CASE STUDIES

RIZFIAN RAMADHAN – A LIFE LONG LEARNER

Optimizing Asset Reliability and Preventing Failures
Prepared by Rizfian Ramadhan
Certified Vibration Analysis Category 2
Professional Engineer and Bachelor of Mechanical Engineering
rizfian1927@[Link] +6281293261800 and +6282312149791

Introduction:
In today's industrial landscape, unplanned downtime and equipment failures lead to significant financial losses and
operational inefficiencies. Predictive maintenance (PdM) leverages data analytics, condition monitoring, and machine
learning to prevent failures before they occur, ensuring optimal performance and cost savings. This document presents case
studies and success stories based on experience as a maintenance practitioner and condition monitoring engineer,
highlighting how predictive maintenance strategies have improved asset reliability, reduced maintenance costs, and
increased operational efficiency in the power generation, oil and gas industries.

Key Highlights:
Condition Monitoring: Continuously tracks machine health using sensors and condition monitoring techniques.
Reduced Downtime: Detects early warning signs to prevent unexpected equipment failures.
Cost Savings: Lowers maintenance costs by addressing issues before they become critical.
Extended Equipment Lifespan: Prevents functional failures and optimizing asset performance.
Data-Driven Insights: Uses historical data and trends to improve maintenance decision-making.
Multi-Technique Approach: Combines vibration analysis, thermography, and oil analysis for comprehensive monitoring.
Case Study
Structural Looseness
Date of completion – March 25th, 2025

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration

Equipment : Seal Oil Pump Refrigerant Compressor A No.1

Area : DPCU
Tag Number : P-2801A-1
Driver : Motor
Manufacturer : Nanyang Ex Protection Weite Motor
Driver RPM : 1665
Amphere : 1.52 A P1
Power Rate : 0.7kW
Bearing Driver NDE : 6204-2Z
Bearing Driver DE : 6204-2Z
Transmission : Coupling (Jaw)
Driven : Gear Pump
Manufacturer : Eckerle
Driven RPM : 1665
Bearing Driven DE : Bushing Mechanical Seal Oil Pump
Bearing Driven NDE : Bushing
Support Type : Rigid
Driver Standard : ISO 10816-3
Driven Standard : ISO 10816-3

CASE STUDY – STRUCTURAL LOOSENESS

Equipment Configuration

The main equipment

The equipment

CASE STUDY – STRUCTURAL LOOSENESS

History, Finding and Analysis
✓ This problem existed when the equipment was first started up.
✓ This equipment is not a critical because have a redundancy and the function just for
circulated lube oil to mechanical seal of refrigerant compressor.
✓ The spectrum shows a dominant peak 60Hz or 1xTS of main equipment, it is transmitted by
the main equipment that caused structural problem. (See picture of equipment configuration)
✓ During operation, the vibration of this equipment is relatively stable within danger level.
✓ Thermal image pattern shows normal condition both motor and pump.

Recommendation
✓ It is necessary to make the structure more rigid than now to separate and or reduce the
vibration from the main equipment.
✓ Ensured the vibration of main equipment always in normal level.
✓ Close monitoring to avoid the secondary failure.

CASE STUDY – STRUCTURAL LOOSENESS

Vibration Spectrum and Waveform
v op [inch/s] DPCU A\Seal Oil Pump No.1\Motor NDE Axial\[Link] 06/01/2025 [Link] v op [inch/s] DPCU A\Seal Oil Pump No.1\Pump NDE Axial\[Link] 06/01/2025 [Link]
M M
0,55 0,40
0,50
0,35
0,45
0,40 0,30
0,35 RPM : 1665 (27,75Hz) 0,25 RPM : 1665 (27,75Hz)
0,30 M(x) : 60,00 Hz (2,16 Orders) M(x) : 60,00 Hz (2,16 Orders)
M(y) : 0,47 inch/s 0,20 M(y) : 0,36 inch/s
0,25
0,20 0,15
0,15
0,10
M1A 0,10 P2A
0,05
0,05
0,00 0,00
0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600
f [Hz] f [Hz]
v [inch/s] DPCU A\Seal Oil Pump No.1\Motor NDE Axial\1005 Time Waveform 06/01/2025 [Link] v [inch/s] DPCU A\Seal Oil Pump No.1\Pump NDE Axial\1005 Time Waveform 06/01/2025 [Link]
0,6 0,5
RPM : 1665 (27,75Hz) RPM : 1665 (27,75Hz)
0,4
0,4 0,3
0,2
0,2
0,1
0,0
0,0
-0,1
-0,2
-0,2
-0,3
-0,4 -0,4
-0,5

0 20 40 60 80 100 120 140 160 180 200 220 240 0 20 40 60 80 100 120 140 160 180 200 220 240
t [ms] t [ms]

The vibrations spectrum shows that the dominant peak is 60Hz (1xTS of main
equipment) with sinusoidal waveform pattern at axial directions both motor and pump.
CASE STUDY – STRUCTURAL LOOSENESS
Corrective Actions and Verification

The new bolts The existing bolts

Performed replace the bolts structure with the new and bigger ones.
CASE STUDY – STRUCTURAL LOOSENESS
Corrective Actions and Verification

Description Point Unit 15-Jul-24 11-Aug-24 11-Sep-24 08-Oct-24 07-Nov-24 06-Dec-24 06-Jan-25 25-Mar-25 26-Mar-25
NDE M1H IPS RMS 0,124 0,161 0,139 0,042 0,028 0,05 0,06 0,064 0,096
NDE M1V IPS RMS 0,266 0,212 0,199 0,308 0,159 0,162 0,17 0,126 0,125
NDE M1A IPS RMS 0,43 0,417 0,399 0,441 0,351 0,332 0,34 0,053 0,058
Motor
DE M2H IPS RMS 0,091 0,155 0,109 0,067 0,028 0,053 0,07 0,063 0,099
DE M2V IPS RMS 0,119 0,07 0,071 0,115 0,073 0,084 0,07 0,105 0,121
DE M2A IPS RMS 0,26 0,287 0,314 0,38 0,215 0,233 0,27 0,052 0,059
DE P1H IPS RMS 0,14 0,186 0,134 0,092 0,059 0,064 0,11 0,097 0,109
DE P1V IPS RMS 0,104 0,11 0,103 0,115 0,098 0,117 0,15 0,143 0,175
Pump NDE P2H IPS RMS 0,147 0,225 0,184 0,08 0,079 0,09 0,07 0,07 0,082
NDE P2V IPS RMS 0,12 0,168 0,169 0,21 0,178 0,19 0,22 0,161 0,172
NDE P2A IPS RMS 0,24 0,286 0,292 0,357 0,209 0,253 0,26 0,043 0,05

The table shows the overall vibration values before and after replaced all bolts of structure.

CASE STUDY – STRUCTURAL LOOSENESS

Vibration Trending

The trends show that the pump

vibrations were significantly decreased.
Electric Motor Gear Pump

The trends show that the motor

vibrations were significantly decreased.

CASE STUDY – STRUCTURAL LOOSENESS

Conclusion and Lesson Learned
✓ The root cause of this problem is structural looseness.
✓ Performed bolts structures replacement is successfully decreased the vibration values.
✓ It is necessary to add bolts in new places to reduce vibration to the maximum as seen in the
picture below.

Recommended places for new bolts to be installed

CASE STUDY – STRUCTURAL LOOSENESS

 Terima Kasih – Paldies
[Link]

CASE STUDY – STRUCTURAL LOOSENESS

Case Study
Bearing Damaged
Date of completion – February 27th, 2025

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration
Equipment : Inlet Cooler Fan No.2 Fan
Area : Inlet Cooler
Tag Number : EM-1501-02
Driver : Motor
Manufacturer : ABB
Driver RPM : 1740 V-Belt Axial
Amphere : 10.7 A
Power Rate : 6.3 KW
M2
Bearing Driver NDE : 6208-2Z/C3
Y-Axis
Bearing Driver DE : 6208-2Z/C3 Motor

Transmission : Timing Belt 8GTV-1000-12

M1 X-Axis
Driven : Fan (#3)
Manufacturer : Moorefans
Driven RPM
Bearing Driven DE
:
:
Unknown
Pillow Block
Inlet Cooler Fan 2
Bearing Driven NDE : Pillow Block
Support Type : Flexible
Driver Standard : ISO 10816-3
Driven Standard : ISO 10816-3

CASE STUDY – BEARING DAMAGED

History, Finding and Analysis
✓ The equipment function is to reduce the temperature entering the production separator.
✓ The high vibration has existed when the equipment commissioned.
✓ The vibration spectrum showed dominant peak 1xTS in the X-Axis direction both NDE and DE
motor, that is indication of structural problem because this also occurred in similar equipment.
✓ Therefore, as a PdM Engineer, we need to monitor if there are any anomalies in the equipment
with a monthly frequency.
✓ On February 05th, 2025, we had found anomaly in the equipment that suspected as bearing
defect with noise.
✓ The spectrum shows dominant peak 451Hz (15.5xTS) with impact and noise floor pattern that
we did not find in previous measurements.

Recommendation
✓ Please replace bearing motor immediately.
✓ For structural issues it is necessary to conduct advanced structural analysis.

CASE STUDY – BEARING DAMAGED

Vibration Spectrum and Waveform

M2Y

The vibrations spectrum shows impact and noise floor pattern on the
velocity spectrum, the pattern has changed in just one month.

CASE STUDY – BEARING DAMAGED

Bearing Conditions

DE bearing were found to be damaged as the lubricant had become contaminated and
hardened. Possibly due to water ingress through the lip seal as the equipment is vertical.

CASE STUDY – BEARING DAMAGED

Corrective Actions and Verification
✓ The DE also NDE bearings has been replaced with the new ones and the spectrum
pattern has changed (451Hz does not appear anymore) – see the evidence.

