve
2nd Sample
..give discontinuities
when ends joined
+ve
-ve
14
FFT pitfalls - Picket Fence Effect
Actual
Spectrum
Measured
Spectrum
15
Frequency Analysis
Basic law of frequency analysis
BT > 1
Bandwidth
Analysis Time
T
Time
min. analysis time must allow

the measured freq. to complete
its cycle / period
16
Fungsi window
17
FFT Spectrum
400 lines FFT
1X
2x
3X
1 kHz
IF Freq. Span is 1 KHz then resolution

= 1000 / 400 lines
= 2.5 Hz
2.5 Hz 5 Hz 7.5Hz
(eg. 2 - IF Span is 40Khz then resolution= 100Hz)
18
Measurement time
Harmonic signals
can be measured in
short time
Random and Pulsed
signals
need longer time
For
FFT spectra C
Theoretical
Theoretical
CC==33for
Signals
forHarmonic
Harmonic
Signals
=
1
pr.
average.
C = 30 For Random Signals
C = 30 For Random Signals
B
B ** TT == C
C
BB==Highest
Highestresolution
resolutionofofAnalysis
Analysis
TT==The
Shortest
measurement
The Shortest measurementtime
time
CC==Constant.
Constant.
In
InPractice
Practice
CC==55for
forHarmonic
HarmonicSignals
Signals
CC==100
For
Random
100 For RandomSignals
Signals
19
FFT - Fast Fourier Transformation
Sample 1
Sample 2
Filtering
Filtering
Window Function
Window Function
Detectors
Detectors
FFT
FFT
Raw Machine
Time Signal
/n =
Avg
FFT Spectrum 1
FFT Spectrum
FFT Spectrum 2
20
Time Synchronous Averaging Analysis

Tacho
Sample 1
Sample 2
Raw Machine
Time Signal
Sample triggered by tacho
(measured wrt speed)
Filtering
Filtering
+
Window Function
Detectors
FFT
Averaged Time Signal
Spectrum
Non synchronous signal will be averaged out.

Reduced
vibration
effect sole
from
nearby
machine
Copyright 2005PT. Putranata
Adi Mandiri
agent
Prftechnik
AG, Germany
21
FFT - How to select Freq. Ranges, lines, Averages
Shaft
Rotating
Speed
Journal
Bearings
instability
Blades
2x
Rolling Element
Bearings
Gear
3x
1 KHz
3KHz
40KHz
22
Monitoring Techniques
Types of Bearings
Journal
JournalBearings
Bearings
Stationary
StationarySignals
Signals
Relative
RelativeLow
LowFrequency
Frequency
Displacement
Displacementtransducer
transducer
Use Proximity probes

Rolling
RollingElement
ElementBearings
Bearings
Modulated
ModulatedRandom
RandomNoise
Noise
Pulsating
Pulsatingsignals
signals
High
HighFrequency
Frequency
Accelerometers
Accelerometers
Use Accelerometers
23
Informasi penting
tentang mesin
Amplitudo
vibrasi
frekuensi
Apa saja yang mungkin menyebabkan vibrasi ?

24
Analisa Amplitudo, Frekuensi dan Fase - 1

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
GAMBAR SPECTRUM
1. Unbalance
Sebanding dgn
ketidak balance,
dominan pd
radial (2x aksial)
1 x rpm
Single
reference
mark
Kondisi sering
ditemui
f
1x
Ve = 15
Vf = 15
Pengukuran getaran :
Ae = 8
Af = 8
Va = 4
Vb = 3
Vc = 4
He = 15
Aa = 3
Ab = 4
Hf = 15
Ac = 5
Ad = 5
Ha = 4
Hb = 5
Hc = 3
Hd = 2
Vd = 4
25

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
2. Misalignment
kopling atau
poros bengkok
Dominan pd
aksial, 50%
atau lebih dari
arah radial
Sering 1 x & 2 x Single

rpm. Kadang 3 x double
rpm
triple
KETERANGAN
GAMBAR SPECTRUM
Ditandai timbulnya vibrasi A

aksial. Gunakan alat laseralignment. Apabila mesin
baru dipasang terjadi
vibrasi, maka kemungkinan
besar karena misalignment.
Ve = 3
f
1x
2x
Vf = 4
Ae = 4
Af = 5
Va = 4
Vb = 10
Vc = 10
He = 4
Aa = 7
Ab = 15
Hf = 3
Ac = 15
Ad = 7
Ha = 5
Hb = 10
Hc = 10
Hd = 5
Vd = 4
26

