Predictive Maintenance - 030223 Prodemy

PREDICTIVE PRODUCTIVITY
MAINTENANCE ACADEMY
PRODUCTIVITY ACADEMY www.prodemyasia.com
PRESENTER OVERVIEW
Name : Angga Hartono
Education : Mechanical Engineering – S1
Certification : Vibration Analyst CAT III - Mobius Institute &
Airborne/Structureborne Ultrasound Level I
Experience : Advanced Analysis
PLTA, PLTG, PLTU, Petrochemical, Fabricator, O&G, Mining.
1
Outline
• Konsep dasar maintenance
• Konsep predictive maintenance
• Jenis-jenis predictive maintenance
• Teknik monitoring kondisi mesin
• Pemilihan metoda monitoring
• Vibration monitoring and Analysis
Konsep Dasar Maintenance
Bolehkah breakdown saat beroperasi?

Safety, Economic, Quality Performance, Environment
Source: https://www.pexels.com/photo/white-united-airlines-plane-1089306/ & https://siar.com/ge-telah-kembangkan-turbin-gas-lebih-dari-26-gw/
2
1/3 dari biaya maintenance adalah pemborosan yang disebabkan pekerjaan tidak efisien dan tidak efektif.
Terry Wireman, NASCAR Racing, USA, 2005
AVOIDING: AIM:
1. Catastrophic failure 1. Improvement equipment reliability
2. Secondary damage 2. Reduce maintenance cost
3. Additional spare parts costs 3. Reduce energy used
4. Unnecessary overtime 4. Improve product quality
5. Injury to staff 5. Reduce downtime
Setiap industri punya organisasi manajemen, keuangan, prioritas dan level sukses yang berbeda-beda.
PILIHLAH TEKNOLOGI dan MONITORING RATE YANG TEPAT

Penting untuk mendeteksi masalah sebelum terjadi
Pahami potensi masalah pada

masa yang akan datang
3
Overall Equipment Effectiveness
Persentase KINERJA MESIN yang menujukkan seberapa EFEKTIF
mesin menghasilkan produk sesuai requirement
Source: Vibration Training Course Book – Mobius Instiitute
4
Type Description Remarks
Breakdown Fix it when breaks Not critical, not impact
Maintenance/Run to production, inexpesive.
failure/Reactive/Hysterical
Preventive Perform regular overhauls Machine wears out in
Maintenance/Planned- so that machine will not known a time, conmon is
Schedule/Calender fail not viable option
based/Historical
Predictive Maintenace If aint broke, don’t fix it Doing conmon to create
risk balance with cost
Proactive To anticipate and solve Goal of every industry that
Maintenance/Reliability problems before they plans to remain
Based become problems. competitive in the 21
Maintenance/Realibility century
Centered
Maintenance/RCA
Source: Vibration Training Course Book – Mobius Instiitute

Cost Type Predictive Preventive Breakdown
Maintenance Maintenance Maintenance
Capital ↑ - ↓
Operational - ↑ -
Breakdown ↓ - ↑
Setiap industri punya organisasi manajemen, keuangan, prioritas dan level sukses yang berbeda-beda.
5
Konsep Predictive Maintenace
If aint broke, don’t fix it
Condition Monitoring = Health Monitoring

Vibration, temperature, lubricants/Oil Sample, sound, motor current, and more
Konsep Predictive Maintenace

• Conmon only tell us condition of machine and allows us to plan our
repairs (we gain control production schedule). Nothing to increase
reliability of the machine or extend their lives. Simply only for
predicting the failure.
• Conmon help to look the future, but you still have to take the
appropriate action.
• Monitor the machine and understand condition of machine
12
6
Jenis-Jenis Predictive Maintenace
Jenis-Jenis Predictive Maintenace