CASE STUDY – BEARING DAMAGED

Conclusion and Lesson Learned
✓ The root cause of this problem is bearing damaged due to contaminated lubricant.
✓ Bearing replacement is successfully eliminated the dominant peak of 451Hz or 15.5xTS and
noise floor pattern in the spectrum .
✓ For structural issues it is necessary to conduct advanced structural analysis using
operation deflection shapes method or motion camera amplification.
✓ Ensure that the bearing parts are available on location.
✓ It is important to conduct daily patrols to visually determine the condition of the
equipment by plant operators.

CASE STUDY – BEARING DAMAGED

 Terima Kasih – Tänu
[Link]

CASE STUDY – BEARING DAMAGED

Case Study
Belt Worn Out
Date of completion – January 03rd, 2025

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration

Equipment : IPC Cooling Fan No.2

Area : GTC-A
Tag Number : EM-1802A-01B
Driver : Motor
Manufacturer : ABB
Driver RPM : 1770
Amphere : 24.2 A
Power Rate : 15 kW
Bearing Driver NDE : SKF 6309/C3
Bearing Driver DE : SKF 6309/C3
Transmission : Timing Belt 8GTV-1600-21
Driven : Fan (#4)
Manufacturer : Moorefans
Driven RPM : Unknown
Bearing Driven DE : Pillow Block
Bearing Driven NDE : Pillow Block
Support Type : Flexible Gas Cooler Fan
Driver Standard : ISO 10816-3
Driven Standard : ISO 10816-3

CASE STUDY – BELT WORN OUT

History, Finding and Analysis
✓ The vibration status is Acceptable based on ISO 28016-3.
✓ The highest vibration value is 0.09 IPS RMS at DE Motor axial (M2A) direction.
✓ The spectrum on motor shows random peak under 1xTS and noise floor pattern on low
frequency (up to 100Hz), possibility affected by the fan wind flow and it‘s normal. – See the
waterfall spectrum pattern
✓ The spectrum on DE motor shows dominant peak 1xTS, 339Hz, 627Hz, and increasing noise
floor pattern, indication of belt worn out problem (synchron timing belt type).
✓ Thermal image pattern at motor, belt, and fan bearing shows normal condition.
✓ Two days after taken the vibration data, noise appear on this equipment.

Recommendation
✓ Please replace the belt immediately to avoid GTC shutdown due to high temperature.
✓ Add the belt dressing to prevent from wear.
✓ Continue monitoring as per schedule.
CASE STUDY – BELT WORN OUT
Vibration Spectrum
v rms [inch/s] GAS COOLER GTC-A\IPC Cooler Fan No.2\DE X-Axis\[Link] 1/3/2025 [Link] AM v rms [inch/s] GAS COOLER GTC-A\IPC Cooler Fan No.2\DE Y-Axis\[Link] 1/3/2025 [Link] AM

0.024 0.034
0.032
0.022
0.030
0.020 0.028
0.026
0.018
0.024
RPM : 1770 (29.50Hz) RPM : 1770 (29.50Hz)
0.016 0.022

0.014 0.020
0.018
0.012
0.016
0.010 0.014
0.012
0.008
0.010
0.006 0.008

0.004 0.006
11/6/2024 0.004 11/6/2024
0.002
12/4/2024 0.002 12/4/2024
0.000 1/3/2025 0.000 1/3/2025
0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600
f [Hz] f [Hz]

DE Motor X-Axis DE Motor Y-Axis (Belt Direction)

CASE STUDY – BELT WORN OUT
Vibration Spectrum
v rms [inch/s] GAS COOLER GTC-A\IPC Cooler Fan No.2\DE X-Axis\[Link] 1/3/2025 [Link] AM

0.024

0.022

✓ The spectrum of the last 3 measurements

0.020

0.018

0.016
RPM : 1770 (29.50Hz) show an increase in pattern and noise floor
0.014
in the medium frequency.
0.012

0.010

0.008

0.006

0.004
11/6/2024
0.002
12/4/2024
0.000 1/3/2025
0 200 400 600 800 1000 1200 1400 1600
f [Hz]

DE Motor Axial
CASE STUDY – BELT WORN OUT
Corrective Actions and Verification
✓ Found half of the belt teeth are chipped.
✓ Replaced the belt with a new ones.
✓ Now, the equipment running smoothly without noise.

Worn out Belt New Belt

CASE STUDY – BELT WORN OUT
Vibration Trending

The trends show that the motor vibrations were stable within acceptable level.

CASE STUDY – BELT WORN OUT

Conclusion and Lesson Learned
✓ The root cause of this problem is belt worn out due to aging.
✓ Belt replacement is the best option to maintain the performance of equipment.
✓ The overall vibration cannot be used as a reference to suspect this problem.
✓ The vibration spectrum pattern is strong enough to suspect this problem.
✓ Create a schedule for preventive maintenance program on CMMS to perform visual check,
belt dressing, and inspection.
✓ As a critical equipment, the spare part must be available in the store.
✓ Suggest to plant operator for walk around in this area to check the anomaly for noise from
the equipment.

CASE STUDY – BELT WORN OUT

 Terima Kasih – Cảm ơn
[Link]

CASE STUDY – BELT WORN OUT

Case Study
Uneven Wear
Date of completion – November 07th, 2024

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration

Equipment : Refrigerant Compressor B

Area : DPCU
Tag Number : K-2801B
Driver : Motor
Manufacturer : ABB
Driver RPM : 3582
Amphere : 397 A
Power Rate : 280 kW
Bearing Driver NDE : 6319/C3
Bearing Driver DE : 6319/C3
Transmission : Coupling (Disc)
Driven : Screw Compressor
Manufacturer : Yantai Moon
Driven RPM
Bearing Driven DE
: 3582
: NSK 7216BEA (2ea/ Shaft); Journal Bearing
Refrigerant Compressor
Bearing Driven NDE : Journal Bearing
Support Type : Rigid
Driver Standard : ISO 10816-3
Driven Standard : ISO 10816-3

CASE STUDY – UNEVEN WEAR

Finding and Analysis
✓ The status of the equipment has just been repaired in the workshop after it got stuck.
✓ The lack of users of this equipment in Indonesia means that there are no experts who can
lead the overhaul process properly.
✓ The absence of proper reference documents that led to assembly errors included additional
housings for thrust bearings and springs for sliding pistons.
✓ Technically, this case study was caused by a lack of documents and human error.
✓ when the equipment is started, noise is heard at 30% load and the vibration spectrum
indicates a rotating looseness problem (excessive wear).

Recommendation
✓ The equipment is not allowed to run.
✓ Perform re-overhauled with the right people and procedures.
✓ Check lube oil filter and oil conditions to prevent from contaminated wear, replaced if
necessary.

CASE STUDY – UNEVEN WEAR

Vibration Spectrum
v op [inch/s] DPCU B\Refrigerant Compressor B\Comp DE Male Horizontal\[Link] 07/11/2024 [Link]v op [inch/s] DPCU B\Refrigerant Compressor B\Comp DE Female Horizontal\[Link] 07/11/2024 [Link]
M M
0,060 0,100
0,095 (179,00 / 0,08)
0,055 (299,00 / 0,05)
0,090
(120,00 / 0,08)
0,050 0,085
0,080
0,045 0,075
0,070
0,040
0,065 (299,00 / 0,06)
0,035
C1H RPM : 3582 (59,70Hz)
0,060
0,055
C2H RPM : 3582 (59,70Hz)
(50,00 / 0,03) M(x) : 120,00 Hz (2,01 Orders) M(x) : 60,00 Hz (1,01 Orders)
0,030 M(y) : 0,04 inch/s 0,050 M(y) : 0,03 inch/s
0,045 (598,00 / 0,04)
0,025
0,040 (60,00 / 0,03)

0,020 0,035
0,030
0,015 0,025
0,020
0,010
0,015

0,005 0,010
0,005
0,000 0,000
0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600
f [Hz] f [Hz]

CASE STUDY – UNEVEN WEAR

Vibration Spectrum
v op [inch/s] DPCU B\Refrigerant Compressor B\Comp DE Male Vertical\[Link] 07/11/2024 [Link] v op [inch/s] DPCU B\Refrigerant Compressor B\Comp DE Female Vertical\[Link] 07/11/2024 [Link]
M M
0,22
0,044
0,21
0,042
(50,00 / 0,04) 0,20 (179,00 / 0,19)
0,040
0,19
0,038
0,18
0,036
0,17
0,034
0,16
0,032
0,15
0,030
0,14
0,028

C1V C2V
0,13
0,026
RPM : 3582 (59,70Hz) 0,12 RPM : 3582 (59,70Hz)
0,024 M(x) : 50,00 Hz (0,84 Orders) M(x) : 60,00 Hz (1,01 Orders)
M(y) : 0,04 inch/s 0,11 M(y) : 0,04 inch/s
0,022
(60,00 / 0,02) 0,10
0,020
0,018 0,09
(299,00 / 0,02)
0,016 0,08

0,014 0,07

0,012 0,06
(598,00 / 0,01) (60,00 / 0,04) (299,00 / 0,03) (598,00 / 0,03)
0,010 0,05
0,008 (898,00 / 0,01) 0,04 (837,00 / 0,03)
0,006 0,03
0,004 0,02
0,002 0,01
0,000 0,00

0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600
f [Hz] f [Hz]

The spectrum shows dominant peaks that are not the forcing frequencies of the internal parts of the
compressor, such as 50Hz and 179Hz.
CASE STUDY – UNEVEN WEAR
Vibration Spectrum
v op [inch/s] DPCU B\Refrigerant Compressor B\Comp DE Male Axial\[Link] 07/11/2024 [Link] v op [inch/s] DPCU B\Refrigerant Compressor B\Comp DE Female Axial\[Link] 09/11/2024 [Link]
M M
0,30
0,44
0,28 0,42
(179,00 / 0,38)
0,40
0,26
0,38
0,24 0,36
0,34
0,22
0,32
0,20 0,30
RPM : 3582 (59,70Hz) 0,28 RPM : 3582 (59,70Hz)
0,18

0,16
C1A M(x) : 60,00 Hz (1,01 Orders)
M(y) : 0,07 inch/s 0,26
0,24
C2A M(x) : 60,00 Hz (1,01 Orders)
M(y) : 0,06 inch/s

0,22
0,14
0,20
0,12 0,18

0,10 0,16
0,14
(299,00 / 0,08)
0,08 0,12

0,06 0,10
0,08
0,04 0,06

0,02 0,04
0,02
0,00 0,00
0 200 400 600 800 1000 1200 1400 1600
f [Hz] 0 200 400 600 800 1000 1200 1400 1600
f [Hz]

The vibrations spectrum shows impact pattern with noise floor, indicates rotating looseness and
uneven wear occurred in the compressor.
CASE STUDY – UNEVEN WEAR
Compressor Conditions

Found uneven wear at screw, casing, and journal bearings of compressor.

