Laser Alignment

Condition Monitoring

Productive Maintenance Technology

 PRÜFTECHNIK worldwide

7 PRÜFTECHNIK subsidiaries
Sole agents & Distributors in over 60 countries
 Pruftechnik in Indonesia

PT. Putranata Adi Mandiri – sole agent since 1989

Division Pruftechnik :
- Ir. Budi Winarto MM : Division Manager
- Ir. Yusrizal : Branch Manager - Pekanbaru
- Ir. Andi Sularto : Sales engineer – online CM products
- Ir. Hartono S. : Sales engineer – offline AL products
- Abdul Haris : Service/Sales eng. – Balancing/Alignment
- Pujo Sumakto : Service eng. – Balancing/Alignment
- Budi Trisman : Branch engineer - Balikpapan
- Anges van der Logt : Technical and sales support
 Pruftechnik in Indonesia

Already sold about : +300 CM and +100 AL products

Our customers
 Condition Monitoring
& Vibration Fundamentals
Penyebab dari breakdown mesin
 Apakah itu, Condition Monitoring ?

Monitoring Parameters Suara !

Apa lagi ?

Temperature Pressure
Output Speed
Phase Vibration
Motor Current Oil Quality & Condition
Casing Expansion Differential Expansion
Eccentricity Rotor position
Valve position
 Tipe Monitoring

Kerusakan pada mesin – Penyebab utama kerusakan

Unbalance Lubrication Blade Component Belt
Oil contam defects resonance vibrations
Mis- Gear mesh Stator Rotor- Bearing
alignment defect defect defect defect

Temperature
8 8 9 8 8 8 8 8 8 9
Suara
8 8 8 8 8 8 9 8 8 9
Oil Analysis
8 8 9 9 8 8 8 8 8 9
Vibration
9 9 9 9 9 9 9 9 9 9
 Data collection and trending

A Overall values are measured

on fixed time intervals
Trend curve

Recorded data are

displayed in a diagramm

t
1999 2001
 Level 1 / Level 2 strategy

Level 1: Level 2:
Monitoring of characteristic overall values Analysis of machine signals

v Unbalance
1. RPM

Alarm

Warning
Alarm spectrum

v
1999 2001 ‚Good conditions‘

Trend graph

Reference spectrum
 Signal analysis

v mm/s

v 0.45

0.40

0.35

0.30

0.25

0.20
v
0.15

0.10

0.05

0.00

0.05
f1 = 1x RPM Unbalance
0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000
t ms
t

T
f

Defect appears in (time)signal

f1 = 1/T

Time signal -> FFT spectrum

f Defect
Frequency analysis
1x RPM Unbalance
2x RPM Misalignment
.... ....

Machine fault diagnosis

Level 1 :
Machine Condition Monitoring Level 2: Machine Diagnosis
 Monitoring Decisions

• Is there something wrong with my machine?

• What is the cause of the problem?

• Can I still run my machine? correct this problem now?

 Overview of Product Categories
Level 1 Level 2 MAIN AUX CHARGESLEEP
VIBRO CORD
®

Measuring Spectrum 6.5. 97 14 54

2637 Hz 1.77 m/s²
15
m/s²

rms
10.5
m/s²

GO ON
FREEZE
CURSOR
COMENT
Hz 7312

SAVE
Balancing
&
MAIN

15
m/s²
AUX CHARGESLEEP

Measuring Spectrum
VIBRO CORD®
6.5. 97 14 54
2637 Hz 1.77 m/s²
MENU
SETUP

7
DISPLAY

8 9
MEASURE

CLR
Alignment
ON
rms
OFF 4 5 6
10.5
ENT m/s²

0 1 2 3 ENTER

Hz 7312
FREEZE COMENT SAVE
GO ON
CURSOR

mm
/s
RMS

No

M
Vibscanner SETUP DISPLAY MEASURE

MENU 7 8 9 CLR

ON
OFF 4 5 6

0 1 2 3 ENTER

Vibrotip Vibrocord

OMNITREND
Software Permalign

STATUS SENSOR SYSTEM

More
SIGNAL ChB
Alarm

Warn

SIGNAL ChB
ESC OK
Error

OK RS 232 C

50 40
50
20 100
VIB 8.xxx
60 30

VIBRONET®
10
70 20 mm/s (=100% =20mA)
7
+ 6 20mA=Alarm short 30 40
short
8 5 20 50
9
0
4
3
ALARM 10
100
60
70 %= ALARM
1 2
-15dB=Warn open
´90
30
80
40
open SIGNALMASTER
dBSV 20 50
WARN 10
100
60
70 %= WARN
´90 80
15 20 Power 15 20 Power
10 25 10 25
5 30 Delay Time 5 30 Delay Time
50 35 50 35
45 40
in sceonds 45 40
in sceonds

