Professional Documents
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Motor Diagnistic Training
Motor Diagnistic Training
MOTOR ANALYSIS
Oleh :
Dede Wahdiat
Andrianto Hapsoro
1
Tujuan
z Meningkatkan reliability
2
Jenis Motor Listrik
z Motor induksi (induction / asynchronous
motor)
z Synchronous motor
z DC Motor
3
Motor Construction
WINDINGS STATOR ROTOR
CORE
END SHIELD
STATIONARY
SWITCH
SHAFT
CENTRIFIGAL
ACTUATOR BALL BEARING
In an AC Motor
The Rotating Element is
called the ROTOR
The Stationary Element is
called the STATOR.
6
ROTOR
9
Definitions
In an AC Motor
The Rotating Element is
called the ROTOR
The Stationary Element is
called the STATOR.
10
The Torque of a DC Motor
11
The Synchronous Motor
12
The Synchronous Motor
The synchronous motor must run
at synchronous speed. Dc from
an exciter is fed through the
salient pole winding of the rotor.
The power fed to this rotor is
capable of correcting for power
factor.
PULL OUT TORQUE: If the motor is not is step with the
moving magnetic field of the stator it will stop. It must run
at synchronous speed or it will not run at all. It the load gets
to great on the machine then it will reach the pull out torque
and stop. It must run at constant speed.
13
Dasar Motor Litsrik
z FL = frekuensi jala-jala (line frequency)
Indonesia = 50 Hz, USA = 60 Hz
z Poles (P) = stator conductors
z Slots (S) = stator winding containers
z Bars (B) = rotor field conductors
14
Dasar Motor Listrik
15
Dasar Motor Listrik
z F = line frequency = 50 Hz
z Slip frequency = difference between magnetic field
frequency and operating speed
z Poles = stator conductors
z Slots = stator winding containers
z Bars = rotor field conductors
z Magnetic field frequency (RPM) =
120 x f / No.poles
16
Perhitungan frekuensi eksitasi
pada motor listrik
z Magnetic field speed, RPM (Ns) = 120 x F / jumlah pole
17
Contoh
z Misal : Sebuah motor listrik di name plate tertera 1480 RPM.
Jumlah rotor bar = 40.
18
Exercise
19
Permasalahan motor listrik
z Mechanical Problem
z Electrical Problem
20
Mechanical Problem
z Unbalance
z Misalignment
z Resonance
z Mechanical Looseness
z Soft Foot
z Keausan bearing (Bearing wear)
z Kerusakan bearing (bearing faults)
z Eccentric Rotor
z Frame Distortion
21
Electrical Problem
z Uneven air gap
z Eccentric rotor
z Broken rotor bars
z Shorted rotor lamination
z Phasing problem
22
Factors Detrimental to Motor Life
z Temperature - a 10C rise in motor heating reduces
the life of the insulation by 50% (NEMA Standard).
z Overload - causes temperature in the motor to
increase which in turn decreases the life of the
motor.
z Phase Imbalance - also causes insulation life to
decrease due to high temperatures.
Metode Pemeliharaan Mesin
Filosofi Baru
Adanya investasi waktu dan uang untuk
mengubah metode perawatan untuk
meningkatkan keandalan plant (plant
reliability).
Preventive Maintenance
Predictive Maintenance
Proactive Maintenance
The philosophy is
28
Breakdown Maintenance
Keuntungan:
z Murah
Kerugian:
z Tidak ada persiapan terhadap terjadinya kerusakan
mesin (downtime) karena terjadinya mendadak.
z Kerusakan akan menyebar ke komponen lain dan
bisa terjadi kerusakan fatal (catastrophic) sehingga
biaya perbaikan akan mahal.
z Kerugian produksi besar.
29
Preventive Maintenance
Dikenal juga sebagai Calendar-based Maintenance,
jenis perawatan ini menggunakan teori yang
menyebutkan bahwa umur mesin terbatas dan
kemungkinan terjadinya kegagalan akan meningkat
seiring dengan meningkatnya umur mesin.
30
Preventive Maintenance
31
Preventive Maintenance
Keuntungan:
z Perawatan dilakukan pada waktu yang sudah ditentukan dan
dipersiapkan.
z Kegagalan mesin yang tidak terduga dapat dikurangi.
z Oleh karena itu kerusakan fatal dapat dikurangi.
z Terganggunya jalan produksi bisa dikurangi.
z Ada pengaturan yang jelas terhadap penyimpanan komponen
cadangan dan biaya.
