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Predictive Maintenance untuk

Mesin-mesin Rotasi
Predictive Maintenance (PdM)

! Langkah-langkah Penerapan PdM

! Teknologi Pendukung PdM

! Case Studies

! Keuntungan Penerapan PdM
Langkah-langkah Penerapan PdM

! Database setup
! Pengambilan data di lapangan
! Analisis data
! Diagnosis permasalahan
! Penilaian kondisi mesin
! Corrective Action : Balancing & Alignment
! Performance Improvement
Vibration

Tribology Predictive Technology Motor Current

IR-Thermography Corrective
On-line Monitoring Balancing & Alignment
Vibration Analysis

Vibration Sensor

Data Collector
Vibration Analysis

SEVERITY

SOURCE OF PROBLEM
Vibration Analysis
Machinery Vibration Diagnostic
Tribology – Oil Analysis
ABRAS WEAR - Abrasive Wear Example
P3 - Mobil DTE hydraulic fluid
Extreme Sample Date: 21-FEB-93

Bad Wear Wear - Bad
Contamination - Extreme
Marginal Chemistry - Good

Fair Bad seal leaking coolant into hydraulics
Saw abrasive wear particles on grid 100x
Good
Check - Viscosity, Breather, Contamination, Shop Mic, Mechanical
Action - Remove Contaminants (water?)
Estimated total water content 2.5089%
In Solution 1% +Emulsified 72%
+Free 27% = 100%

Contamination Chemistry
Infrared Thermography
*>33.0°C
Infrared Picture
*>81.6°C
32.0
30.0 80.0

28.0
Hot spot reveal the 70.0
This hot spot proves
26.0 source of heat from the 60.0 Spot 2 not enough cooling
73.0
from the fan.
24.0
33.2
motor winding. 50.0
22.0 40.0 Spot 1
Diff. 1 78.8
20.0 30.0
Spot 3
13.9
19.3 75.0
18.0
20.0
16.0
10.0
14.0
0.0
12.0

*<11.4°C *<-6.6°C

Photo Visual
Note : 1.Average ampere of
Spot 1 = 78.8 ºC the motor = 112 A
Spot 2 = 73.0 ºC 2. Full load
Spot 3 = 75.0 ºC Ampere = 132 A

Courtesy of VICO Indonesia
Motor Analysis

! Vibration Analysis " Mechanical faults

! Untuk mendeteksi electrical faults
– Shaft Current / Voltage
– Electric Current Analysis
– Temperature
Electric Current Analysis
Shaft Voltage Measurement

Fluting with Spalling
Pengukuran Temperatur

TBI TSI TS TSO TBO TTH TCP
C

TAF
Electrical Faults

! Stator Eccentricity, Shorten Laminations or
Loose Iron
! Uneven (variable) Air Gap
! Eccentric Rotor
! Broken / Cracked Rotor Bars or Shorting Rings
! Bad / Loose Connection Rotor Bars/Shorting
Rings
! Shorted Rotor Laminations
Corrective Action - Balancing &
Precision Alignment
One Plane Two Plane Multi-Plane

Simple Rotors Large/Overhung Complex
Rotors or Rolls Equipment
Corrective Action - Balancing &
Precision Alignment
Contoh Penerapan Multi-Teknologi

The Alignment parameter band(2 X RPM) was
chosen to trend over time. A forecast of when the
fault level would be exceeded with the current
trending of values is also applied.
2 x RPM
Vibration
Analysis was
requested to
provide more
insight

Nspectr
automated fault
diagnostics was
run on the
spectrum and it
came up with
the Shaft
misalignment at
the coupling as
the most
probable fault.
Thermography indicated misalignment

Excessive heat at the coupling
Excessive heat at
the bearing from
increased load.
Alignment of the motor
and pump shafts was
performed. The graph
at the right shows the
before and after
alignment condition.
The vibration
trend of the
alignment
parameter band
decreased back
to normal levels
after the shaft
alignment job.
Integrated report showing the Vibration and Infrared Data
and an Explanation and Urgency of the problem.

Urgency

Explanation

IR
Thermogram
Vibration
Trend
Analisis Multi-Teknologi
MA#7 - GEARBOX DRIVE-SUCTION ROLL
GBX-DSROLL-G3R G-BOX OUTPUT SHAFT - RADIAL
0.6

– Vibration 0.5 G G G G G G G G G G
ROUTE SPECTRUM
18-OCT-94 08:37:00

PK Velocity in In/Sec
OVRALL= .6516 V-DG
0.4
PK = .6892
• FFT, waveform, & phase analysis 0.3
BPFO harmonics show severe
LOAD = 100.0
FPMrace defect
= 3518.
0.2 RPM = 381.
• Automated diagnostics 0.1 >FAG 61896
G=BPFO
0