VIB 5.756I VIB 5.755 I

10 - 1000 Hz

SIGNAL
VIBREX®
Machine Condition Monitoring

Vibronet
Vibrex Signal Master

Fault Fault Fault

Detection Diagnostic Correction
 Off-line Maintenance Solutions
Vibrotip :
- Overall vibration measurement
- Shock pulse measurement
- Cavitation, temperature & speed

Vibscanner :
+ FFT spectrum up to 15 kHz
+ Adjustable envelope analysis
+ 2 plane balancing
+ Process parameters, manual input
Vibrocord :
+ FFT spectrum up to 40 kHz
+ Multispectrum, triggered time signals
+ Shaft orbit
+ Tracking
 Condition Monitoring Products Overview

Off-Line Condition Monitoring On-Line Condition Monitoring

• VIBROTIP® Multimeter • VIBREX®
• VIBROTIP® • VIBRONET®
• VIBSCANNER® • SIGNAL MASTER®
• VIBROCORD® STATUS SENSOR

More
SYSTEM

SIGNAL ChB
Alarm

Warn

SIGNAL ChB
ESC OK
Error

OK RS 232 C

50 40
50
20 100
VIB 8.xxx
60 30

VIBRONET®
10
70 20 mm/s (=100% =20mA)
7
+ 6 20mA=Alarm short 30 40
short
8 5 20 50
9
0
4
3
ALARM 10
100
60
70 %= ALARM
1 2
-15dB=Warn open
´90
30
80
40
open SIGNALMASTER
dBSV 20 50
WARN 10
100
60
70 %= WARN
´90 80
15 20 Power 15 20 Power
10 25 10 25
5 30 Delay Time 5 30 Delay Time
50 35 50 35
45 40
in sceonds 45 40
in sceonds

VIB 5.756I VIB 5.755 I

10 - 1000 Hz

VIBREX®

Vibronet
Machine Condition Monitoring

Vibrex

MAIN AUX CHARGE SLEEP

VIBRO CORD®
Measuring Spectrum 6.5. 97 14 54
2637 Hz 1.77 m/s²
15
m/s²

rms
10.5
m/s²

Hz 7312
FREEZE COMENT SAVE
GO ON
CURSOR

SIGNAL
SETUP DISPLAY MEASURE

MENU 7 8 9 CLR

ON
4 5 6
OFF
Signal Master
0 1 2 3 ENTER
 Vibration Monitoring Example (A)

Which is a Good Machine ?

Danger Danger
Limit Limit

Alert Alert
Limit Limit

Ref Ref

Machine ‘A’ Machine ‘B’

 Vibration Monitoring Example (B)

Which is a Good Machine ?

Vibration
Level
Danger Limit

Alert Limit
Machine ‘A’

Machine ‘B’

Time
 Vibration Monitoring Example (C)

Which is a Good Machine ?

Vibration
Level
Danger Limit

Alert Limit
Machine ‘A’

Machine ‘B’

Time
Our customers
 Products for Condition Monitoring

Offline Systems

Level 1

Level 1
and
VIBROTIP Level 2
VIBSCANNER VIBROCORD

Online Systems

VIBREX
VIBRONET Signalmaster
 Types of Maintenance

1. Run to Break Maintenance

2. Preventive Maintenance
(Time based Maintenance)

3. Predictive Maintenance
(On- Condition Monitoring)
Failure
Machine condition

Danger Level

ing
nd
Tre
Alert Level

Lead time
before failure
Running Time
 Types of Monitoring

a) Slow Deterioration
Breakdown

Rate of Alarm
Deterioration

Warning
On-Line Intermittent Monitoring MASTER No. STRING No. MUX No. SENSOR No. SENSOR

More

Alarm

Warn
SYSTEM

SIGNAL

RS 232 C

Error Rx OK

OK Tx OK

RESET CONFIRM DIAGNOSE

s1 s1 s1 s1 s1 s1 Master No.