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
3. Anti friction
bearing buruk
Tidak stabil,
ukur percepatan,
gunakan
acceleration
probe
Sangat tinggi,
beberapa kali
Rpm, 1x, 2x, 3x,
4x 10x
Tdk tentu,
Berubahrubah
A
Vibrasi akan timbul
apabila bearing sdh
parah. Gunakan
vibrotip / shockpulse u
deteksi awal
Ve = 5
GAMBAR SPECTRUM
f
1x
2x
3x
Vf = 3
Ae = 4
Af = 2
Va = 2
Vb = 4
Vc = 5-10
He = 4
Aa = 4
Ab = 3
Hf = 4
Ac = 10-15
Ad = 5
Ha = 3
Hb = 3
Hc = 5-10
Hd = 4
Vd = 3
27
4x
Frekuensi bearing karakteristik
28
Dimensi bearing
29
Kalkulasi frekuensi dari elemen bearing
Kerusakan di outer race = fr 1

2
Kerusakan di inner race = fr 1 +

2
BD
cos ( Hz )
PD
BD
cos ( Hz )
PD
2
BD
PD
Kerusakan pada elemen berputar =

fr 1
cos ( Hz )
BD
PD
fr BD
Kerusakan pada cage = 1

cos ( Hz )
2 PD
dimana:
BD &PD : lihat gambar
fr : Frekuensi rotasi dari inner race

n : jumlah elemen berputar
: sudut kontak
30
Why shock pulses for rolling bearing noise ?

c
m
fnat =
x
Machine vibration
1
m
1
l
1
d
1
a
c = stiffness
)
m = Mass
Material crack
plastical / elastical
deformation
Shock pulse range rolling bearing
Natural frequencies rolling bearing pieces

fnat,O
fnat,B
fnat,
2
1
Example
l
1
l = n m
f x 1/1m
fnat x 30 Hz
d = n 1 mm
f x 1/1 000 m
fnat x 30 000 Hz
a
f
fnat
1 000
10 000
36 000
100 000
= n m
x 1 / 1 00 000 m
x 3 00 000 Hz
flog / Hz
ultra sound emission

Copyright 2005- PT. Putranata
Adi Mandiri sole agent
Prftechnik
AG, Germany
31
velocity
acceleration
shock
pulses
Overall values for Bearing condition

Acceleration - Crest Factor
Spike Energy Value
BCU - Value
Kurtosis Factor
gSE - Value
SEE - Value
Shock Pulse
Measurement
Normalising with
Shaft speed (rpm)
Shaft Diameter (Bearing Size)
?
?
?
Time
Time
32
Normalising of shock pulse signals

dBsv
dBsv
90
35
90
ideal
measurement
dBn
measurement location
with signal damping
P
dBn
25
15
dBm
dBm
10
dBc
dBc
dBi
dBia
0
-9
-9
dB sv = absolute shock pulse value
dBn = normalised shock pulse value
dBi = initial value
dBia = adjusted inital value
signal damping of real measurement location
influencing factors like load condition

Copyright 2005PT.
Putranata
Adi
Mandiri
sole
agent
Prftechnik
AG,
Germany
33
determined through RPM and
lubrication and
bearing
type
Basic value of the normalised
shock pulse values
diameter of the bearing
34
Fungsi envelope
35
Signature Rolling Bearing Defects

No rolling track defect:
Rolling track defect:
Time signal:
Time signal:
a in
m/s2
a in
m/s2
Envelope
Enveiope
t in s
t in s
Ta
Envelope spectrum:
Envelope spectrum:
a in
m/s2
a in
m/s2
f in Hz
fRPOF
2fRPOF 3 fRPO F 4 fRPOF
f in
Hz
fRPOF=
1
TRPOF
Defect frequency
36
Envelope Spectrum bearing

Location :PT. Caltex\Water Plant\Fresh Water
Pump\Centrifugal Pump\Coupling Side\rolling
bearing >120
am
/s
2.0
1.8
0.63
0.96
1.6
25.00
0.21
50.00
0.14
Alarm
176.88
0.10
W
arn
151.88
0.10
0.6
126.88
0.08
0.4
4.38
0.08
20.63
0.07
29.38
0.07
1000
fHz
9
15.00
0.06
1.4
1.2
1.0
0.8
0.2
0.0
0
100
200
300
400
500
600
700
800
900
37

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
GAMBAR SPECTRUM
4. Sleeve, metal,
Jurnal bearing
(friction
bearing) /
eksentrik
Tidak besar,
aksial
lebih tinggi
1 x rpm, seolaholah seperti

unbalance
Single
pd rodagigi vibrasi segaris

dengan pusat kontak. pd
motor/gen vibrasi hilang
bila mesin dimatikan. pd
pompa/blower
kemungkinan unbalance
Ve = 4
f
1x
Vf = 4
Ae = 4
Af = 5
Va = 4
Vb = 7
Vc = 3
He = 4
Aa = 7
Ab = 15
Hf = 3
Ac = 4
Ad = 4
Ha = 3
Hb = 8
Hc = 5
Hd = 3
Vd = 5
38