Kerugian:
z Masin terlalu sering diperbaiki bahkan pada saat dimana
mesin itu sebenarnya tidak mengalami masalah sama sekali.
z Tindakan perawatan seringkali menambah masalah daripada
menguranginya.
z Masih terjadi unscheduled breakdowns.
32
Predictive Maintenance
Predictive maintenance, disebut juga dengan Condition
Based Maintenance adalah suatu proses yang
membutuhkan teknologi dan keahlian orang yang
menggabungkan semua data diagnostik dan
performance yang ada, maintenance histories, data
operasi dan desain untuk membuat keputusan kapan
harus dilakukan tindakan perawatan pada major /
The philosophy is critical equipment.
“if it ain’t broken, don’t fix it”
33
Predictive Maintenance
34
Predictive Maintenance
Keuntungan:
z Kerusakan mesin (downtime) yang tidak terduga
dapat dikurangi.
z Komponen hanya dipesan saat dibutuhkan jadi
penumpukan stok komponen bisa lebih dikurangi.
z Tindakan perawatan bisa lebih direncanakan.
Kerugian:
z Biaya yang tinggi dalam mempersiapkan peralatan
instrumen dan tenaga ahli.
z Tidak ada kepastian apakah umur mesin bisa lebih
panjang.
35
Proactive Maintenance
Dikenal juga sebagai Precision Maintenance dan
Reliability Based Maintenance. Metode perawatan ini
lebih menitikberatkan pada indentifikasi akar
permasalahan dan memperbaikinya untuk
mengurangi kemungkinan mesin akan rusak.
The philosophy is
36
Proactive Maintenance
Memaksimalkan umur operasi mesin dan
meningkatkan keandalan serta efisiensinya melalui :
¾Analisa penyebab kegagalan (Root Cause Failure Analysis)
¾Instalasi mesin dilakukan dengan kepresisian yang tinggi.
¾Pelatihan personel.
3 hal yang harus ditelusuri:
¾Mengapa mesin selalu mengalami kegagalan berulang-ulang
?
¾Jenis tindakan apa yang harus dilakukan ?
¾Apakah mesin beserta komponen-komponennya telah
terpasang dengan benar ?
37
Proactive Maintenance
Keuntungan:
z Umur operasi mesin bisa lebih diperpanjang
z Keandalan mesin meningkat
z Kegagalan mesin dapat dikurangi
z Biaya perawatan keseluruhan bisa dikurangi
Kerugian:
z Investasi dengan biaya tinggi untuk peralatan instrumen dan
keahlian personel
z Diperlukan keahlian khusus dari para personelnya.
z Dibutuhkan investasi waktu untuk menerapkan metode ini.
z Butuh perubahan cara berpikir (filosofi) dari mulai level
manajemen sampai ke level paling bawah.
38
Condition Monitoring
39
Integrated Condition Monitoring
Memonitor kondisi dari mesin bisa dianalogikan dengan
memonitor kesehatan manusia
Gambaran total
40
Integrated Condition Monitoring
Memakai sistem tunggal yang bisa menunjang beberapa
teknologi sekaligus dari satu produsen, sehingga tidak perlu lagi
secara manual menggabungkan beberapa teknologi untuk
menyajikan informasi mengenai kondisi suatu mesin.
ATAU
41
Metode Perawatan Motor Listrik
z Vibration Analysis
z Motor Current Signature Analysis (MCSA)
z Flux Measurement
z Shaft Current / Voltage Measurement
z Temperature
z Infra red Thermography
42
Vibration Analysis
43
Titik pengukuran
44
Uneven air gap
45
Uneven air gap
Penyebab uneven air gap:
z Soft foot
z Frame Distortion
46
Jenis-jenis Soft Foot
47
Soft foot
48
Cara mendeteksi soft foot
Dial Indicator
•Pasang dial indicator pada kaki mesin,
•kencangkan baut dan set nol pada dial
kendorkan baut
•catat berapa perubahannya
49
Signal vibrasi akibat uneven air
gap
z Muncul frekuensi 2xLF (100 Hz)
z Amplitudo meghilang tiba-tiba saat power
cut off
50
Eccentric Rotor
z Rotor tdk sempurna atau bengkok
z Amplitudo hilang saat power cut off
z Muncul frekuensi 1 dan 2XLF yang disertai dengan side
band sebesar pole pass frequncy
z Kadangkala rotor bar pass frequency muncul dengan
sideband 2XLF
51
Rotor Problems
z Broken / Cracked rotor bars / shorting rings, bad
joints antara rotor bars dan shorting rings, atau
shorted rotor laminations Æ muncul 1XRPM
dengan sideband pole pass freq.