String No.
Mux No.
Sensor No.
time
®
Mux Mux VIBRONET
Mux Mux Mux Mux MASTER VIB 8.300
Master Mux Mux Mux Mux

Off-Line Intermittent Monitoring ENT

mm/
IN
A
M

Measuring Spectrum

s
rm

.5

²
0
1

/s
m
5
1

²
/s
m
X
U
A
E
G
R
A
H
C

P
E
L
S

VIBRO

²
/s
.m
z1
H
7
3
6
2
4
1
7
9
.5
6
CORD ®

s1 s1 s1
s
2
1
3
z7
H

RMS
GO ONFREEZE
CURSOR COMENTSAVE

No

SETUP DISPLAY MEASURE

MENU 7 8 9 CLR

ON
4 5 6
OFF

0 1 2 3 ENTER

b) Fast Deterioration
break down
Rate of Alarm
Deterioration

On-Line Continous Monitoring 50

60
70
7
8
9
0
1
+

dBSV
40
30
20
6
45
32
20mA=Alarm
ALARM

-15dB=Warn
WARN
short

open
50
20
10
30
20
10
100
´90
30
20
10
100
100

40
50
mm/s(=100% =20mA)

60 %= ALARM
70
80
40
50
60 %= WARN
70
short

open

Warning
Power ´90 80 Power
15 20 15 20
10
5 30 Delay Time
25 10
5 25 Delay Time
30
50 35 in sceonds 50 35 in sceonds
45 40 45 40
VIB 5.756I VIB 5.755 I
10 - 1000 Hz

®
VIBREX
Machine Condition Monitoring

time
 Measurement Interval and Condition Deterioration Rate

Duration - analogue level measurement 50

60
70
7
8
9
0
1

15
+

dB
SV
40
30
20
6
5
4
3
2

20
20mA=Alarm
ALARM

-15dB=Warn
WARN
short

open

Power
50
20
10

30
20
10
100
´90
30
20
10
100
´90
15
100

40
50
70
80
40
50
mm/s(=100% =20mA)

60%= ALARM

60%= WARN
70
80
20
short

open

Power
10 25 10 25
30 Delay Time 30 Delay Time

s
5 5
50 35 in seconds 50 35 in seconds

VIBREX
45 40 45 40

VIB 5.756I VIB 5.755 I

10 - 1000 Hz

®
VIBREX
Machine Condition Monitoring

Duration - measurement value sampling MASTER No. STRING No. MUX No. SENSOR No. SENSOR

More

Alarm

Warn
SYSTEM

SIGNAL

VIBRONET
RS 232 C

s s s s s s
Error Rx OK

OK Tx OK

RESET CONFIRM DIAGNOSE

Master
Master No.

Mux
Mux
Mux
String No.

Mux
Mux
Mux
Mux No.
Sensor No.

Mux
Mux
Mux
Mux
VIBRONET
MASTER
®

VIB 8.300
Online

MASTER No. STRING No. MUX No. SENSOR No. SENSOR SYSTEM
More

Alarm

Warn SIGNAL

Duration - measurement value sampling multiplexed Error

RS 232 C

Rx OK

VIBRONET
OK Tx OK

RESET CONFIRM DIAGNOSE

Quartz
Quartz
s1 s2 s3 s1 s2 Master No.
String No.

Mux
Mux
Mux
Mux
Mux No.
Sensor No.

Mux Mux
VIBRONET
MASTER
®

VIB 8.300
s1 Standalone
normal operation
Master Mux Mux Mux Mux

20 minutes = 1st cycle 2nd cycle = 20 minutes

Data collecting after warning/alarm

ENT

1 No
mm/s
RMS

VIBROTIP /
May
s1 s5 s37 s1 M

s1 VIBSCANNER
1 day 1 week trending
alarm occurs

Data collecting and trending of results

ENT

No
mm/s
RMS

VIBROTIP /
July s1 s2 s67 s1 M

s1 VIBSCANNER
1 day 1 month trending normal
operation

Measurement once in a few months ENT

mm/
s
RMS
ENT

mm/s
RMS

1997 VIBROTIP /
No No

s1 s1 M M
s1
1 year GREENTIP
Measurement Interval for Off-line Monitoring
 Setting of Alarms

Setting of Alarms
D
C
B
A

• Normally set relative to a baseline. Recommended to be higher by 25% of the

upper limit of zone B. If baseline is low, the Alarm may be below zone C

• Where there is no baseline, based on experience and after a period time

establish a steady state baseline.