– Tribology 0 400 800
Frequency in Hz
1200 1600

MTR - Forced Draft w/ Broken Bars

• Trivector wear, chemistry, & 15
12 70 CF ALARM
450 HP MTR-RB1 Current Rotor Bar Analysis
WAVEFORM Ph=1
DISPLAY
18-OCT-94 08:37:00
Spectrum Display

Acceleration in G-s
9 RMS = 4.38
contamination analysis 6
3
60 PK(+) = 14.53
PK(-) = 11.78
07-DEC-90 09:25

0 PK ALARM CRESTF= 3.32 AMPS = 43.32
PK ALARM

– Motor Monitoring
-3 50 LOAD = 65%
-6
-9

dB AMPS
-12 40
• Automated rotor & stator -15 CF ALARM
Freq: 79.29
0 50 100 150 200 250 300 350

diagnostics with current & flux 30
Time in mSecs
Label: Severe BPFO defect - need action
Ordr:
Spec:
12.50
.04412

Priority: 4 20 RPM = 711.
RPS = 11.85
– Thermography 10

• Palette & plot annotation tools 0

• Temp profile & histogram analysis 50 52 54 56 58 60

Frequency in Hz
62 64 66 68 70

Label: MOTOR WITH 4 BROKEN ROTOR BARS

– Alignment & Balancing
• Tolerance plots by the job
CASE HISTORIES

! BEARING DEFECT ON NASH VACUUM
PUMP

! FIELD BALANCING

! HIGH VIBRATION ON VERTICAL PUMP
Kerusakan Bearing Pompa
#1 #2 #3 #4

MOV MIV PIV POV
MOH MIH PIH POH
MIA PIA POA

•Pompa vacuum di PTA Plant
•Critical Equipment
•Vibrasi tinggi
Kerusakan Bearing Pompa
PT4 - NASH Vacuum Pump FJ-10
NVP - PTS=POV POH POA (26-APR-00)

Max Amp
5.30

Plot
Scale
PK Velocity in mm/Sec

3 NVP -POA

0 NVP -POH

NVP -POV
0 200 400 600 800 1000
Frequency in Hz

Spektrum pada Pump Outboard Bearing, frekuensi
bearing muncul
Kerusakan Bearing Pompa
PT4 - NASH Vacuum Pump FJ-10
NVP -POV Pump Outboard Vertical
7
Route Spectrum

6
C C C C C C C 26-APR-00 16:14:04

OVRALL= 12.94 V-DG
Inner race defect !!
PK = 12.96
LOAD = 100.0
RPM = 742.
5
RPS = 12.36
PK Velocity in mm/Sec

>TMK 71450 CONE
4 C=BPFO

PT4 - NASH Vacuum Pump FJ-10
NVP -POH Pump Outboard Horizontal
7
RMS Acceleration in G-s

3 ANALYZE SPECTRUM
6 D D D D D D 26-APR-00 16:09:13
5 (PkVue-HP 1000 Hz)
RMS = 11.91
2 4 LOAD = 100.0
RPM = 740.
3
RPS = 12.33
1 2
>TMK 71450 CONE
1
D=BPFI
0
0
0 20 40 60 80 100
0 20 40 60 80 100
Frequency in Order
Frequency in Order
120
ANALYZE WAVEFORM
100
Acceleration in G-s

26-APR-00 16:09:13
80 (PkVue-HP 1000 Hz)
RMS = 11.73
60 PK(+) = 102.51
PK(-) = 13.21
40

Outer race defect !! 20
0
CRESTF= 8.74

-20
0 50 100 150 200 250 300 350 400
Time in mSecs
Field Balancing
R2V R1V
R2H R1H
R2A R1A

TURBINE
GEARBOX
GENERATOR

R4V R3V TOV
GOV R4H R3H TOH
GOH R4A R3A TOA
GOA
Generator Gearbox Gearbox Turbine
outboard outboard inboard inboard

Figure.1 Machine diagram of DGT-7
Equipment Description

! GE Gas turbine coupled with generator
! Capacity 25 MW
! Turbine speed = 5100 RPM
! Generator speed = 3600 RPM
! Configuration : Turbine – Gearbox – Generator
! Bearing type : journal bearing
Before & After Balancing
PGTD - Duri Gas Turbine 7
DGT-7 - PTS=GOV GOH
Max Amp
.53 after balancing DGT-7 -GOH
21-DEC-99 14:58
Plot
Scale
1.2
PK Velocity in In/Sec

before balancing DGT-7 -GOH
16-DEC-99 09:20

after balancing DGT-7 -GOV
21-DEC-99 15:01

0

before balancing DGT-7 -GOV
16-DEC-99 09:18
0 20 40 60 80 100 120
Frequency in kCPM
Keuntungan PdM

! Menghindari unschedule breakdown

! Menjamin Reliability & Availability

! Inventory control

! Menjaga kelangsungan proses produksi
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