Technology Measured Type of Tools/Checked
Vibration Vibrate object (UB, MA, bearing, Single/dual channel, multiply channel
gearbox, cavitation, turbulence,
electrical motor, resonance, etc)
Ultrasound Ultrasound (Leak, Electrical, Valve, Airborne & Structure Borne
Steam Trap, Mechanical)
Thermography Radiated energy Spot, Movie cameras
Electrical Motor Current, voltage (winding, air gap Static (off-line), Dynamic (online) test
faults, rotor fault, etc)
Oil Analysis Viscosity, moisture, element Oil Bath, spectroscopy, FTIR, total acid, total
analysis, contamination (8-10 µm) base, water, particle count
Wear particle Like oil analysis with more large of Oil Bath, spectroscopy, FTIR, total acid, total
size of particle base, water, particle count
7
Teknik Monitoring Kondisi Mesin
Consider:
1. Accesibility
2. Location
3. Hazard
Effect of failure:
1. Downtime
2. Secondary damage
3. Parts/labour cost
4. Capital/replacement cost
15
Pemilihan Metode Monitoring Mesin

Type of Monitoring Description
Routine Monitoring 1. Tests are typically performed every 30 - 90 days
2. Collect vibration readings at each bearing
3. Collect vertical, horizontal and axial data on the machine
Online Monitoring 1. For machines in hazardous area
2. Permanent sensors and junction boxes
3. Data still manually collected on "route"
4. Automatically collects data
5. Warns on change vibration level
Continuous Monitoring 1. For critical machine, i.e turbine
2. Permanently installed
3. Protection system
8
Pemilihan Metode Monitoring Mesin
Tools Picture Auxiliary
/Software
Single-Dual
Channel
AMS Health
Machinery
Multi Channel
Ez Thomas, Ez
Analyst
Vibration Monitoring and Analysis
Vibration is the response of a system to some internal or external stimulus or force applied to the system.
Vibration has three important parameters which can be measured - Amplitude (how much); Frequency (how
many times per minute or per second); and Phase (which describes how it is vibrating).
Common Problem by Vibration Analysis:

1. Unbalance
2. Eccentric Rototr
3. Bent Shaft
4. Misalignment
5. Resonance
6. Mechanical Looseness
7. Bearing
8. Flow turbulence & Cavitation
9. Gearbox
10. Motor
11. Belt
9
Parameter/ Tipe Sensor Kelebihan Kekurangan Unit
Displacement / Eddy 1. Wide freq. response (0-10 kHz) 1. Instalasi Mahal µm p-p
Current Probes 2. Relative movement shaft 1-10 mm 2. Butuh kalibrasi jika berbeda atau
(Perubahan Posisi) 3. T: -50 – 200 oC material mils
3. Glitches tidak bisa dihilangkan
Velocity / Electro Dynamic 1. Tidak butuh power eksternal 1. Tidak cocok pada mesin mm/s
Velocity Sensor 2. Mudah digunakan kecepatan rendah atau terlalu RMS
(Kecepatan) 3. T: -50 – 200 oC tinggi atau
2. Butuh kalibrasi jika berbeda in/s
temperatur
Accelerometer 1. Very wide freq. response (0.1-30 1. Tidak cocok untuk mesin mm/s2
(Laju Perubahan kHz) kecepatan rendah RMS
Kecepataan) 2. T: up to 125 oC 2. T limit atau
3. Stable to calibration in/s2
4. Aplikasi yang luas