Conclusion and Lesson Learned
✓ The root cause of this problem is rotating looseness and uneven wear due to faulty
assembly processes.
✓ Uneven wear can cause unknown peaks to appear in the spectrum.
✓ The casing overall vibration can not be a reference in determining the severity due to the
thickness of the casing.
✓ Lube oil sampling and analysis can be the best option for early detection of wear on
compressor.

CASE STUDY – UNEVEN WEAR

 Terima Kasih – Ačiū
[Link]

CASE STUDY – UNEVEN WEAR

Case Study
Loose Stator Coils
Date of completion – October 19th, 2024

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration

Equipment : Lube Oil Cooler Fan DPCU A

Area : DPCU
Tag Number : EM-2805A
Driver : Motor
Manufacturer : Nanyang Ex Protection Weite Motor
Driver RPM : 1450
Amphere : 8.37
Power Rate : 4 kW
Bearing Driver NDE : Unknown
Bearing Driver DE : Unknown
Transmission : Direct Shaft
Driven : Fan (#4)
Manufacturer : Unknown
Driven RPM : 1450
Bearing Driven DE : N/A Lube Oil Cooler Fan
Bearing Driven NDE : N/A
Support Type : Flexible
Driver Standard : ISO 10816-3
Driven Standard : ISO 10816-3

CASE STUDY – LOOSE STATOR COILS

History, Finding and Analysis
✓ On August 13th, 2024, the vibration of this equipment reached hi-hi alarm after fan replacement
with the other unit (swap from unit B to A), but the axial still in good level.
✓ The spectrum shows dominant 1xTS, that indication of structural and or unbalance problem.
✓ The support has installed on motor to reduce the vibration value due to structural problem but
still unsuccessful (only reduce 30%).
✓ The condition of fan was re-checked and found that the axial hub is out of tolerance. Therefore,
shim added to make it in tolerance.
✓ The vibration status on motor is acceptable (close with alarm level) after corrective action added
shim at fan hub.
✓ The last measurement shows the highest value is 0.165 IPS RMS at NDE motor X-Axes direction.
✓ The spectrum at axial direction shows 1xTS and harmonics also 35xTS with sideband 1xTS,
indication of electrical problem (Coil Pass Frequency) and bearing defect.
✓ Thermal image pattern on motor shows normal condition.
Recommendation
✓ Need to check the condition of motor if the vibration value increased.
CASE STUDY – LOOSE STATOR COILS
Vibration Spectrum and Waveform

M1A M1A M1A

Aug 24 Sep 24 Oct 24

The vibrations spectrum shows impact pattern at enveloping and velocity spectrum.
CASE STUDY – LOOSE STATOR COILS
Motor Conditions
Inspection was performed by Mr. Hermawan (VA Cat 2)

✓ Unfortunately, the motor is suddenly stop (10 days after giving the recommendation).
✓ Megger test shows that the motor is short-circuited.
✓ The motor stator conditions shows lot of carbon presence on winding.
✓ The NDE bearing housing also shows friction conditions in the axial direction.
CASE STUDY – LOOSE STATOR COILS
Corrective Actions and Verification

Currently, the electric motor has been

disassembled for repair at the workshop.

CASE STUDY – LOOSE STATOR COILS

Overall Vibration and Trending
Description Point Unit 14-Aug-24 14-Aug-23 16-Aug-23 29-Aug-24 31-Aug-24 11-Sep-24 9-Oct-24
NDE M1X IPS RMS 0.03 0.42 0.289 0.331 0.198 0.172 0.165
Motor NDE M1Y IPS RMS 0.032 0.483 0.256 0.337 0.2 0.163 0.155
NDE M1A IPS RMS 0.017 0.096 0.076 0.099 0.084 0.06 0.107

The radial vibration trend shows a relatively stable trend, but the axial vibration
tends to increase but not too high if compared to the previous measurement.
CASE STUDY – LOOSE STATOR COILS
Conclusion and Lesson Learned
✓ The root cause of this problem is loose stator coils (electrical problem).
✓ Vibration technology can capture this problem very well.
✓ Need to performed check the motor conditions immediately if the pattern appear.
✓ The axial force on motor might be affected from axial flow of air.

✓ The thermal image pattern can not capture this

problem as good as vibration.

CASE STUDY – LOOSE STATOR COILS

Terima Kasih – Tack så mycket
[Link]

CASE STUDY – LOOSE STATOR COILS

Case Study
Oil Gelation
Date of completion – October 13th, 2024

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration
Equipment : Air Compressor No. 3
Area : Hull
Tag Number : V-6301C
Driver : Motor
Manufacturer : Baldor
Driver RPM : 1780
Amphere : 132 A M1 M2 C1 C2 Vertical
Power Rate : 142 kW
Bearing Driver NDE : SKF 6314
AIr
Bearing Driver DE : SKF 6319 Motor Compressor Axial
Transmission : Coupling (Flexible)
Driven : Screw Compressor (Male #4, Female #6)
Manufacturer : Quincy Horizontal
Driven RPM : 1780
Bearing Driven DE : Male and Female (SKF 32016 X/Q)
Male (SKF 32016 X/Q, SKF 31316 J1/QCL7A,
Instrument Air Compressor
Bearing Driven NDE : SKF NU216 ECP)
Female (SKF 32016, SKF 33216)
Support Type : Rigid
Driver Standard : ISO 10816-3
Driven Standard : ISO 10816-3

CASE STUDY – OIL GELATION

History and Finding
✓ On October 13th, 2024, mechanic found that the main instrument air compressor unable to
load, therefore the leg 1 equipment automatically ran for back up.
✓ The mechanic and electrical team tried to troubleshoot the problem in the field, but the
compressor remained unable to load despite using the forced mode.
✓ Unfortunately, the rubber coupling broken due to the compressor jammed.
✓ Mechanic tried to manually rotated using the hand tool, but the compressor still jammed.
✓ Superintendent decided and assigned mechanic team to disassembly the compressor to check
the internal component such as bearing and screw.
✓ Before the compressor disassembled, mechanic wanted to drain the oil from the separator but
they were found the drain port stuck due to oil gelation.
✓ Even though the oil unable to drain, the dismantling of the compressor still continued.
✓ The result was that the oil was found to be sticky and even hardened on the bearings and
compressor.

CASE STUDY – OIL GELATION

Evidence
Evidence
Oil Used

✓ RAI Screw Oil 2000

✓ Mineral Based Oil
✓ Manufactured By PT Raja Angin Indonesia (RAI)
✓ Premium Compressor Oil
✓ Unique additive technology
✓ Maximal protection from type of deposit on compressor

CASE STUDY – OIL GELATION

Conclusion and Lesson Learned
✓ The root cause of this problem is oil gelation phenomenon that causes compressor jammed.
✓ Varnish also presence on inner race bearing that often caused by the oxidation of oil.
✓ It is necessary to change the compressor oil regularly in accordance with OEM oil
recommendations.
✓ Change the oil product, brand, and or upgraded oil formulation from mineral to synthetic to
extend service life. (API group II and III oils and Synthetic Oils Polyalphaolefin to be used)
✓ Perform oil sampling and analysis to know the actual condition of oil health.

CASE STUDY – OIL GELATION

Theory of Gelation
Defining Gelation
According to ASTM International, oil gelation is defined by a rheological condition of an oil
characterized by a marked increase in the flow resistance over and above the normal
exponential increase of viscosity with due to excessive temperature.

Gelation Standards
The American Petroleum Institute (API) has established standards for the gelation index in
motor oils. In most cases, the maximum acceptable gelation index is 12, with a maximum
viscosity of 40,000 centipoise.

Causes of Oil Gelation

✓ Solid particles contaminant.
✓ Oil oxidation (exposed of air and high temperatures).
✓ Excessive water content in oil (emulsions phenomenon).
✓ Improper operation parameter such as pressure and temperature.
✓ Expired life time of oil.
CASE STUDY – OIL GELATION
 Terima Kasih – ‫شكرا ً لك‬
[Link]

CASE STUDY – OIL GELATION

Case Study
Bearing Damaged
Date of completion – August 26th, 2024

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration
Equipment : TEG Recirculation Pump A
Area : TEG
Tag Number : EM-2504A
Driver : Motor
Manufacturer : Jiangsu Dazhong
Driver RPM : 3555
Amphere : 56.1 A
Power Rate : 37 kW
Bearing Driver NDE : Unknown
Bearing Driver DE : Unknown
Transmission : Coupling
Driven : Multistage Centrifugal Pump (9 Stage)
Manufacturer : Source Pump & System
Driven RPM : 3556
Bearing Driven DE : SKF 603EC Glycol Pump
Bearing Driven NDE : SKF 7306BECBM
Support Type : Rigid
Driver Standard : ISO 10816-3
Driven Standard : ISO 10816-3

CASE STUDY – BEARING DAMAGED

History, Finding and Analysis
✓ The highest vibration value is 0.139 IPS RMS at NDE Motor Horizontal (M1H).
✓ On August 13th, 2024, the vibration value at NDE Pump was increased with the impact
pattern compared from previous measurement on July, 09th, 2024.
✓ The high frequency (enveloping) and velocity spectrum at pump shows 1xTS with severe
harmonics that indication of rotating looseness condition.
✓ Thermal images pattern at motor and pump shows normal conditions.