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
GAMBAR SPECTRUM
5. Rodagigi
buruk atau
bersuara
Rendah, ukur
kecepatan &
percepatan,
gunakan
acceleration
Sangat tinggi
Jumlah gigi x
rpm
Tdk tentu
Awal rusak
bersuara, semakin
lama keras.
Vibrasi biasanya
dalam toleransi.
Ve = 7
f
2x
1x
3x
tooth
Vf = 3
Ae = 8
Af = 5
Va = 4
Vb = 3
Vc = 7
He = 6
Aa = 3
Ab = 4
Hf = 4
Ac = 8
Ad = 9
Ha = 3
Hb = 2
Hc = 7
Hd = 7
Vd = 7
39
4x

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
GAMBAR SPECTRUM
6. Gear mesh
buruk atau
bersuara
(pada saat
start / stop)
Rendah, ukur
kecepatan &
percepatan,
gunakan accel.
Sangat tinggi
Jumlah gigi x
rpm
Tdk tentu
Sering terjadi
pada saat
pemasangan
f
2x
1x
3x
tooth
Ve = 7
Vf = 3
Ae = 8
Af = 5
Va = 4
Vb = 3
Vc = 7
He = 6
Aa = 3
Ab = 4
Hf = 4
Ac = 8
Ad = 9
Ha = 3
Hb = 2
Hc = 7
Hd = 7
Vd = 7
40
4x
Gear frequencies for Parallel Offset Gear
Pinion speed, rpm.......................................(Rp)

Number of teeth on gear.............................(Ng)
Data needed
from the gear
Number of teeth on the pinion...................(Np)
Gear speed, rpm.........................................(Rg)

Gear rotational frequency, Hz...................(frg)
Mesh frequency, H................................(fm)

Tooth repeat frequency, Hz......................(ftr)
Info calculated
from the data
Pinion rotational frequency, Hz.................(frp)
Assembly phase passage frequency, Hz.....(fa)

41
42
43
44
45
46
47
48
49
50
51
52
53
Pumps are found in nearly every industry in a wide array of

sizes and capacities. Larger pumps, such as boiler feed pumps
and reactor recirculation/coolant pumps, are often permanently
monitored, though many smaller units are not. Regardless, the
following parameters are necessary to effectively evaluate
process-related phenomena:
Speed
Suction pressure and temperature
Discharge pressure and temperature
Flow
Bearing metal and oil drain temperatures
Driver power
54
Air Compressor
55
Air Compressor
56
57
Centrifugal Compressor
58
Centrifugal Compressor
The compressor is one of the petrochemical industry's most durable and

dependable machines. In general, there is a more limited set of variables to
be monitored in compressors than in gas and steam turbines, which helps
when you are analyzing and troubleshooting. However, rotational speeds
tend to be much higher. The following process parameters are considered
key items:
Suction pressure and temperature
Discharge pressure and temperature
Product (gas) flow rate
Gas analysis (mole weight)
Compressor speed
Driver power
59
Generator
60
Generators
Generators are generally well-behaved dynamically, due to

their less complicated construction, compared to gas and steam
turbines. Unbalance, thermal bows, and seal rubs comprise the
majority of problems seen. The process variable list reflects
this:
Output (kW or MW)
Reactive loading (vars)
Power factor
Coolant gas temperature and pressure
Winding temperatures
Field current
61
62
Gas Turbine
63
gas turbines
It is easy to see the interaction of process and vibration characteristics by

studying industrial and aeroderivative gas turbines, because they are really
three machines in one. They are a compressor that pressurizes ambient air,
a combustor that introduces fuel and burns the air/fuel mixture, and an
expansion (or power) turbine through which the hot, high pressure
combustion gases expand, driving the compressor and any other connected
machinery.
Gas turbines are subject to wide performance and vibration variations when
ambient air, fuel, or load values change. For example, high inlet air
temperature reduces gas turbine performance, requiring higher fuel
consumption for a specific power level. Conversely, low air temperature
causes the power to increase. If humidity is high, ice can form on the inlet
filters, inlet ducting, and inlet casing of the compressor. Large
accumulations of ice reduce and distort the airflow, which may cause
compressor stall and surge.
64
Steam turbines
Steam turbines are used in almost every industry for driving compressors,
generators, pumps, and other equipment. Sizes vary from small, single
stage units of less than 100 hp to large power generation units capable of
over 1,000 MW in a single machine train. However, despite these size
variations, steam conditions generally provide significant insight into any
rotor response changes, such as rubs and shaft bow. Process variables that
should be monitored on each driver include:
Steam supply and exhaust conditions - temperature, pressure, flow, quality
Extraction conditions (if applicable)
Condenser vacuum
Gross generation (kW) or shaft speed and torque
Reheat steam conditions (if applicable)
Kvars (generator drive applications)
65
66
67
68
69
70
71
72
Phase Analysis
Trending for Acceptance Regions