Integration & Diffentiation (Unit Problem)
Windowing (Leakage Problem)
Averaging (Noise Problem)
Signal Analog Signal Digital TWF, Spectra, Advanced Analysis
Analisa & REPORT
Predictive Maintenance/
Low pass filters: let through low frequencies Maintenance Action
Band pass filters: let through frequencies within a band
Band stop filters: block frequencies within a band
High pass filters: let through high frequencies Review
(Aliasing Problem)
10
ANALISIS TRANSIENT STEADY DESCRIPTION REMARKS
Time √ √ Nilai Vibrasi vs Waktu Record., menghasilkan pola Unbalance, damaged belt, bearing fault, gearbox,
Waveform tertentu kavitasi, rotating looseness
The time waveform turbine section shows a sinusoidal graph and will show a harmonic spectrum, in the
generator section an impact phenomenon begins to appear but there is no modulation which indicates the
absence of sidebands in the spectrum. In general, the possibility that we can observe through this time
waveform is a bearing problem. We will need supporting analysis to verify this possibility.
TIME WAVEFORM
22
11
Spectrum √ √ Nilai Vibrasi vs Freq., menghasilkan pola tertentu Hampir semua permasalahan pada rotating equipment
akan muncul
All data capture points show a 1X (50 Hz) harmonic spectrum. This
spectrum may indicate loose in housing bearing, 1X peak and moderate
at 2X indicates misalignment caused by soft foot. Misalignment caused
by the soft foot will usually cause angular misalignment.
Understanding Spectra
FORCING FREQUENCIES NOISE
Allow us to know relate individual source to machine Generate by: random vibration, single event in the TWF (impact)
component/mechanical fault. Noise floor can tell about cond. Of machine like bearing faulf, gearbox,
Refer to Fault Freq or defect freq. cavitation, loosenes, lube., Turbulance, impact, rub.
Ex: Blade passing Freq, BPFI, BPFO, gearmesh, belt, RBF, cage rate, Noise can come internal or external machine.
ball spin, vane passing F. HOW to reduce noise:
use average data, use better dynamic range, transducer specify, dll
HARMONICS
Fundamental Freq: first peak ORDER help us in:
Harmonics: Multipy the first peak and have space periodically 1. Forcing freq calculation
Random vibration, clipping, distorted, impacting, will be have 2. Allow us to compare two spectra in different speed
harmonic spectrum. 3. To see related in each speed
Cond. Make the harmonics: Misalignment, looseness, bear fault,
CRITICAL SPEED: Speed when machine RPM coincides with the first
gear fault mode vibration (excite resonance)
SIDEBANDS up resonance = up vibration amp = up stress = weld crack,
Sidebands: rolling elements bearing, gearbox, electrical motor, dll metal fatigue, bearing fault, gear fault, dll
Sidebands (modulation freq) position in around center frequency
(carrier freq)
Ex center freq: GMF, BPFI, BPFO, RBF, LF
Ex sidebands: Shaft speed, FT, PPF
12
Sub Syn. Synchronous Non Syn.

Area<1x, forcing freq generate at All energy above
Come from: another turning speed its turning speed freq. that
component in machine, multiples, is not an exact interger
another machine, belt Come from: unbalance, multiple of turning
freq. hydraulic missaligment, bent speed. Come from:
instability in journal shaft, looseness, blade another component in
bearing, rotor rub, or Vane Pass freq., machine, belt freq.,
shaft rub, compressor reciprocating motion, rolling element
wheel rub, cage freq in gears, eccentricity, LF bearing, system
rolling bearing, severe Motor resonances, cavitation,
looseness electrical, lube pumps,
sliding surfaces,
another machine.

CONVERT UNIT
13
Strip chart √ √ Nilai Overall Vibration vs Waktu Real Time Mengetahui nilai vibrasi tertinggi
The coast down process starts from the unit with a load of 53MW until the unit stops at 0 RPM and no load.
This process is divided into several conditions, namely when the load starts to be reduced from 53MW at the
point before (A), after that the unit is in the FSNL condition at point (A). The FSNL condition of the rotating
speed starts to approach 0 RPM (B).