• Should not exceed 1.25 times the upper limit of zone B

 ISO 10816-3

11 0.44

7.1 0.28

4,5 0.18

3,5 0.11

2,8 0.07

2,3 0.04

1.4 0.03

0,71 0.02

mm/s rms inch/s rms

rigid flexible rigid flexible rigid flexible rigid flexible Foundation
pumps > 15 kW medium sized machines large machines
radial, axial, mixed flow 15 kW < P ≤ 300 kW 300 kW < P < 50 MW Machine Type
integrated driver external driver motors motors
160 mm ≤ H < 315 mm 315 mm ≤ H
Group 4 Group 3 Group 2 Group 1 Group
A newly commissioned
B unrestricted long-term operation
C restricted long-term operation
D vibration causes damage
 Significant Change in Vibration
ISO limits
mm/s
... not exceed 1.25x upper limit of zone C ie. 5.75 mm/s

4.5
... not exceed 1.25x upper limit of zone B ie. 3.5 mm/s
1.6x
2.8 Example B
2.6 ref. is high

2x
1.4

25% of 2.8 mm/s = 0.7 + 0.2 = 0.9

Example A
0.2 “new” ref. very low

Time
 Level 1 and 2 Philosophy
Time Signal
v 80
mm/s
40

-40

-80
0 100 200 t (ms)

Trending (Level 1) Fast Fourier Transform (Level 2)

mm/s
mm/s
Alarm

C Short-term operation allowed

Warning

B Long-term operation allowed

Pre-Warning

A Newly commissioned

Frequency (Hz)
Time
 Machine Vibration Signal and FFT

Time Signal

+ + + ...

A2, T2, A3, T3, f3

A1, T1, f1
f2
 Information in FFT Spectrum
mm/s
Random Frequency
Discrete Frequency Range
Machine Range
Vibration Pass Frequencies Rolling Bearing

1x 2x 3x Gear Mesh

Blade Pass

1 kHz 3 kHz 5 kHz 36 kHz Frequency (Hz)

FFT ANALYSIS & DIAGNOSTIC

Productive Maintenance Technology

 Typical Signal Forms

Signal Waveformx Time Signal A

Spectrum Practical Application

a) Wave • Unbalance
Time
f f (Hz)
T
A
x
b) Rectangular • mechanical
Vibration looseness
Time f 3xf 5xf etc. f (Hz)
T
x A
c)Shock pulses • Rotor Rub
with repeat
frequency Time f 2xf etc. f (Hz)
T

x A
• Eccentricity
d)Amplitude of Gears
modulated (generalproblem)
Sine Waves Time -f2 f1 +f2 f (Hz)

T2 T1
x 2 1
A
• Cracked /Broken
Tooth
Time (local problem)
...-2xf2 -f2 f1 +f2+2xf
2 ... f (Hz)

T2 T1
 Machine Vibration Example 1

Unbalance Misalignment

fn fn

Machine spectrum:
Machine spectrum:
v v
[mm/s] [mm/s]

fn f [Hz] fn 2xfn f [Hz]

Symptom : High Amplitude at Symptom : Increased amplitude visible at fn and/ or 2x

fn
RPM [Rev/min]
• Fundamental Freq. Fn = • First and Second order of rotor frequency
60
• Evaluation criteria:ISO 10816-3 • Radial : parallel misalignment
axial : angular misalignment
 Machine Vibration Example 2
Gear mesh faults Cracked / Broken Tooth

fn2
fn1 z2 fn1

z1 z1 z2
fn2

Machine Spectrum: a Machine Spectrum:

a mm/s²
mm/s²

fz 2xfz 3xfz f (Hz)

fz 2xfz 3xfz 4xfz f (Hz)