Shaft crack detection
Rub detection
Shaft balancing
Shaft/structural resonance detection
Shaft mode shape
Location of a fluid-induced instability
73
Trending
74
Shaft Crack
75
Rubs
76
Shaft Structure
77
Shaft balancingShaft mode

shape
78
79
80
81
82
Location of fluid-induced
instability
83
Rotational & Mesh Gear Frequencies
Gear & Pinion rotational frequencies :

f rg =
Rg
60
( Hz ),
f rp =
Rp
60
( Hz )
Mesh frequency :
f m = f rp N p = f rg N g ( Hz )
84
Assembly phase passage gear frequency (1)
Ng = 15
Gear tooth
1-10-4-13-7
2-11-5-14-8
3-12-6-15-9
Np = 9
Pinion Tooth
1-7-4
2-8-5
3-9-6
85
Ng = 15
Gear tooth
1-10-4-13-7
2-11-5-14-8
3-12-6-15-9
Np = 9
Pinion Tooth
1-7-4
2-8-5
3-9-6
86
Assembly phase passage frequency :

fm
( Hz )
fa =
Na
N a = Product of common prime factors
example :
Fg = 1,3,5,15
Fp = 1,3,3,9
N a = 1 3 = 3
Ng = 15
Gear tooth
1-10-4-13-7
2-11-5-14-8
3-12-6-15-9
Np = 9
Pinion Tooth
1-7-4
2-8-5
3-9-6
87
Tooth repeat gear frequencies
Tooth repeat frequency :

fm Na
( Hz )
f tr =
Ng N p
or for a true hunting tooth combination
( when N a = 1) :
f tr =
f rg
Np
( Hz )
88
Summary gear frequencies for parallel offset gear

To
obtain
f tr
f rg
f rp
N a /N g
1/M g
N p /N a N p
N a /N p
Mg
N g /N a N g
fa
fm
multiply
f rp
f rg
fm
by
N a /(N g
1/N g 1/N p
Np )
1/N a
N a = Number of assembly phases, N p = Number of teeth on pinion

N g = Number of teeth on gear, M g = Ratio gear, f tr = Tooth repeat freq (Hz)
f rg = Gear rotational freq (Hz), f rp = Pinion rotational freq (Hz)
f a = Assembly phase passage freq (Hz), f m = Mesh frequency (Hz)
89
Gear frequencies for Planetary Gear
90
91
Application mill drive - cement industry
[bar]
[m/s]
[bar]
4x [C]
Machine speed
Alarm status
[m/s]
[m/s]
[m/s]
[m/s]
PCS
External
expert
Data backup
LAN / WAN
Internal
expert
Interne
t
92
Gear frequencies for

Planetary Gear
Planetary Gear :
Ts x Tr
Tooth Mesh Freq =
x Ns = Tr x Nc (Hz)
Ts + Tr
Tr
np x Tr
x Nc (Hz)
x
Ns
np
x
Defect on Sun =
=
Ts
Ts + Tr
Tr
Defect on Planet = 2 x Nc x
(Hz)
Tp
Defect on Ring = np x Nc (Hz)
where :
Ns = speed of sun gear (output), Nc = speed of carrier (input)
Ts = number of teeth on sun, Tr = number of teeth on ring
np = number of planets
93
Comparison of Sinusoidal and

Impact Gear Tooth Contact
94

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
7. Mechanical
looseness
(Housing
bearing aus)
Tinggi pada
aksial
2 x rpm
2 referensi Sering
agak kacau bersamaan dgn
unbalance /
misalignment
Ve = 3
GAMBAR SPECTRUM
A
f
2x
Vf = 3
Ae = 4
Af = 4
Va = 4
Vb = 12
Vc = 5
He = 4
Aa = 3
Ab = 15
Hf = 2
Ac = 5
Ad = 3
Ha = 3
Hb = 12
Hc = 5
Hd = 4
Vd = 5
95

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
GAMBAR SPECTRUM
8. Mechanical
Looseness (Pondasi
kendor dudukan
lemah/karatan
baut kendor)
Tinggi pada
vertikal
Kurang dari
1 x rpm
Tdk tentu
Kencangkan baut
Untuk memastikan
f
<1x
Ve = 3
Vf = 2
Ae = 4
Af = 3
Va = 9
Vb = 10
Vc = 5
He = 3
Aa = 3
Ab = 4
Hf = 4
Ac = 2
Ad = 2
Ha = 2
Hb = 4
Hc = 2
Hd = 4
Vd = 3
96

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
9. Mechanical
looseness
(Pondasi
melengkung)
Tinggi pada
vertikal,
horizontal &
aksial
2 x rpm
2 referensi Sering
unbalance /
misalignment
Ve = 3
GAMBAR SPECTRUM
A
f
2x
Vf = 3
Ae = 4
Af = 4
Va = 9
Vb = 12
Vc = 5
He = 4
Aa = 7
Ab = 6
Hf = 2
Ac = 5
Ad = 3
Ha = 13
Hb = 14
Hc = 5
Hd = 4
Vd = 5
97