z Cracked rotor bar muncul harmonik 1 sd 5XRPM
dengan pole pass frq. Sideband
z Loose / broken rotor bar akan ditandai muncul
rotor bas pass freq. (RBPF = jumlah rotor bar x
RPM)
52
Rotor Problem
53
Phasing Problem
z Motor beroperasi hanya 2 dari 3 phasa
z Disebabkan oleh loose / bad connector
z Muncul frekuensi 2XLF dengan sideband
1/3 LF
54
Synchronous Motor
z Typical spectrum
55
General Recommendation untuk
analisis vibrasi motor
z 5 titik untuk trending
• MOH - motor outboard horizontal
• MOV - motor outboard vertical
• MOA (or MIA) - motor outboard (or inboard) axial
• MIH - motor inboard horizontal
• MIV - motor inboard vertical
z Fmax = 6XBPFI atau 40-50XRPM, sleeve brg
10XRPM
z Resolusi = 1-2 Hz
56
General Recommendation untuk
analisis vibrasi motor
z 3 High resolution point
• HOH - high resolution, motor outboard horizontal
• HIH - high resolution, motor inboard vertical
• HOA (or HIA) - high resolution, motor outboard (or inboard)
axial
z Fmax = 200 Hz, 1600 lines
z Resolusi = 0,125 Hz
57
General Recommendation untuk
analisis vibrasi motor
z 2 extended range points
• EOH - extended range, motor outboard horizontal
• EIH - extended range, motor inboard horizontal
z Fmax = 5000 Hz, 6400 lines
z Untuk data trending / bulanan cukup dengan 400 –
800 lines untuk menghemat memori
58
Motor Current Signature Analysis
MCSA
59
Motor Current Signature Analysis -
MCSA
RB1 - phase 1 current signature
(Hi-resolution 1600-3200 lines)
•Fmax : 80 Hz
60
Actual photo of motor current data
collection process
61
Keterbatasan MCSA
z Harus mengakses panel listrik
z Ammeter dihubungkan kabel listrik
z Membutuhkan electrician untuk membantu
62
Basic Concept
z A broken or cracked rotor bar creates heating and
thermal expansion as cracks heat due to increased
current resistance and as adjacent bars now carry
additional current to compensate for the broken bar
z These stresses, which are especially aggravated
by frequent starts, can cause :
• adjacent bars to break,
• thermal bowing of the rotor,
• loosening of the broken bar
63
Basic Concept
z If the broken bar works out of the rotor, then
it could rub the stator causing secondary
damage and possibly resulting in
catastrophic failure
64
Parameter tingkat kerusakan rotor
z Fr = motor rotational frequency
LSB1 = lower slip sideband of line frequency
Lf = fine frequency
NP = number of poles
SF = slip frequency
65
Parameter tingkat kerusakan rotor
z Selisih dB amplitude antara LF dan LSB1
66
Contoh bad rotor
67
Contoh
68
PRIORITIZATION
z Motors indicated less than one broken rotor
bar. At this level of fault prediction, the motor
is normally still considered to be in
acceptable condition
z Motor which were estimated to have 1 to 3
broken bars may be considered marginal
and require increased monitoring of the
electric current signature for warning of
future degradation
69
PRIORITIZATION
z Motor which high resistance joints or casting
voids can contribute to the prediction.
z Unit which were calculated to have greater
than three broken rotor bars were
considered to have at least one but probably
multiple broken bars; these units should be
monitored closely and inspected/repaired at
the next outage
70
Flux Measurement
71
Flux Measurement
z Prinsip pengukuran flux
72
Flux Measurement
z An electric motor by definition produces
magnetic flux.
z Any small unbalance in the magnetic or
electric circuit of motors is reflected in the
axially transmitted fluxes
73
Flux Measurement
z Consistent placement of a formed flux coil
on the axial outboard end of the motor is
critical for obtaining reliable and trendable
data
z It is recommended that flux measurements
be acquired axially at the centered position.
74
Flux Measurement
z The flux coil spectrum has been shown to
provide information on rotor bar condition at
number of poles times slip frequency
sidebands of line frequency (just as seen in
electric current measurements)
75
Unbalanced Voltage Supply
z Voltage unbalance is defined by the National
Electrical Manufacturers Association (NEMA) as
100 times the absolute value of the maximum
deviation of the line voltage from the average
voltage on a three-phase system, divided by the
average voltage.