Recommendation
✓ Equipment not recommended to long term operation.
✓ It is necessary to check the condition of NDE Pump bearing in the next PM and prepare for
immediate replacement.
✓ The vibration and thermal pattern should be monitored.

CASE STUDY – BEARING DAMAGED

Vibration Spectrum and Waveform

P2H P2H Hi-Freq

July 9th , 24 Aug 13th , 24 Aug 13th , 24

The vibrations spectrum shows impact pattern at enveloping and velocity spectrum.
CASE STUDY – BEARING DAMAGED
Bearing Conditions
Inspection was performed by Mr. Hermawan (VA Cat 2)

It was found that the NDE bearing (duplex with face to face) was damaged by burning on the inner race and shaft.

CASE STUDY – BEARING DAMAGED

Corrective Actions and Verification
✓ The NDE bearings has been replaced with the new ones.
✓ The vibration spectrum both velocity and hi-freq have changed after bearing replacement.

Before After Before After

Velocity High Frequency

CASE STUDY – BEARING DAMAGED

Vibration Trending

The trends show that the pump vibrations were decreased after NDE bearing replacement.

CASE STUDY – BEARING DAMAGED

Conclusion and Lesson Learned
✓ The root cause of bearing damaged because the bearing lock nut is loose.
✓ Bearing replacement is successfully decreased the impact pattern of the spectrum and
waveform.

Found Bearing lock nut loose

✓ Please always maintain the lubrication level of the bearing.

✓ As this equipment is critical, please ensured the availability
of bearing parts.
✓ When installing a new bearing, make sure the lock nut is
tightened.

CASE STUDY – BEARING DAMAGED

 Terima Kasih – Спасибо
[Link]

CASE STUDY – BEARING DAMAGED

Case Study
Bearing Damaged
Date of completion – April 30th, 2024

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration
Equipment : Potable Water Pump 2
Area : Hull
Tag Number : Unknown
Driver : Motor
Manufacturer : WEG
Driver RPM : 3480
Amphere : 9.39 A
Power Rate : 5.5 kW
Bearing Driver NDE : 6206 2Z
Bearing Driver DE : 6307 2Z
Transmission : Direct Shaft
Driven : Centrifugal Pump
Manufacturer : WEG

Potable Water Pump

Driven RPM : 3480
Bearing Driven DE : N/A
Bearing Driven NDE : N/A
Support Type : Rigid
Driver Standard : ISO 10816-3
Driven Standard : ISO 10816-3

CASE STUDY – BEARING DAMAGED

History, Finding and Analysis
✓ This is non-critical equipment in the gas production process, therefore there is no vibration
monitoring program (run to failure).
✓ Equipment has redundancy for backup and runs intermittently to achieve pressure in tank.
✓ There is a noise from the electric motor when the machine is in operation.
✓ The vibration has been collected on electric motor and the overall vibration value status is
over the limit or “Danger” zone.
✓ The enveloping and velocity spectrum shows impact patterns both DE and NDE that suspected
from bearing defect.

Recommendation
✓ Please replace the bearing DE and NDE motor side as soon as possible to maintain the
equipment in a good performance.

CASE STUDY – BEARING DAMAGED

Vibration Spectrum and Waveform

M1H E1H E2H

The vibrations spectrum shows impact pattern at enveloping and velocity spectrum
CASE STUDY – BEARING DAMAGED
Bearing Conditions

Found NDE and DE bearings damaged when manually rotated (bad lubrication)

CASE STUDY – BEARING DAMAGED

Corrective Actions and Verification
✓ The NDE and DE bearings has been replaced with the new ones and the spectrum
pattern has changed – see the evidence.

Before

After

CASE STUDY – BEARING DAMAGED

Overall Vibration Value

✓ The table shows the overall vibration values before and after bearing replacement.
✓ The trends show that the motor vibrations were significantly decreased after bearing replacement.

Description Point Unit 22-Apr-24 30-Apr-24

NDE M1H IPS RMS 0.203 0.04

NDE M1V IPS RMS 0.21 0.04

Motor
DE M2H IPS RMS 0.184 0.022

DE M2V IPS RMS 0.154 0.019

CASE STUDY – BEARING DAMAGED

Conclusion and Lesson Learned
✓ The root cause of this problem is bearing damaged.
✓ Bearing replacement is successfully decreased the vibration value from zone D (Danger) to
Zone A (Acceptable).
✓ Due to this equipment is non-critical, visual check is essential to determine the condition of
the bearings in the absence of a vibration monitoring program.
✓ Ensure that the bearing parts are available on location.
✓ Please create the schedule for equipment switch over A to B every month.

CASE STUDY – BEARING DAMAGED

 Terima Kasih – Merci
[Link]

CASE STUDY – BEARING DAMAGED

Case Study
Misalignment
Date of completion – April 20th, 2024

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration

Vertical

M1 M2 P1 P2

Motor Gear
Pump Axial

Horizontal

Diesel Fuel Transfer Pump

CASE STUDY – MISALIGNMENT

History, Finding and Analysis
✓ This case was limited by the absence of data on vibration during commissioning and the
number of teeth from pump.
✓ The equipment have high vibration value from the first monitoring.
✓ About 6 month the equipment always on monitoring and shows the stable trends with high
vibration value.
✓ The highest vibration spectrum still consistent to shows a dominant peak at 358Hz or 12.5xTS
that indicates gearmesh frequency of pump.
✓ However, in the last measurement we found an anomaly that the highest vibration was more
dominant on the DE motor side especially in axial direction with difference pattern.
✓ The spectrum shows a 2xTS dominant peak and has harmonics that are suspected to be
misalignment issues.

Recommendation
✓ Please stop the equipment and inspect the condition of coupling.
✓ If possible, also inspect the pump condition.

CASE STUDY – MISALIGNMENT

Vibration Spectrum and Waveform

M2A M2H P2A

The highest vibration is 0.193 IPS RMS on DE Motor Horizontal (M2H) direction.
Misalignment suspected by axial direction with dominant peaks 2xTS or 60Hz.
CASE STUDY – MISALIGNMENT
Visual Inspection
✓ A damaged coupling condition in angular misalignment was found during the inspection.
✓ The jaw and rubber pad was broken.
✓ This causes the coupling is shifting so that they do not grip each other properly.

CASE STUDY – MISALIGNMENT

Corrective Actions and Verification

On April 20th, 2024, after the couplings were replaced with new ones and sized, also
performed re-alignment, the overall vibration at all measurement points decreased.
CASE STUDY – MISALIGNMENT
Conclusion and Lesson Learned
✓ The root cause of coupling failure is that the keyway and lock seat are damaged on pump side.
✓ The dominant gear spectrum can hide the misaligned spectrum at a time.
✓ This equipment is critical which the function to supply diesel fuel to GTG while the gas
suddenly shut off. Therefore, spare parts availability is a must.
✓ Fortunately, in this case the failure of the equipment can be captured by vibration technology
before the equipment stopped.
✓ Preventive Maintenance should be generated to perform visual check and so on.
✓ Need to inspect the pump condition for further action to ensure the condition of gear.

CASE STUDY – MISALIGNMENT

 Terima Kasih – Gracias
[Link]

CASE STUDY – MISALIGNMENT

Case Study
Gear Problem
Date of completion – April 20th, 2024

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration

Vertical

M1 M2 P1 P2

Motor Gear
Pump Axial

Horizontal

Diesel Fuel Transfer Pump

CASE STUDY – GEAR PROBLEM

History, Finding and Analysis
✓ This is a follow-up case after a broken coupling was found.
✓ Coupling was replaced and added shims to aligned the shaft.
✓ The motor and pump spectrum still showed dominant peaks at 358Hz or 12.5xTS and
harmonics, which were suspected to be due to gear pump issues (misalignment).
✓ The waveform shows a modulation pattern that is thought to be gear-derived as well, but the
side bands are still in low peaks.

Recommendation
✓ Stop the equipment and inspect the condition of gear.
✓ Repair and replace if its necessary to maintain the pump performance.