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
GAMBAR SPECTRUM
10. Drive belt

buruk
Tdk
tentu/berpulsa
1,2,3
atau 4 x
rpm belt
1 atau 2
tergantung
frekuensi,
tdk tetap
Biasanya terjadi
karena belt tdk berada
pada tempatnya secara
sempurna.
Belt
Ve = 8
f
1x
2x
3x
Vf = 4
Ae = 8
Af = 3
Va = 3
Vb = 2
Vc = 10
He = 7
Aa = 2
Ab = 3
Hf = 2
Ac = 10
Ad = 10
Ha = 2
Hb = 4
Hc = 10
Hd = 8
Vd = 10
98
4x

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
GAMBAR SPECTRUM
11. Elektrikal
Tidak tinggi, ada

suara
berdengung,
lebih terasa bila
dimatikan
2 x rpm lebih
tinggi daripd
1 x rpm.
Single/
rotate
double
mark
Vibrasi & suara

hilang bila
mesin dimatikan
f
1x
Ve = 3
2x
Vf = 2
Ae = 3
Af = 3
Va = 7
Vb = 6
Vc = 4
He = 3
Aa = 6
Ab = 7
Hf = 1
Ac = 5
Ad = 5
Ha = 8
Hb = 8
Hc = 5
Hd = 3
Vd = 3
99
Jenis-jenis motor listrik
- Motor induksi (induction / asynchronous motor)

- Synchronous motor
- DC motor
100
Permasalahan pada motor listrik - Electrical
- Eccentric rotor
- Uneven airgap
(penyebab : softfoot / frame distortion)
- Broken rotor bars
- Shorted rotor lamination
- Phasing problem
101
Istilah-istilah motor listrik
- Line frequency (frekuensi jala-jala) = FL

(di Indonesia : 50 Hz, USA : 60 Hz)
- Poles (P) = stator conductors = 2FL / RPM (FL dlm CPM)
- Slots (S) = stator winding containers
- Bars (B) = rotor field conductors
102
Frequencies of electric motors
Magnetic field speed, RPM (Ns) = 120 x FL / (# poles)

Slip frequency (SF) = Ns actual speed
Pole pass frequency (Fp) = SF x (# poles)
Rotor bar pass freq. (RBPF) = (# bars) x RPM
Stator slot pass freq. (SSPF) = (# stator slot) x RPM
Example :
Info on Name plate of electric motor :
Speed = 1480 RPM, # rotor bars = 40
-> # poles = (2 x 3000) / 1480 = 4
-> Ns = 120 x 50 / 4 = 1500 RPM
-> SF = 1500 1480 = 20 RPM = 0.33 Hz
-> Fp = 4 x 20 RPM = 80 RPM = 1.33 Hz
-> RBPF = 40 x 1480 RPM = 59200 RPM = 986.67 Hz
103
Analisa vibrasi pada motor listrik 1 / 4
- Stator eccentricity, loose iron, shorted laminations :

Amplitude
1x
2FL
FL = Line Frequency (3000 CPM, for 50 Hz Line Freq.)
2x
Frequency
Amplitude
- Uneven air gap (variable air gap) / Eccentric rotor :

1x
2FL
FL = Line Frequency (3000 CPM, for 50 Hz Line Freq.)

Fp Sidebands around FL
Fp
Frequency
Pole pass frequency (Fp) = SF x (# poles)
Slip frequency (SF) = Ns actual speed
Magnetic field speed, RPM (Ns) = 120 x FL / (# poles)
104
- Rotor problems 1 (broken/cracked rotor bars /

shorting rings, shorted rotor laminations) :
Amplitude
1x
3x
2x
* Fp Sidebands around 1x for broken rotor bars

* Fp Sidebands around 1x, 2x, 3x, . for cracked
rotor bars
Frequency
- Rotor problems 2 (loose/broken rotor bars) :

Amplitude
RBPF
1x
2FL Sidebands around RBPF or its harmonic freq.

2x
RBPF = Rotor Bar Pass Frequency = # Bars x RPM
Frequency
105
- Phasing problems (motor beroperasi hanya 2 dari 3

phasa, disebabkan oleh loose / broken connectors) :
2FL
Amplitude
1/3 FL Sidebands around 2FL
Frequency
Loose stator coils pada synchronous motors :

Amplitude
CPF
1x RPM Sidebands around CPF = Coil Pass Freq.
1x 2x
CPF = # stator coils x RPM
Frequency
106
- DC motor problems 1 (broken field winding, bad

SCR and loose connection) :
Amplitude
6FL = SCR Firing Freq. or its harmonic freq.
1x
2x
Frequency
- DC motor problems 2 (loose/blown fuses, shorted

control card) :
Amplitude
FL
Amplitude tinggi pada 1x hingga 5x Line Freq.