• For example, if the measured line voltages are 462, 463,
and 455 volts, the average is 460 volts. The voltage
unbalance is:
(460 - 455)/460 x 100 = 1.1%
76
Unbalanced Voltage Supply
z Unbalanced supply voltage will cause motor
heating and eventually lead to premature
degradation of the stator windings.
77
Unbalanced Voltage Supply
z The additional temperature rise is estimated with
the following equation=
2 x (% voltage unbalance )2.
z For example :
a motor with a 100°C temperature rise would experience a
temperature increase of 8°C when operated under
conditions of 2% voltage unbalance.
78
Unbalanced Voltage Supply
79
Flux Measurement
2xLF
Slot Pass
increase decrease
in flux in flux -2xLF
-4xLF 4xLF
-6xLF 6xLF8xLF
-10xLF
-8xLF 10xLF
81
Pembuatan Database Menggunakan
RBMwizard
82
Tujuan :
83
Pembuatan Database Menggunakan RBMwizard
•Aktifkan Program
RBMware
•Klik ikon
RBMwizard
•Pilih create new
database dan klik
OK
•Masukkan nama
database “motor
current” dan klik
OK
84
Pembuatan Database Menggunakan RBMwizard
85
Pembuatan Database Menggunakan RBMwizard
86
Pembuatan Database Menggunakan RBMwizard
87
Pembuatan Database Menggunakan RBMwizard
88
Pembuatan Database Menggunakan RBMwizard
89
Pembuatan Database Menggunakan RBMwizard
•Pilih Constant Speed / Constant Load pada Type. Pilih RPM pada Speed
Units dan 100 %. Load. Select Smooth sebagai alarm criteria.
•Thermography screen muncul. Pilih Category Mechanical - Rotating dan Tipe
AC motor- Driven Machine, lalu klik Finish.
90
Pembuatan Database Menggunakan RBMwizard
• Klik Configure. Dan kita akan memasuki Component Design Studio (CDS).
• Pilih New Configuration dan This File pada Location, lalu klik Finish.
91
Pembuatan Database Menggunakan RBMwizard
92
Pembuatan Database Menggunakan RBMwizard
94
Pembuatan Database Menggunakan RBMwizard
95
Pembuatan Database Menggunakan RBMwizard
96
Pembuatan Database Menggunakan RBMwizard
97
Pembuatan Database Menggunakan RBMwizard
98
Route Management Dan Analyzer
Data Transfer RBMware
99
Tujuan
z Mengetahui cara pembuatan route dengan Route
Management.
z Mengetahui cara mengedit route yang telah dibuat dengan
Route Management.
z Mengetahui cara penggunaan Analyzer Data Transfer untuk
transfer data dari RBMware ke CSI 2120 atau sebaliknya.