CASE STUDY – GEAR PROBLEM

Vibration Spectrum and Waveform
v rms [inch/s] ENGINE ROOM\DIESEL FUEL TRANSFER PUMP A\Motor DE Horizontal\[Link] 9/20/2024 [Link] AM
v rms [inch/s] ENGINE ROOM\DIESEL FUEL TRANSFER PUMP A\Motor NDE Horizontal\[Link] 9/20/2024 [Link] AM M
M 0.18
0.12 RPM : 1720 (28.67Hz)
RPM : 1720 (28.67Hz) 0.16 M(x) : 357.00 Hz (12.453 Orders)
M(x) : 358.00 Hz (12.488 Orders) M(y) : 0.15 inch/s
0.10 M(y) : 0.11 inch/s 0.14
0.12
0.08
0.10
0.06 0.08

0.04 M2H 0.06 M1H

0.04
0.02 0.02
0.00
0.00
0 200 400 600 800 1000 1200 1400 1600
0 200 400 600 800 1000 1200 1400 1600 f [Hz]
f [Hz]
v [inch/s] ENGINE ROOM\DIESEL FUEL TRANSFER PUMP A\Motor DE Horizontal\1005 Time W aveform 1/28/2025 [Link] AM
v [inch/s] ENGINE ROOM\DIESEL FUEL TRANSFER PUMP A\Motor NDE Horizontal\1005 Time W aveform 1/28/2025 [Link] AM0.4
M RPM : 1720 (28.67Hz)
0.3
RPM : 1720 (28.67Hz)
0.3
M(x) : 16.11 ms
0.2 M(y) : 0.18 inch/s 0.2

0.1 0.1
0.0
0.0
-0.1
-0.1 -0.2

-0.2 -0.3

0 20 40 60 80 100 120 140 160 180 200 220 240

0 20 40 60 80 100 120 140 160 180 200 220 240 t [ms]
t [ms]

The spectrum at the motor shows a dominant peak of 12.5TS, which is thought
to be transmitted from the pump.
CASE STUDY – GEAR PROBLEM
Vibration Spectrum and Waveform
v rms [inch/s] ENGINE ROOM\DIESEL FUEL TRANSFER PUMP A\Pump DE Vertical\[Link] 9/20/2024 [Link] AM v rms [inch/s] ENGINE ROOM\DIESEL FUEL TRANSFER PUMP A\Pump NDE Axial\[Link] 9/20/2024 [Link] AM
M M
0.12 0.09
0.08
0.10 0.07
(358.00 / 0.11)
RPM : 1720 (28.67Hz) 0.06 RPM : 1720 (28.67Hz)
0.08
M(x) : 358.00 Hz (12.488 Orders) M(x) : 358.00 Hz (12.488 Orders)
0.05 M(y) : 0.07 inch/s
0.06
P1V
(715.00 / 0.03)
M(y) : 0.11 inch/s
0.04 P2A
0.04 0.03
(1073.00 / 0.01) (1431.00 / 0.01) 0.02
0.02 0.01

0.00 0.00

0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600
f [Hz] f [Hz]

v [inch/s] ENGINE ROOM\DIESEL FUEL TRANSFER PUMP A\Pump DE Vertical\1005 Time W aveform 1/28/2025 [Link] AM v [inch/s] ENGINE ROOM\DIESEL FUEL TRANSFER PUMP A\Pump NDE Axial\1005 Time W aveform 1/28/2025 [Link] AM
0.25
RPM : 1720 (28.67Hz) RPM : 1720 (28.67Hz)
0.3 0.20
0.15
0.2
0.10
0.1 0.05
0.0 0.00
-0.05
-0.1 -0.10
-0.2 -0.15
-0.20
-0.3

0 20 40 60 80 100 120 140 160 180 200 220 240 0 20 40 60 80 100 120 140 160 180 200 220 240
t [ms] t [ms]

The spectrum at the pump showed a dominant peak of 12.5xTS and harmonics,
it was obvious to suspect that a gear problem was occurring at the pump.
CASE STUDY – GEAR PROBLEM
Visual Inspections
✓ Inspection results show excessive wear on the housing, bushings, and chipped gears.

Inspection was performed by Mr. Hermawan (VA Cat 2)

CASE STUDY – GEAR PROBLEM

Conclusion and Lesson Learned
✓ The root cause of gear problems is due to excessive wear and clearance on the bushings.
✓ Misalignment issues can also be a root cause that leads to excessive wear.
✓ As spare parts were not available, the pump decided to reassemble to ensure the equipment
was ready to run with monitoring.
✓ The vibration trends of the equipment is relatively stable till now (January 2025).

VIBRATION TRENDING ON DIESEL FUEL TRANSFER PUMP A

0,25

0,2 Diesel Fuel Transfer Pump B (GM-6611A) Pump DE P1H

Replaced Coupling and re-alignment
IN/SEC RMS

0,15 Diesel Fuel Transfer Pump B (GM-6611A) Pump DE P1V

0,1 Diesel Fuel Transfer Pump B (GM-6611A) Pump NDE P2A

0,05

CASE STUDY – GEAR PROBLEM

Terima Kasih – Takk skal du ha
[Link]

CASE STUDY – GEAR PROBLEM

Case Study
Structural Looseness
Date of completion – March 05th, 2024

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration
Equipment : HPC Cooling Fan No.1
Area : GTC-A
Tag Number : EM-1803A-01A
Driver : Motor
Manufacturer : ABB
Driver RPM : 1770
Amphere : 24.2 A
Power Rate : 15 kW
Bearing Driver NDE : SKF 6309/C3
Bearing Driver DE : SKF 6309/C3
Transmission : Timing Belt 8GTV-1600-21
Driven : Fan (#4)
Manufacturer : Moorefans
Driven RPM : Unknown
Bearing Driven DE : Pillow Block
Bearing Driven NDE : Pillow Block
Support Type : Flexible Gas Cooler Fan
Driver Standard : ISO 10816-3
Driven Standard : ISO 10816-3

CASE STUDY – STRUCTURAL LOOSENESS

History and Observation
This equipment consists of a motor and fan with belt transmission. Predictive maintenance using
vibration and IR thermography technology has been implemented for monthly on because it is one of the
critical equipment that must be available. In the field, vibration data collection can only be done on the
motor because there is no access to the fan bearing. With limited access, as an engineer must be careful in
analyzing the condition of the equipment. One of the things that must be done is to make visual
observations and understand the characteristics of the equipment.
In this case, the equipment is in stand-by condition and it is time to take vibration and IR
thermography data. After the equipment was turned on, the engineer felt something abnormal by hearing
the sound produced by the fan. Visually it can be seen that the fan is experiencing very high vibrations. This
can be observed by looking at the condition of the belt which is very loose. Fortunately, the fan did not hit
the case and activated the vibration switch to command shut down (this means that secondary failure did
not occur). Vibration data was collected on the motor and immediately coordinated with the control room to
shut down the equipment for maintenance action.

CASE STUDY – STRUCTURAL LOOSENESS

History, Finding and Analysis
✓ Visually , the belt shows loose condition.
✓ The spectrum shows 25Hz that indicated as a Fan Pass Frequency.
✓ The waveform shows impact pattern and its abnormal conditions.
✓ This condition occurs suddenly without any initial symptoms.

Recommendation
✓ Re-tightened the bolts at lower pillow block bearing due to loose.
✓ Makesure all bolts of pillow block and structure are tightened.
✓ Conducted belt tensioning and adjustment.

CASE STUDY – STRUCTURAL LOOSENESS

Vibration Spectrum and Waveform

M2A M2Y

The spectrum on motor side shows dominant peak at 25Hz and has an impact pattern.

CASE STUDY – STRUCTURAL LOOSENESS

Visual Inspections

Loose bolts found in the lower pillow block bearing and affected to the belt as well.
CASE STUDY – STRUCTURAL LOOSENESS
Corrective Actions and Verification

Description Point Unit 24-Aug-23 22-Sep-23 8-Oct-23 6-Nov-23 6-Dec-23 4-Jan-24 4-Feb-24 5-Mar-24 5-Mar-24
NDE M1X IPS RMS 0.06 0.06 0.058 0.052 0.063 0.041 0.032 0.182 0.049
NDE M1Y IPS RMS 0.054 0.056 0.062 0.092 0.08 0.059 0.085 0.292 0.03
NDE M1A IPS RMS 0.066 0.059 0.062 0.059 0.058 0.045 0.107 0.618 0.041
Motor
DE M2X IPS RMS 0.03 0.048 0.042 0.032 0.029 0.037 0.038 0.167 0.032
DE M2Y IPS RMS 0.064 0.043 0.055 0.047 0.044 0.045 0.047 0.391 0.037
DE M2A IPS RMS 0.06 0.072 0.056 0.074 0.062 0.081 0.101 0.734 0.046

The table shows the overall vibration values before and after tightening
the bolts of lower pillow block bearing and structure.

CASE STUDY – STRUCTURAL LOOSENESS

Vibration Trending

The trends show that the motor vibrations were significantly

decreased after performed corrective actions.

CASE STUDY – STRUCTURAL LOOSENESS

Conclusion and Lesson Learned
✓ The root cause of this problem is structural looseness at pillow block bearing.
✓ After performed corrective actions, the vibration on motor was dropped significantly from
zone D (Danger) to zone A (Acceptable).
✓ Visual inspection is one of the important things when you perform maintenance.
✓ For critical equipment, added vibration sensors on equipment that doesn’t have direct access
should be considered to monitor its health.
✓ It is better to use motor with VFD or time delays during initial startup to prevent from
pounding and excessive force.
✓ Create a schedule for preventive maintenance program on CMMS to perform visual check
and inspection.

CASE STUDY – STRUCTURAL LOOSENESS

 Terima Kasih – Obrigado
[Link]

CASE STUDY – STRUCTURAL LOOSENESS

Case Study
Pulley Misalignment
Date of completion – January 5th, 2024

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration

Gas Cooler Fan

CASE STUDY – PULLER MISALIGNMENT

History and Observation

✓ After commissioning, condition monitoring was carried out on this equipment.

✓ Unfortunately, we don't have any information about vibration data when the equipment was
commissioned.
✓ When vibration monitoring is performed, the first data shows a high vibration with “High
Alarm" limit.
✓ For this reason, it was decided to carry out a monitoring with notes in order to see the trends
of the vibration behavior.