Bode Plot √ Menunjukan lokasi natural freq., efek damping, Natural Freq untuk validasi resonansi
perubahan fasa
Polar Plot √ Mekanisame sama dg bode plot, namun Natural Freq untuk validasi resonansi
ditampilkan dalam polar
From the bode plot, it can be seen that the critical speed in the turbine section (Turbine Inboard and
Outboard) occurs at around 1020 RPM @ 204 deg and 1896 RPM @ 194 deg.
14
BODE PLOT & POLAR PLOT
AF Description
<2.5 Critically Damped
<5 Very good
<8 Still acceptable
8-10 Marginal
>10 Poorly damped
Source: Acceptance of Damping Condition - API 616 for Gas Turbine

Centerline √ Mengetahui pergerakkan shaft dari kondisi rest Unbalance, MA, air gap fault, dll
Plot sampai steady di dalam bearing
On all four bearings it is shown

that the shaft centerline were
pressing against the bottom
limit of the bearing clearance.
This could indicate a possible
sign of misalignment. It could
also be caused by gap voltage
reference error which was taken
during slow roll process instead
of during standstill. Considering
low overall vibration level on all
four bearings, it is still within
normal condition.
15
Waterfall √ √ Nilai Vibrasi vs waktu dan kecepatan Sama dengan spectrum, kelebihan bisa melihat
Plot perubahan niali vibrasi dalam 2 parameter secara
bersamaan
The waterfall plot on both

turbine bearings are
dominated by 1X and 2X
peaks. During coast-down,
there is a significant
increase in amplitude of
1X peak when the turbine
passes its critical speed at
1020 RPM, which then
subsides afterwards.

Phase √ Pergerakkan relatif pada mesin. Tipe: Absolut dan Unbalance, MA, bent shaft, coocked bearing,
Relatif looseness
16
Orbit √ √ Pergerakkan shaft di dalam bearing dengan Unbalance, MA, oil whirl, oil whib, rubbing
membandingkan 2 sensor displacement V dan H
On turbine inboard
bearing, unfiltered orbit
plot shows erratic pattern
with an elliptical shaped
orbit at 1X vibration. This
might indicate a preload
condition on the turbine
shaft, which can be
caused by misalignment.
ORBIT
17
REKOMENDASI
1. Balancing (metode: trim run, splitting weight, four run balanced method, dll)
2. Re-alignment (metode: straight edge/feeler gauge, Using laser MA, Dial
indicator)
3. Lakukan CLIT

Operating deflection shape
Memvisualisasikan suatu struktur dalam kondisi normal operasi, berdasarkan nilai
magnitude vibrasi dan phase.
Fungsi: pengecekkan resonansi, weakness, looseness, soft foot, unbalance, dan MA
Source: https://www.youtube.com/watch?v=JOebIetua38
18
MODAL analysis
Analisa teknikal untuk mengamati natural freq., damping, dan shape mode.
Dilakukan pada saat mesin mati. Dapat dikombinasi dg FEA untuk analisa:
stresses, heat transfer, simulasi kegagalan, fluid dinamik.
Fungsi: pengecekkan resonansi, weakness, looseness, soft foot, unbalance, dan
MA
How to reduce resonance:

1. Change the speed of the machine – if feasible.
2. Add stiffness to the structure to increase the natural frequency.
3. Add mass to reduce the natural frequency.
4. Add damping to reduce the level of vibration.
5. Balance and align the machine to reduce the exciting forces.
6. Add a tuned absorber to ‘split’ the resonance.
7. Isolate the exciting force from the structure if possible
19
HIGH frequency technique