Symptom : Harmonics of fz Symptom : Side bands with fn

•visible
Gear mesh frequency fz = fn1. Z1
• = fn2. Z2
Z, Z2 : number of gear teeth
• fn1 : rotational frequency driven shaft
• Side band distance fn is the fundamental frequency
of the defective gear (broken tooth)
• many side bands around fz gear mesh with slowly
decreased amplitudes
 Machine Vibration Example 3

Bad foundation Turbulences

s=9

fn fn

x=3
(e.g. fixture for
bearing)
v Machine spectrum: v
mm/s mm/s Machine spectrum:

fn 2xfn 3xfn 4xfn f (Hz) fn fBPF x ∗ fBPF f (Hz)

Symptom : Harmonics of fn are visible Symptom : Blade pass frequency fBPF

RPM [Rev/min]
• fundamental freq. f n = • Blade pass frequency fBPF = fn . s
60
• Higher orders x*fBPF = fn . s . x
• Root Cause: Resonance or Instability
• s: number of blades
• x: number of disturbance locations
 Machine Vibration Example 4
Resonance b) Bode diagram in coast down
v
mm/s

fn Resonance step-up

nRes. n in Rev/min
ϕ
a) Machine spectrum (°)
V Phase shift of 180°
mm/s

nRes. n in Rev/min
c) Waterfall diagram velocity
spectra in coast down

v fn 2xfn 3xfn
fn 2xfn 3xfn 4xfn 5xfn f (Hz) mm/s
Resonance step-up
Symptom : Harmonics of fn visible
preferably uneven multiples
RPM [Rev/min]
• fundamental freq. fn =
60
Natural frequency f (Hz)
n (Rev/min)
 Types of Rolling Bearing Damages (1)

Damages types/ Causes wear

1 Wear - lifetime expired

- overloading
- assembly / shock pulses
manufacturing error
- greasing deficiency
wear

shock pulses
- lifetime expired
2 Damage to - bearing overloaded
rolling track - bearing under-loaded damage
- greasing deficiency
envelope

high variation in
- Damaged rolling track shock pulse levels
3 Contaminated - damaged sealing and defect
frequencies
lubricant - contaminated
lubricant
 Types of Rolling Bearing Damages (2)

Damages types/ Causes

4 Greasing - greasing deficiency

- Under-loading
deficiency
temperature
rises very late

shock pulses
air gap
- assembly error
5 Unround - manufacturing defect damage
frequencies
deformation of in shaft or bearing in envelope
bearing race housing

dirt

- in bearing housing
6 Jammed loose (sliding fit)
bearing - mis-calculation of
housing design fixed bearing loose bearing
high vibration
increasing bearing
temperature
 Types of Rolling Bearing Damages (3)

Damages types/ Causes

- maintenance error
7 Excessive (quantity, interval) -
Large temperature
Greasing - defective grease Increase after greasing
grease drain

8 Installed at an - assembly error

Whistling
angle Bearing noise

- assembly error at
9 Rolling bearing bearing with taper sleeve Large temperature
increase after greasing
clearance too small - shaft diameter to large to deficiency
inner race diameter
- got hot by friction after
greasing deficiency
 Types of Rolling Bearing Measurement Methods

k (t) Method ?

Spike Energy Value

?
BCU Value
Kurtosis Factor
gSE - Factor
SEE Factor
Acceleration Crest Factor

Shock pulse measurement

• Normalising
• Alarm Levels
• Gradient of trend development
is necessary for evaluation of rolling
bearing condition
 Normalising of Shock Values
dBsv
dBsv
90 90
ideal
measurement
measurement location
with signal damping
dBn

dBm

dBm

dBc

dBi dBc
0

0 dBia

-9 -9
dBsv = absolute shock pulse value dBn = normalised shock pulse value

dB i = initial value
dBi = (f(φ, rpm) dB ia = adjusted initial value dBia = (f(φ, rpm)
• Basic normalised shock pulse value • Actual measurement location
• function of RPM and shaft diameter dBn = dBsv – dBi dBn = dBsv – dBia
(not at load zone)
• influencing factors like load condition
dBia = dBi + dBa
lubrication and bearing type
Where dBa(dB) is
the adjusting value
Normalising of Shock Pulse Measurements