CASE STUDY – PULLER MISALIGNMENT

History, Finding and Analysis
✓ The first vibration data status at motor is ”High Alarm” (Oct, 2023)
✓ Fan pulley did not have access to take vibration data.
✓ After three months monitoring, the vibration status at motor increased significantly to be a
”High-high Alarm” (Jan, 2024)
✓ The highest vibration value is 0.65 IPS RMS at DE Motor Axial direction and was increased
significantly with dominant spectrum 1xTS motor that indicated pulley misalignment issue.
✓ The vibration at radial especially in belt direction also increased significantly with dominant
spectrum at 1xTS motor and several harmonics that indicated of structural problem issue
affected from pulley misalignment.
✓ The waveform also shows M and W pattern that suspected misalignment problem.
✓ There is any noise that indicated from belt.
Recommendation
✓ Please re-alignment pulley as soon as possible.
✓ Please re-tighten all bolts at structure.
✓ Please inspect belt condition and conduct belt dressing to prevent from noise and wear.
CASE STUDY – PULLER MISALIGNMENT
Vibration Spectrum and Waveform

DE Motor Y-Axis (Belt Direction) DE Motor Axial Direction

CASE STUDY – PULLER MISALIGNMENT
Visual Inspections

A pulley level measurement was carried out and

the result shows that the pulley was tilted.

CASE STUDY – PULLER MISALIGNMENT

Corrective Actions and Verification
✓ Pulley alignment and adjustment using magnetic water level on motor side.
✓ Performed all bolts structure tightening.
✓ The highest vibration dropped from 0.65 to 0.051 IPS RMS
✓ The noise was disappears after performed belt dressing.
✓ Thermal image pattern at motor and fan bearing shows normal conditions.
✓ Now, the equipment is acceptable to run continuosly.

Description Point Unit 3-Oct-23 3-Nov-23 4-Dec-23 3-Jan-24 5-Jan-24 2-Apr-24

NDE M1X IPS RMS 0.055 0.065 0.076 0.151 0.042 0.028
NDE M1Y IPS RMS 0.154 0.133 0.124 0.497 0.051 0.052
NDE M1A IPS RMS 0.225 0.216 0.232 0.232 0.041 0.041
Motor
DE M2X IPS RMS 0.031 0.044 0.05 0.109 0.033 0.034
DE M2Y IPS RMS 0.103 0.097 0.096 0.217 0.034 0.032
DE M2A IPS RMS 0.229 0.206 0.237 0.65 0.041 0.065
CASE STUDY – PULLER MISALIGNMENT
Vibration Trending

The trends show that the motor vibrations were significantly decreased.

CASE STUDY – PULLER MISALIGNMENT

Conclusion and Lesson Learned
✓ The root cause of this problem is pulley misalignment.
✓ Performed pulley alignment is successfully decreased the vibration value from zone D
(Danger) to A (Acceptable).
✓ Added vibration sensors on critical equipment is important to implementing of a predictive
maintenance program on critical equipment without physical access.
✓ Create a schedule for preventive maintenance program on CMMS to perform visual check,
belt dressing, and inspection.

CASE STUDY – PULLER MISALIGNMENT

 Terima Kasih – Danke
[Link]

CASE STUDY – PULLER MISALIGNMENT

Case Study
Structural Looseness
Date of completion – October 14th, 2023

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration
Equipment : Condensate Flash Vessel Pump A
Area : Condensate
Tag Number : EM-2902A
Driver : Motor
Manufacturer : Luofu
Driver RPM : 3540
Amphere : 3.02 A P1
Power Rate : 3 kW
Bearing Driver NDE : Unknown
Bearing Driver DE : Unknown
Transmission : Coupling
Driven : Magnetic Drive Centrifugal Pump
Manufacturer : Hebei Beigong Pump
Driven RPM : 3500
Bearing Driven DE : Unknown Condensate Flash Vessel Pump
Bearing Driven NDE : Unknown
Support Type : Rigid
Driver Standard : ISO 10816-3
Driven Standard : ISO 10816-3

CASE STUDY – STRUCTURAL LOOSENESS

History, Finding and Analysis
✓ This is the new equipment at a gas plant, It runs once a day to transfer condensate from a
vessel.
✓ Preventive maintenance is performed before a condition monitoring program is carried out.
✓ Taking the first vibration data, there were anomalous symptoms indicated by vibration values
that were too high.
✓ Vibration spectrum shows strong dominant peak at 0.5xTS in the vertical and axial directions
both the pump and motor. (See vibration spectrum and waveform picture)

Recommendation
✓ This issue was immediately analyzed on site and perform visually checked based on the
spectrum that suspected structural problem.
✓ During perform visually checked, I had found the bolts of structure are loose.
✓ Therefore, the recommendation is to tighten the bolts structure with proper torque.
✓ The action is to tighten the bolts that have been assigned to the mechanic.
CASE STUDY – STRUCTURAL LOOSENESS
Vibration Spectrum and Waveform

M1V M1A P1A

The vibrations spectrum shows that the dominant peak is 24Hz (0.5xTS).

CASE STUDY – STRUCTURAL LOOSENESS

Visual Inspections

The loose bolts was found in Pump A and B.

CASE STUDY – STRUCTURAL LOOSENESS
Corrective Actions and Verification

Condensate Pump B (EM-2902B)

1 Description Point Unit 11-Oct-23 14-Oct-23
NDE M1H IPS RMS 0.061 0.047
NDE M1V IPS RMS 0.259 0.027
NDE M1A IPS RMS 0.201 0.028
Motor
DE M2H IPS RMS 0.033 0.025
DE M2V IPS RMS 0.153 0.025
DE M2A IPS RMS 0.129 0.029
DE P1H IPS RMS 0.054 0.025
Pump DE P1V IPS RMS 0.03 0.025
DE P1A IPS RMS 0.184 0.029
The table shows the overall vibration values before and after tightening all bolts structure.

CASE STUDY – STRUCTURAL LOOSENESS

Vibration Trending

The trends show that the motor and pump vibrations were significantly decreased.

CASE STUDY – STRUCTURAL LOOSENESS

Conclusion and Lesson Learned
✓ The root cause of this problem is structural looseness.
✓ Performed bolts structures tightening is successfully decreased the vibration value from zone
D (Danger) to zone A (Acceptable).
✓ It is essential to check all listed programs when commission the equipment.
✓ Please perform preventive maintenance in compliance with standard operating procedures.
✓ Handover report from project management to operation and maintenance team did not
match with the reality in the field.

CASE STUDY – STRUCTURAL LOOSENESS

 Terima Kasih – Grazie
[Link]

CASE STUDY – STRUCTURAL LOOSENESS

Case Study
Structural Resonance
Date of completion – June 15th, 2023

Rizfian Ramadhan
rizfian1927@[Link]
Equipment Configuration

DRIVER ELECTRIC MOTOR

SPEED 1460 RPM
POWER 7.5KW
CURRENT 16.1A

V-BELT

DRIVEN FAN
SPEED 421 RPM
NO OF BLADE 3
Lube Oil Cooler Fan GTC

CASE STUDY – STRUCTURAL RESONANCE

Finding and Analysis
✓ The highest overall vibration value is M2Y 0.863 in/sec RMS and the status is High (Zone D).
✓ The highest vibration occurs in the motor both NDE and DE side but only in the belt
directions.
✓ The dominant amplitude shown 1xfan pass frequency.
✓ Visually vibrations are also visible on the frame of motor and fan.
✓ Based on vibration symptoms, there is an indication of structural problem with possible
causes of resonance or weakness.
✓ The strong possibility of frame and motor vibration is transmitted or excited by fan shaft.

Recommendation
✓ Do the bump test to know the natural frequency of structure.
✓ Please add support towards the highest vibration to distribute the vibration to all frames.

CASE STUDY – STRUCTURAL RESONANCE

Vibration Spectrum and Waveform

M2Y – Motor Inboard Y-Axis

The highest vibration value is M2Y 0.86 IPS RMS

CASE STUDY – STRUCTURAL RESONANCE
Bump Test Result

✓ Dominant peak at 18Hz and 25Hz

✓ 18Hz is close with Fan pass frequency
✓ 25Hz is close with 1xrpm of motor

CASE STUDY – STRUCTURAL RESONANCE

1st Corrective Actions and Verification
✓ Bump test has been done and the results is frequency of structure close with the fan pass
frequency, about 15% (NF Structure is 18Hz and Fan pass frequency is 21.8Hz)
✓ For temporary action, support with scaffolding pipes in the direction with the highest
vibration is added. The result is that the highest vibration decreased significantly from 0,863
to 0,189 in/sec RMS but the vibration still in Alarm (Zone C).

Temporary Support

CASE STUDY – STRUCTURAL RESONANCE

Vibration Spectrum After 1st Corrective Actions

The overall vibration value at M2Y

significantly decreased from 0,863
to 0,189 in/sec RMS after added
temporary support but the limit still
in alarm (Zone C)

CASE STUDY – STRUCTURAL RESONANCE

2nd Recommendation
✓ After installed the temporary support and the equipment continued running, the trending
vibrations relative stable to 0,185 in/sec RMS for the last month measurement before Turn
Around (TAR) schedule.
✓ Close monitoring for ensure the vibration still stable with the temporary support.
✓ The support must be installed permanently to increase the proper stiffness.
✓ Because this equipment can’t be turned off for corrective action (No Redundancy), please
prepare and plan for additional permanent support and check belt conditions when Turn
Around (TAR) begins.

CASE STUDY – STRUCTURAL RESONANCE

2nd Corrective Actions and Verification
✓ The permanent support has been added at the same place with the temporary support. The
result is that the overall vibration dropped significantly from 0,185 to 0,059 in/sec RMS and
currently the status is Acceptable (Zone A).

Permanent Support

CASE STUDY – STRUCTURAL RESONANCE

Vibration Trending

27 February
Before added scaffolding
support

27 February - 15 May
After added scaffolding
support

15 June
After added permanent
support

CASE STUDY – STRUCTURAL RESONANCE

Conclusion and Lesson Learned
✓ The root cause of high vibration on this equipment is due to Structural Resonance that
excited by Fan pass frequency at normal operating conditions.
✓ For this case, added the stiffness is an option to avoid the resonance that successfully
decreased the vibrations value from Zone D (danger) to zone A (Acceptable).
✓ Resonance will be different at each direction and the weakest direction structure will be the
vibration victims.
✓ Handover report from project management to operation and maintenance team did not
match with the reality in the field.
✓ Important to check the vibration acceptance tests for all rotating equipment when
commissioning phase project progresses.