2FL
3FL
4FL
5FL
Frequency
107
Rekommendasi untuk analisa vibrasi motor listrik
Untuk mendeteksi uneven airgap, eccentric rotor :

-> 3 titik resolusi tinggi (diambil 1x setahun)
* HOH : high resolution, motor outboard horizontal
* HIH : high resolution, motor inboard horizontal
* HOA (or HIA) : high resolution, motor outboard (or
inboard) axial
-> Fmax = 200 Hz, 1600 lines
-> Resolusi = 0.125 Hz
108
Rekommendasi untuk analisa vibrasi motor listrik
Untuk mendeteksi munculnya rotor bar pass frequency

atau stator slot pass frequency :
-> 2 titik extended range (diambil 1x setahun)
* EOH : extended range, motor outboard horizontal
* EIH : extended range, motor inboard horizontal
-> Fmax = 5000 Hz, 3200 lines, jika tidak diketahui
jumlah rotor atau stator slot, sebenarnya cukup s/d
frekuensi : (2x rotor / stator slot pass freq. + 400 Hz)
-> Jika ingin mengambil data ini 1x sebulan, cukup
dengan 400 800 lines untuk menghemat memori
109

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
GAMBAR SPECTRUM
12. Gaya
aerodinamik /
hidrolik
Tinggi pada
vertikal atau
horizontal
1 x rpm atau
jumlah sudu
atau fan atau
impeler x
rpm
Tdk tentu
Lebih terasa bila

beban tidak
stabil.
f
1x
Ve = 14
Jml x
Vf = 13
Ae = 7
Af = 7
Va = 1
Vb = 2
Vc = 4
He = 13
Aa = 1
Ab = 3
Hf = 14
Ac = 5
Ad = 3
Ha = 2
Hb = 2
Hc = 3
Hd = 4
Vd = 4
110

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
GAMBAR SPECTRUM
13. Gaya
reciprocating
Dominan aksial
1 x,2 x rpm
atau lebih
Single,
double,
triple
Pada mesin
reciprocating
bisa ganti
desain/isolasi
Ve = 2
f
1x
2x
Vf = 2
Ae = 3
Af = 3
Va = 7
Vb = 8
Vc = 3
He = 4
Aa = 6
Ab = 7
Hf = 2
Ac = 4
Ad = 4
Ha = 8
Hb = 7
Hc = 2
Hd = 4
Vd = 3
111
Ringkasan Analisa Amplitudo, Frekuensi dan Fase

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
GAMBAR SPECTRUM
1. Unbalance
Sebanding dgn
ketidak balance,
dominan pd
radial (2x aksial)
1 x rpm
Single
reference
mark
Kondisi sering
ditemui
Dominan pd
aksial, 50%
atau lebih dari
arah radial
Sering 1 x & 2 x Single

rpm. Kadang 3 x double
rpm
triple
Ditandai timbulnya vibrasi A

aksial. Gunakan alat laseralignment. Apabila mesin
baru dipasang terjadi
vibrasi, maka kemungkinan
besar karena misalignment.
Tidak stabil,
ukur acceleration
untuk freq.
tinggi
Sangat tinggi,
beberapa kali
Rpm, 1x, 2x, 3x,
4x 10x
Tdk tentu,
Berubahrubah
Vibrasi akan timbul

apabila bearing sdh
parah. Gunakan
enveloping &
shockpulse
4. Sleeve, metal,
Jurnal bearing
(friction
bearing)
Tidak besar,
aksial
lebih tinggi
1 x rpm, seolaholah seperti

unbalance
Single
pd rodagigi vibrasi segaris

dengan pusat kontak. pd
motor/gen vibrasi hilang
bila mesin dimatikan. pd
pompa/blower
kemungkinan unbalance
5. Rodagigi
buruk atau
bersuara
Rendah, ukur
kecepatan &
percepatan,
gunakan accel.
Awal rusak bersuara,

semakin lama keras.
Vibrasi biasanya
dalam toleransi.
2. Misalignment
kopling atau
poros bengkok
3. Anti friction
bearing buruk
f
1x
Sangat tinggi
Jumlah gigi x
rpm
Tdk tentu
f
1x
2x
1x
2x
f
3x
4x
f
1x
f
1x
2x
3x
tooth
112
4x

PENYEBAB
AMPLITUDO
FREKUENSI
6. Gear mesh
buruk atau
bersuara pada
saat start/stop
Rendah, ukur
kecepatan &
percepatan,
gunakan accel.
Sangat tinggi
Jumlah gigi x
rpm
7. Mechanical
looseness
(Housing
bearing aus)
Tinggi pada
aksial
2 x rpm
8. Mechanical
Looseness (Pondasi
kendor dudukan
lemah/karatan
baut kendor)
Tinggi pada
vertikal
9. Mechanical
looseness
(Pondasi
melengkung)
Tinggi pada
vertikal,
horizontal &
aksial
2 x rpm
10. Drive belt

buruk
Tdk
tentu/berpulsa
1,2,3
atau 4 x
rpm belt
Kurang dari
1 x rpm
FASE
Tdk
tentu
KETERANGAN
Sering terjadi
pada saat
pemasangan
GAMBAR SPECTRUM
A
f
1x
2 referensi Sering
unbalance /
misalignment
Tdk tentu
Kencangkan baut
Untuk memastikan
2x
3x
4x
f
2x
f
<1x
2 referensi Sering
unbalance /
misalignment
1 atau 2
tergantung
frekuensi,
tdk tetap
Biasanya terjadi
karena belt tdk berada
pada tempatnya secara
sempurna.
f
2x
f
1x
2x
3x
113
4x