100
Membuat Route
101
Membuat Route
102
Membuat Route
105
Mengedit Route
107
Mengedit Route
109
Menggunakan Analyzer Data Transfer
110
Menggunakan Analyzer Data Transfer
AMPL = .0027
50 LOAD = 71%
dB AMPS
40
30
20 RPM = 711.
RPS = 11.85
10
0
Freq: 66.04
50 52 54 56 58 60 62 64 66 68 70
Ordr: 5.575
Frequency in Hz Spec: -9.142
Label: MOTOR WITH 4 BROKEN ROTOR BARS
AMS SuiteTM: Machinery HealthTM Manager
MotorView II diagnosed data
Repaired rotor bars on same
machine
MTR - Forced Draft w/ Broken Bars
450 HP MTR-FC1 FLUX COIL OUTBOARD END
70
Spectrum Display
01-DEC-92 15:11
60
AMPL = .0016
50 LOAD = 65%
dB AMPS
40
side bands
30
20 RPM = 712.
RPS = 11.86
10
50 52 54 56 58 60 62 64 66 68 70
Frequency in Hz
Label: MOTOR WITH BROKEN BARS REPAIRED
Bad Rotor Bars on same machine
MTR - Forced Draft w/ Broken Bars
450 HP MTR-RB1 Current Rotor Bar Analysis Ph=1
70
Spectrum Display
07-DEC-90 09:25
60
AMPS = 43.32
50 LOAD = 65%
dB AMPS
40
30
20 RPM = 711.
RPS = 11.85
10
50 52 54 56 58 60 62 64 66 68 70
Frequency in Hz
Label: MOTOR WITH 4 BROKEN ROTOR BARS
Good Rotor Bars on same machine
MTR - Forced Draft w/ Broken Bars
450 HP MTR-RB1 Current Rotor Bar Analysis Ph=1
70
Spectrum Display
01-DEC-92 12:47
60
AMPS = 38.91
50 LOAD = 59%
dB AMPS
40
30
20 RPM = 712.
RPS = 11.87
10
50 52 54 56 58 60 62 64 66 68 70
Frequency in Hz
Label: MOTOR WITH BROKEN BARS REPAIRED
Flux Monitoring
$ Use 343 Flux Coil
$ Position on the fan shroud of a motor
$ Measures magnetic flux signature of AC induction
motors
$ Detects
$ rotor bar faults
$ stator faults
$ unbalanced voltage
$ motor speed
FLUX Notes
$ Do not need to know load
$ Do not need to know # of bars
$ Do not need to know # of stator slots
$ Need to position coil consistently
$ Need MCSA baseline
FLUX Benefits
z Detects same faults as motor current and more
• without accessing electric panels
• without connecting to live power leads
• without requiring an electrician
• during vibration route collection
Flux Analysis for Stator Faults
z Baseline flux reading mandatory
z Two Measurements required:
1) Low: Trend LF with sidebands of RPS.
2) High: Trend slot pass family Slot Pass Freq. with sidebands
of 2xLF
AMPL = 3.4593
70 LOAD = 102%
dB FLUX-AU
60
50
40 RPM = 1185.
RPS = 19.75
30
20
Freq: 1757.8
0 600 1200 1800 2400 3000
Ordr: 89.02
Frequency in Hz Spec: 63.78
Label: no stator fault Dfrq: 120.00
50%
Load 85% Load
Test Measurement #1
AMPL = 9.3242
60 LOAD = 100%
dB FLUX-AU
50
40
30 RPM = 1185.
RPS = 19.75
20
10
Freq: 1758.8
0 600 1200 1800 2400 3000
Ordr: 89.03
Frequency in Hz Spec: 53.24
Label: stator fault coils A to B Dfrq: 120.00
increase decrease
in flux in flux -4xLF
-2xLF
4xLF 8xLF
6xLF 10xLF
-10xLF -6xLF
-8xLF
70 AMPL = 4.8288
LOAD = 98%
dB FLUX-AU
60
50
40
RPM = 1186.
30
RPS = 19.76
20
10
Freq: 1519.7
0 600 1200 1800 2400 3000
Ordr: 76.91
Frequency in Hz Spec: 38.33
Label: stator fault coils B to C Dfrq: 120.00
increase decrease
in flux in flux -2xLF
-4xLF 4xLF
AMPL = 53.26
50 LOAD = 96%
dB FLUX-AU
40
30
20 RPM = 1186.
RPS = 19.77
10
0
Freq: 1759.7
0 600 1200 1800 2400 3000
Ordr: 89.02
Frequency in Hz Spec: 31.42
Label: stator fault/severe coils C to D Dfrq: 120.00
20
15
10
8.1
5 4.3
1.1
0
No Small Medium Severe
Short Short Short Short
Setting MotorView
145
Parameter Kerusakan Rotor Bar
Jika dB :
• >54 dB = Good Motor
• 45 – 54 = marginal condition
dB
• 40 – 45 = setidaknya satu
broken rotor
• < 40 = - Lebih dari satu
broken rotor bar
146
Menggunakan Rotor Bar Analysis
150
Menggunakan Rotor Bar Analysis
151
Menggunakan Rotor Bar Analysis
152
Menggunakan Rotor Bar Analysis
153
Menggunakan Rotor Bar Analysis
Παδα εθυιπμεντ ψανγ λαιν τερλιηατ βαηωα αδα σιδεβανδ δι σεκιταρ λινε
φρεθυενσι
Dengan tingkat kepercayaan 43 % kemungkinan ada bar yang patah
154
Flux
Flux Coil
Coil Analysis
Analysis
155
Sinyal – Sinyal Hasil Pengukuran Flux Coil
156
Sinyal – Sinyal Hasil Pengukuran Flux Coil
157
Unbalance Voltage Supply
158
Unbalance Voltage Supply
159
Shorted Winding Turn
160
Shorted Winding Turn
161
Memilih Motor Analsis Option
164
TERIMA KASIH
165