CASE STUDY – STRUCTURAL RESONANCE

Terima Kasih – Thank You
[Link]

CASE STUDY – STRUCTURAL RESONANCE

Case Study
IR Thermography
Date of completion – 2024

Rizfian Ramadhan
rizfian1927@[Link]
Finding and Corrective Actions
1. Finding : High ΔT due to looses connections
Actions : Tightened the connections

Finding After Corrections

CASE STUDY – THERMOGRAPHY

Finding and Corrective Actions
2. Finding : High temperature at body pump due to insufficient parameter
Actions : Operated with proper parameter

Finding After Corrections

CASE STUDY – THERMOGRAPHY

Terima Kasih – Ich danke Ihnen
[Link]

CASE STUDY – INFRARED THERMOGRAPHY

 Vibration Symptoms and Hypothesis
By Rizfian Ramadhan & Hady Zhakwan Nugroho
Certified Vibration Analyst Category II
Reference: Mobius Training Manual

A. Introduction

Vibration is the most technology widely used to diagnose rotating machine failure. The failures that
can be detected by vibration technology such as unbalance, misalignment, bearing defect, etc. Many
references mention how the vibration pattern for each failure and very useful for analyzing actual
conditions in the field. As consulting machinery diagnostics engineers for the oil, gas, and energy
industries in Indonesia, we have identified several failure modes by vibration technology and provided the
recommendations for forward plan. but unfortunately, we were not able to verify the failure that was
found. Therefore, this paper is only limited to findings and hypotheses based on vibration patterns. We
hope this can be an open topic for readers to discuss together.

VIBRATION SYMPTOMS AND HYPOTHESIS

Page. 1 Vibration Symptoms and Hypothesis

1. Structural Problem
Equipment : Motor and Pump
Configuration : Horizontal
Fluid : Crude Oil

Hypothesis

The spectrum MIH and MIV showed dominant peak at 1xTS (1770 RPM), there is indications of
structural problems both looseness or weakness. We suspect it due to the 1xTS horizontal vibration being
greater than the 1xTS vertical direction “MIH>>MIV” and usually show sinusoidal waveform. For forward
plan, we need to check several modes of the problem caused such as the bolt between motor feet and
baseplate, shim, and/or check the condition of structure (corrosion and crack).

Page. 2 Vibration Symptoms and Hypothesis

2. Misalignment Problem

Equipment : Motor and Pump

Configuration : Horizontal
Fluid : Water

1x, 2x TS

1x, 2x TS

Hypothesis

The spectrum MIH and MIV showed dominant peak at 1x, 2xTS and has M/W waveform pattern,
there is an indication of misalignment problem. In other cases, if we are not sure to suspect that it is a
misalignment problem, we can perform phase measurements. For forward plan, we need to check the
alignment between the motor and pump both parallel and angular, then please conduct re-alignment.

Page. 3 Vibration Symptoms and Hypothesis

3. Blade Pass Frequency

Equipment : Motor and Pump

Configuration : Horizontal
Fluid : Hot Water

Random Impact

Hypothesis

The spectrum POV showed dominant peak at 5xTS and has raised noise floor, there is an indication
of blade pass frequency that generated due to cavitation problem. Cavitation also can be detected by
looking the random impact pattern at waveform. In this case, it’s a normal condition as long as the
vibration still in acceptable level but to overcome this problem, we need to check the flow parameter of
pump such as suction & discharge pressure, line restrictions (possibly clogged), and or to know the pump’s
Best Efficiency point to confirmed the operating state of the pump.

Page. 4 Vibration Symptoms and Hypothesis

4. Bearing Defect

Equipment : Motor and Pump

Configuration : Horizontal
Fluid : Crude Oil

93.19 Hz

92.55 Hz

Repetitive Impact

Hypothesis

The MIV spectrum shows a dominant peak at 3.19xTS and harmonics, there is indication of impact
problem on the motor. The highest peak appears in the non-synchronous area which is likely that the
source of the impact is from the bearing because in this case we don’t know the serial number of the
bearing. If we look at the waveform, there is any frequency that matched with the highest peak in the
spectrum and showed repetitive pattern. Therefore, we suspect it is the bearing fault frequency. For
forward plan, please conduct re-greasing if the vibration is stable and be prepared to replace the bearing
if the vibration increases (or possibly to combine with others technology first such as Infrared
Thermography and ultrasound).

Page. 5 Vibration Symptoms and Hypothesis

5. Rotor Bar Passing Frequency

Equipment : Motor and Pump

Configuration : Horizontal
Fluid : Hot Water

120 Hz

42Times

Modulation pattern

Hypothesis

The MIA spectrum showed dominant peak 42xTS with sideband 2xLF at high frequency and 1x,
2xTS at low frequency. The waveform also shows a modulation pattern with the sideband spacing is
120Hz. In the circular format, there is an impact of 42 times that matched with the spectrum and possibly
as a number of rotor bar. There is an indication of rotor bar passing frequency and it’s common to see due
to each rotor bar passes slight disruptions in the magnetic field due to the current’s path through the rotor
and stator. For forward plan, we need to monitor the amplitude because if it increases, it can be a
symptom of damage rotor bar. We can also combine with MCSA technology to get the best result.

Page. 6 Vibration Symptoms and Hypothesis

6. Rotating Looseness

Equipment : Motor and Pump

Configuration : Horizontal
Fluid : Water

1xTS

Hypothesis

The spectrum M1H showed dominant peak 1x and harmonics more than 10 times, there is an
indication Rotating looseness problem. The time waveform will often display either once per revolution
impacting or a truncated or clipped wave. Rotating looseness can be caused by worn-out bearing
conditions, loose on shaft, and or possibly loose on housing. For forward plan we need to prepare to
replace bearing as soon as possible and always monitor temperature level of the bearing.

Page. 7 Vibration Symptoms and Hypothesis

7. Unbalance

Equipment : Motor and Fan

Configuration : Horizontal

1xTS

The sinusoidal wave patterns Phase measurement

Measurement
Phase (°) Coherence Condition
Point
F1H – F1V -75.61 1 Out of phase
F1H – F2H -0.87 1 In Phase
F1V – F2V 2.55 1 In phase
F2H – F2V 88.08 1 Out of Phase

Hypothesis

The spectrum Fan outboard (H-V-A) showed dominant Peak 1xTS and followed 2xTS. There is an
indication of unbalance problem because the unbalanced condition will produce a sinusoidal wave.
To determine the type of unbalance that occurs, we perform phase measurements. Based on the
phase measurement, there is a static unbalance condition due to in phase (±30°) on both bearings (H-
H and V-V) and out of phase (90°±30°) on the same bearing (H-V). For forward plan, we need to inspect
the condition of Fan (dirt, corrosion, or broken) and schedule to perform balancing.

Page. 8 Vibration Symptoms and Hypothesis

8. Gear Mesh Frequency

Equipment : Motor, Gearbox, and Fan

Configuration : Horizontal motor, Gearbox and Axial flow Fan

1xGMF

2xGMF

Low sidebands

Not show impacting pattern

Hypothesis

The spectrum GOH showed dominant peak 1xTS, followed 236.61 and 473.33xTS. There are
indications of gear mesh frequency and 2xGMF (common to see). For analyzing, we can detect by
looking the amplitude of GMF and its sidebands. Another way is to look at the impact produced by
the time waveform (Pk-Pk and or Crest factor value). For this case, the spectrum showed low sideband
in GMF and has no impact on the waveform that means there is no indications of gear problem. If it
indicates the problem of gear, we also need to investigate with circulate format for analyzing. For
forward plan, we need to inspect the condition of lubricants (wear, chemistry, and contaminants) and
gear.

Page. 9 Vibration Symptoms and Hypothesis

 Case Study High Vibration on
Vertical Motor Pump Equipment
Rizfian Ramadhan
Project Department
PT Tiara Vibrasindo Pratama
Jakarta, Indonesia
rizfian1927@[Link]
Hidayatullah Bahri
Project Department
PT Tiara Vibrasindo Pratama
Jakarta, Indonesia
hidayatullahm26@[Link]