1. Too much data: waste time or longer time
2. Too little: not enough info
3. Collect repeatable data for trending
4. Collect good quality data and verification (ski slope, noise,
sensor overload, loose mounting, etc)
5. Type Sensor (env., equipment, etc)
6. Location sensor
7. Whats about alarm limit?
8. When doing overhaul
9. More variable need to be concern
1. Qualified
2. Expereience
3. Fit physically
4. Equipment/Tools
20
Time √ √ Nilai Vibrasi vs Waktu Record., menghasilkan pola Unbalance, damaged belt, bearing fault, gearbox,
Waveform tertentu kavitasi, rotating looseness
Spectrum √ √ Nilai Vibrasi vs Freq., menghasilkan pola tertentu Hampir semua permasalahan pada rotating equipment
akan muncul
Strip chart √ √ Nilai Overall Vibration vs Waktu Real Time Mengetahui nilai vibrasi tertinggi
Bode Plot √ Menunjukan lokasi natural freq., efek damping, Natural Freq untuk validasi resonansi
perubahan fasa
Polar Plot √ Mekanisame sama dg bode plot, namun Natural Freq untuk validasi resonansi
ditampilkan dalam polar
Centerline √ Mengetahui pergerakkan shaft dari kondisi rest Unbalance, MA, air gap fault, dll
Plot sampai steady di dalam bearing
Waterfall √ √ Nilai Vibrasi vs waktu dan kecepatan Sama dengan spectrum, kelebihan bisa melihat
Plot perubahan niali vibrasi dalam 2 parameter secara
bersamaan
Phase √ Pergerakkan relatif pada mesin. Tipe: Absolut dan Unbalance, MA, bent shaft, coocked bearing,
Relatif looseness
Orbit √ √ Pergerakkan shaft di dalam bearing dengan Unbalance, MA, oil whirl, oil whib, rubbing
membandingkan 2 sensor displacement V dan H
Thank You
PRODUCTIVITY ACADEMY
: prodemy.global@gmail.com
: 082112235378
: Productivity Academy (PRODEMY)
: @prodemyasia
: www.prodemyasia.com
21

Predictive Maintenance - 030223 Prodemy

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Predictive Maintenance - 030223 Prodemy

Uploaded by

Copyright:

Available Formats

PREDICTIVE PRODUCTIVITY

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

Konsep Dasar Maintenance

Bolehkah breakdown saat beroperasi?

Source: https://www.pexels.com/photo/white-united-airlines-plane-1089306/ & https://siar.com/ge-telah-kembangkan-turbin-gas-lebih-dari-26-gw/

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

Konsep Dasar Maintenance

Pahami potensi masalah pada

PRODUCTIVITY ACADEMY www.prodemyasia.com

Source: Vibration Training Course Book – Mobius Instiitute

PRODUCTIVITY ACADEMY www.prodemyasia.com

Konsep Dasar Maintenance

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

Konsep Dasar Maintenance

PRODUCTIVITY ACADEMY www.prodemyasia.com

Condition Monitoring = Health Monitoring

PRODUCTIVITY ACADEMY www.prodemyasia.com

Konsep Predictive Maintenace

PRODUCTIVITY ACADEMY www.prodemyasia.com

Jenis-Jenis Predictive Maintenace

PILIHLAH TEKNOLOGI dan MONITORING RATE YANG TEPAT

PRODUCTIVITY ACADEMY www.prodemyasia.com

Pemilihan Metode Monitoring Mesin

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

Vibration Monitoring and Analysis

Common Problem by Vibration Analysis:

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

Vibration Monitoring and Analysis

Signal Analog Signal Digital TWF, Spectra, Advanced Analysis

Analisa & REPORT

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

Sub Syn. Synchronous Non Syn.

PRODUCTIVITY ACADEMY www.prodemyasia.com

Vibration Monitoring and Analysis

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

Vibration Monitoring and Analysis

PRODUCTIVITY ACADEMY www.prodemyasia.com

Source: Acceptance of Damping Condition - API 616 for Gas Turbine

PRODUCTIVITY ACADEMY www.prodemyasia.com

Vibration Monitoring and Analysis

On all four bearings it is shown

PRODUCTIVITY ACADEMY www.prodemyasia.com

The waterfall plot on both

PRODUCTIVITY ACADEMY www.prodemyasia.com

Vibration Monitoring and Analysis

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

Vibration Monitoring and Analysis

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

Vibration Monitoring and Analysis

How to reduce resonance:

PRODUCTIVITY ACADEMY www.prodemyasia.com

PRODUCTIVITY ACADEMY www.prodemyasia.com

Vibration Monitoring and Analysis