PENYEBAB
AMPLITUDO
FREKUENSI
FASE
KETERANGAN
GAMBAR SPECTRUM
11. Elektrikal
Tidak tinggi, ada

suara dengung,
lbh terasa bila
dimatikan
2 x rpm lebih
tinggi daripd
1 x rpm.
Single/
rotate
double
mark
Vibrasi & suara

hilang bila
mesin dimatikan
Tinggi pada
vertikal atau
horizontal
1 x rpm / jml
sudu / fan
atau impeler
x rpm
Tdk tentu
Lebih terasa bila

beban tidak
stabil.
12. Gaya
aerodinamik /
hidrolik
13. Gaya
reciprocating
Dominan aksial 1 x,2 x rpm

atau lebih
f
1x
2x
f
1x
Single,
double,
triple
Pada mesin
reciprocating
bisa ganti
desain/isolasi
Jml x
f
1x
2x
114
Phase Analysis
Kegunaan informasi fase untuk analisa masalah mesin :

- Mendeteksi shaft crack
- Mendeteksi rubbing
- Diperlukan sewaktu Balancing
- Mendeteksi resonansi dari shaft atau casing
- Mengetahui bentuk gerakan shaft (shaft bending)
115
Phase Analysis
Tanda-tanda shaft crack :

- Nilai tinggi pada frekuensi 1x RPM di gambar spectrum
- Perubahan dalam nilai fase yang cukup signifikan
A m plitudo
6
5
4
3
2
1
0
0
20
40
60
80
100
120
140
160
180
200
220
240
180
200
220
240
Time (interval 20 minutes)
Time (interval 20 minutes)

0
20
40
60
80
100
120
140
160
P ha s e la g
0
20
40
60
80
100
120
116
Phase Analysis
Tanda-tanda masalah rubbing :

- Nilai amplitudo yang berfluktuasi di frekuensi 1x RPM
- Nilai fase yang secara kontinu berubah
Polar Vibration Trend Plot of
steady state vibration due to a seal rub
0
340
320
20
40
300
60
4
2
280
80
0
260
100
240
120
220
140
200
160
180
117
Phase Analysis
Mengetahui bentuk gerakan shaft :

- Untuk menentukan balancing 1 atau 2 plane
- Untuk mendeteksi resonansi dari shaft atau struktur
1
118
Cepstrum Analysis
Cepstrum
Cepstrumis
isaaspectrum
spectrumof
ofaalogarithmic
logarithmicspectrum
spectrum
FFT Spectrum
Time Signal
F
raw
V (dB)
Cepstrum
-1
V
28,1 ms (35 Hz)
100
FFT
95,9 ms (10 Hz)
90
FFT
80
70
100 200
Spectrum
Frequency (Hz)
Harmonics
Filter
Magnitude
300 400
500
Hz
0,1
0,2
0,3
Cepstrum
Qerfuency (ms)
Rahmonics
Lifter
Gamnitude
Sideband patterns easily diagnosed and trended with Cepstrum analysis

119
Bode Plot
Bode
Bodeplot
plotinvolves
involvesplotting
plottingthe
thevibration
vibrationamplitude
amplitude
and
andphase
phaseagainst
againstrotational
rotationalspeed
speed
0o
Phase
90o
180o
Critical
Speed
Amplitude
Slow roll
Use for identifying resonance or critical speed. Very sensitive to run-out
Rotational Speed
120
Polar Plots (Nyquist plots)

Polar
Polarplot
plot--the
thevibration
vibrationamplitude
amplitudeis
isplotted
plottedagainst
against
Phase
Phaseon
onaapolar
polargraph
graphpaper
paper
90o
Critical Speed
90o Phase shift
Amplitude
at critical
speed
Increasing
Shaft speed
180o
0o
Origin
Residual
unbalance
Same information as Bode plot different presentation.

Advantage: Easy to correct for run out by shifting orgin for all vectors.
121
122
Proximity probes signal

AAproximity
proximityprobe
probeprovides
providestwo
twosignal
signaloutput:
output:
1.
1. Shaft
Shaftdynamic
dynamicmotion
motionrelative
relativeto
tothe
theprobe
probemounting
mounting(AC
(ACsignal)
signal)
2.
2. Shaft
Shaftaverage
averageposition
positionrelative
relativeto
tothe
theprobe
probemounting
mounting(DC
(DCsignal)
signal)
AC Signal
Gap
DC
Signal
123
Shaft centerline plot

Plotting
PlottingX-Y
X-Ycoordinates
coordinatesof
ofGap
Gap(DC
(DCsignal)
signal)
o
from
from22prox.
prox.probe
probespace
space90
90oapart
apartat
ateach
eachbearing
bearing
um
+
++ ++
+
b
+ +
++
a
um
Provides exact determination of the average shaft

Centerline position relative to the bearing clearance
Compared with bearing centerline for measurement
of shaft attitude angle = exceeds 90o ~ instability
a
124
Orbits (lissajou)
Orbits
OrbitsPlotting
PlottingX-Y
X-Ycoordinates
coordinatesof
oftwo
twosignals
signals
o
(shaft
(shaftdisplacement)
displacement)space
space90
90oapart
apartat
ateach
eachbearing
bearing
Y, vertical
X, horizontal
Two pure sine waves of equal amplitude with 90o phase difference = circular orbit
If they have different amplitudes but retain 90o phase = elliptical with the major axis
In the direction of the largest amplitude
125
Orbits (lissajou)
Orbits
Orbitsuse
useto
todisplay
displayaaaccurate
accuratepicture
pictureof
ofshaft
shaftmotion
motion
greatly
greatlymagnified,
magnified,and
andeasily
easilyunderstood
understood
Line of action
Y, vertical
X, horizontal
External forces reduces amplitude:

Gravity, Preload by pressure dam
bearings, Misalignment of shafts restrain
126
Typical misalignment
Produce a 180o phase shift across coupling
This phase shift can be observed in radial vibration and/or
shaft centerline (connecting the trigger points)
127
128
129
Order
Amplitude
Phase
Run-up/
Coastdown
Speed
130
131
Time vs FFT
Time Signal:
FFT
Fast Fourier
Transformation
transient signals, repeat

frequencies, beats and sine
waveform good visible
but:
Individual Frequencies of the
Vibration Spectrum
almost not visible
Amplitude Spectrum:
good visibility of the dominant
frequencies of the vibration signal
but:
transient Signals, shocks with
repeat frequency and beat signals
almost not visible
132
Predictive Maintenance
Start
Rules
+
Experi
NO
YES
Create
Ref.
Regular
Meas.
Compare
limits
Fault
Diagnostics
Fault
correction
Input
m/c
specs
Create
New Ref. & Limits
133

VIBRASI - SE 3 (Level2)

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Vibration Analysis Level 2

for assessing machine potential failure modes

Broad Band Vibration Analysis

Broad Band Vibration Analysis

Effect of Machine speed variation

Overall Vibration Level

Always ask.... Are you measuring RMS or Peak , etc ??

Machine Freq are function of RPM

How to make a frequency analysis?

An ideal filter will only signals to pass within its bandwidth

Practical filter have roll-off, express as half-power (-3dB)

In FFT analysis, the bandwidth = Frequency span / no. lines

x, y, z are constant % of their center frequency

- As the name imply, a high pass filter allows high

- Allow low frequencies to pass through

- Allows only frequencies within the band

- Low pass filter at half the sampling frequencies

FFT (DFT) - Pitfalls

FFT pitfalls - Aliasing Effect

Sampling rate too slow

FFT pitfalls - Leakage

FFT pitfalls - Picket Fence Effect

Basic law of frequency analysis

min. analysis time must allow

IF Freq. Span is 1 KHz then resolution

(eg. 2 - IF Span is 40Khz then resolution= 100Hz)

FFT - Fast Fourier Transformation

Time Synchronous Averaging Analysis

Non synchronous signal will be averaged out.

FFT - How to select Freq. Ranges, lines, Averages

Use Proximity probes

Apa saja yang mungkin menyebabkan vibrasi ?

Analisa Amplitudo, Frekuensi dan Fase - 1

Analisa Amplitudo, Frekuensi dan Fase - 2

Sering 1 x & 2 x Single

Ditandai timbulnya vibrasi A

Analisa Amplitudo, Frekuensi dan Fase - 3

Frekuensi bearing karakteristik

Kalkulasi frekuensi dari elemen bearing

Kerusakan di outer race = fr 1

Kerusakan di inner race = fr 1 +

Kerusakan pada elemen berputar =

Kerusakan pada cage = 1

fr : Frekuensi rotasi dari inner race

Why shock pulses for rolling bearing noise ?

Shock pulse range rolling bearing

Natural frequencies rolling bearing pieces

ultra sound emission

Overall values for Bearing condition

Normalising of shock pulse signals

dBn = normalised shock pulse value

dBi = initial value

dBia = adjusted inital value

signal damping of real measurement location

influencing factors like load condition

Signature Rolling Bearing Defects

Rolling track defect:

2fRPOF 3 fRPO F 4 fRPOF

Envelope Spectrum bearing

Analisa Amplitudo, Frekuensi dan Fase - 4

1 x rpm, seolaholah seperti

pd rodagigi vibrasi segaris

Analisa Amplitudo, Frekuensi dan Fase - 5