Abstract— Condition monitoring is a process of checking or equipment, the maintenance team made the decision to carry
monitoring a condition of the machine. In its implementation, out repairs immediately to avoid functional failure.
condition monitoring can be done using several technologies
and methods such as Vibration Analysis, Infrared
Thermography, Partial Discharge Monitoring, and Motor
II. THEORY
Current Signature Analysis. This case study uses the Vibration
analysis method which is one of the effective technologies in the A. Vertical Machine
field of condition monitoring. Vibration analysis itself is one of Vertical machine such as pump is usually supported by
the most widely used and successful methods in checking foundations and exhibit 1xTS values at the free end of the
conditions on rotating machines. Some symptoms of machine machine regardless of the actual unbalance of the
damage can be detected by vibration analysis. In this case component. Although the unbalanced force is radial and is
study, vibration data was taken on a monthly basis and high transmitted to the surroundings, vertical machines tend to
vibration exceeding the limit was found in the vertical pump sway in one axis at their most flexible. Vertical machines
motor. As this was a critical piece of equipment, the also usually have a high degree of stiffness in the pipe
maintenance team made the decision to carry out repairs direction.
immediately to avoid functional failure. As a result, it was
found that the baseplate of the equipment was uneven (tilted),
causing a soft foot condition. The vibration value can be B. Characteristics of Machine Vibration Damage
lowered by loosening some of the equipment baseplate bolts.
1. Unbalance
Keywords—vertical motor pump, condition monitoring, Is a condition where the center line of the geometry does
vibration analysis. not coincide with the center line of the mass of an object or
commonly defined as non-uniformity of mass distribution.
I. INTRODUCTION Unbalance can be caused by various factors such as design
Condition monitoring is a process of checking or errors , machining processes, corrosion, cracks and others. In
monitoring a condition of the machine. Checking is done to vibration analysis, unbalance symptoms will produce a
find out the current condition of a machine whether it is in dominant 1x TS peak in the spectrum and a sinusoidal shape
good condition or has symptoms of damage so that it can be in the waveform. In addition, unbalance symptoms can also
further analyzed. In its implementation, condition monitoring be confirmed through taking phase data in the radial
can be done using several technologies and methods such as direction either on one bearing or both.
Vibration Analysis, Infrared Thermography, Partial
Discharge Monitoring, and Motor Current Signature 2. Looseness
Analysis. This case study uses the Vibration analysis method In general, looseness diagnosis is divided into 3 types
which is one of the effective technologies in the field of of looseness itself, namely rotating looseness, structural
condition monitoring.
looseness or weakness and non-rotating looseness, rotating
Vibration analysis itself is one of the most widely used looseness is rotating looseness caused by excessive
and successful methods in checking conditions on rotating clearance between rotating and stationary elements.
machines. Some symptoms of machine damage can be Structural looseness or weakness is structural looseness
detected by vibration analysis such as unbalance, occurs where there are weaknesses in the base plate,
misalignment, structural problems, bearing defects, and foundation or legs, and the machine can sway from side to
resonance. With the detection of symptoms of machine side. Non-rotating looseness is looseness between two
damage, the treatment that will be applied to the machine can normally stationary parts, such as the foot and the
also be planned properly, this is what makes condition foundation, or the bearing housing and the machine.
monitoring as a cost profitability in the maintenance system Symptoms of looseness in vibration will produce a
of a plant.
dominant 1x peak in the spectrum and will have harmonics
In this case study, vibration data was taken on a monthly if it occurs in rotating or non-rotating looseness.
basis and high vibration exceeding the limit was found in the
vertical pump motor. As this was a critical piece of
 3. Soft Foot operating parameters still tend to be stable and do not
Soft foot occurs when not all feet on the machine are experience an increase or anomaly.
level, not all are the same height or one may be bent. Soft
TABLE 4. 2 OVERALL VIBRATION DATA
foot occurs when there are too many shims under the feet
and they start to act like springs. The most common cause of
soft foot is an uneven foundation. Symptoms of soft foot in
vibration will produce a dominant 1xTS peak in the
spectrum sometimes 2xTS and 3xTS also appear.
III. METHODOLOGY

A. Process Flow
The methodology used in this case study is:
1) Database Setup
The database set up used to collect vibration data in
this case study is F-Max 1000Hz, cut off frequency 2Hz,
averages 6, lines 3200, and hanning window type.
2) Data Collection (vibration and operating parameters) TABLE 4. 2 OPERATING PARAMETER

Using vibration analyzer CSi 2140 with a monthly

retrieval vibration data schedule.
3) Analysis and Discussion
4) Execution of recommendations and verification
5) Conclusion.

B. Object Configuration B. Data Analysis

1) Finding
• Has the highest peak in the radial direction (M1Y)
at 1x TS on the spectrum as shown in Figure 4.1.
• The waveform pattern shows a sinusoidal shape as
shown in Figure 4.2.

Figure 4.1 M1Y Spectrum

Figure 3.1 Object Configuration

The function of this equipment is to transfer condensed

water from the steam turbine to the cooling system.

IV. RESULT AND DISCUSSION

A. Vibration Data and Operating Parameter

Tables 4.1 and 4.2 show the vibration, temperature and
pressure data taken in the last 5 measurements. From Table
4.1, it can be seen that there is an increase in the overall
velocity value at the M1Y (NDE Bearing) measurement
point, while in Table 4.2 it can be seen that the values of the Figure 4.2 M1Y Waveform
 2) Diagnose After replacing the motor, a vibration value of 12.00
mm/s RMS was obtained with the same pattern and
• The dominant peak is 1xTS that indicates of motor symptoms of damage as before. In view of this, the analysis
unbalance, looseness, and structural problem. is then directed to structural problems in this case there is an
asymmetry of stiffness or uneven foundation and tension in
3) Analysis
the discharge pipe which causes vibration to lead to one side
• Unbalance is very likely to occur in vertical
motors, this is supported by phase readings at the
NDE bearing ± 90 ° and between V-V ± 30 °.
• Structural looseness in this case study is unlikely to
occur because the phase readings between the
baseplate and foundation are all in-phase. Rotating
looseness is also not confirmed because the
Spectrum does not show any harmonics
• Soft foot could have occurred if the NDE H/V
bearing amplitude ratio is >3, which means that
there is a possibility of asymmetric stiffness in the
foundation or tension in the pipe. Data from phase
measurements did not support any indication of
problems with the structure.
4) Conclusion
• The motor has indications of unbalance.
• There is a possibility of structural problems (soft only. From the results of the discussion, 2 options were
obtained to make adjustments to the source of stiffness,
foot) because in this case the equipment has
namely flexible joint pipes and baseplate bolts.
unsymmetrical rigidity.
Figure 4.4 Joint Position
5) Recommendation.
• Looking at the trending history of the vibration a. Re-adjusting the bolts on the flexible joint pipe
value at point M1Y which has increased linearly The process of re-adjusting the flexible joint by loosening
with indications of unbalance and structural the bolts has no effect on the measurement of vibration
problems, it is recommended to prepare for motor values.
replacement referring to the best guess prediction
from AMS Software as shown in Figure 4.3. b. Re-adjusting the bolts on the baseplate
The process of re-adjusting the bolts on the baseplate has
an influence on the measurement of vibration values as
shown in Figure 4.5.

Figure 4.3 Best Guess Prediction

C. Execution of Recommendation and Verification Figure 4.5 Effect of re-adjusting bolts on baseplate again
the vibration value
1. Execution of Recommendation
The cascade spectrum shows that the vibration value was
Based on the consideration of trending vibration values in dropped significantly after corrective actions. Currently The
motors that continue to increase linearly, motor replacement vibration value of the vertical motor pump equipment is still
is an option taken by the maintenance team from the Plant in a stable condition and has not increased as shown in
2. Verification Figure 4.6.
 structure or in this case the occurrence of soft foot due to
uneven or tilted foundations.
2. Re-adjusting the bolts on the flexible joint has no
effect on the measured vibration value.
3. Re-adjusting the bolts on the baseplate joint has a big
Before After influence on the measurement of vibration values to reach
the smallest value, which is below 1 mm/s RMS under the
condition that the motor and pump are already coupled with
normal loads. The vibration status has changed from Danger
to Acceptable zone.

REFERENCES
[1] James E. Berry., 1997. Concentrated Vibration
Signature Analysis and Related Condition Monitoring
Figure 4.6 Trending of vibration values before and after Techniques. Second Edition.
motor replacement and verification.
[2] Mobius Institute. 2016. Vibration Analysis Training
V. CONCLUSION Manual Category I. 4.1 Version.
Based on the results of the adjustments made to the [3] International Standard. 2009. Mechanical Vibration
vertical motor pump equipment, the results are obtained in Measurement and Evaluation of Machine Vibration.,
the form are as the follows : Second Edition., ISO-10816-3. Switzerland.
1. The damage detected by vibration technology
originates from the asymmetry of the stiffness of the
Penambahan Fasilitas Pengambilan Data
Vibrasi Gearbox Cooling Tower Fan

Rizfian Ramadhan
Pendahuluan
• PT PJB PLTU UBJOM Tenayan
merupakan pembangkit listrik tenaga uap
yang resmi beroperasi pada tahun 2017
dengan kapasitas 2x110MW
• Condition Based Maintenance (CBM)
merupakan divisi yang melakukan
monitoring semua peralatan berputar
dengan berbagai teknologi.
• Kerusakan pada fan cooling tower tidak termonitor dikarenakan tidak
ada akses untuk melakukan monitoring.
• Teknologi vibrasi bisa mendeteksi kegagalan yang ada pada gearbox
dan fan cooling tower
Landasan Teori
Vibration analysis sendiri merupakan salah satu metode yang paling
banyak digunakan dan berhasil dalam melakukan pengecekan kondisi
pada rotating machines. Beberapa gejala dari kerusakan mesin bisa
dideteksi oleh vibration analysis seperti unbalance, misalignment,
structural problem, fan problem, gear defect, bearing defect, rotating
looseness, electrical problem, belt worn out, flow turbulance, dan
resonance. Dengan terdeteksinya gejala kerusakan mesin maka perlakuan
yang akan diterapkan kepada mesin tersebut juga bisa direncanakan
dengan baik, hal inilah yang membuat condition monitoring sebagai cost
profitability dalam sistem perawatan dari sebuah plant.

Condition Monitoring and Vibration analysis

Metodologi
1. Material dan Bahan yang Digunakan

1 2 3 4 5

1. Accelerometer Sensor (AC-102).

2. Kabel Sensor (CB 206-A2A-010M)
3. Mounting Pad
4. Junction Box SB-102-12B
5. Lem Devcon Flexus MA300
6. Pipa Konduit
7. Fleksibel Konduit
6 7
Metodologi
2. Wiring Diagram
Metodologi
3. Tahapan Pekerjaan dan Pembobotan
Volume Bobot
No Uraian Pekerjaan
(Lot) (%)
1 Pemasangan Junction Box 1 8.33

2 Pemasangan Sensor Vibrasi Cooling Tower Fan A 1 8.33

3 Pemasangan Sensor Vibrasi Cooling Tower Fan B 1 8.33

4 Pemasangan Sensor Vibrasi Cooling Tower Fan C 1 8.33

5 Pemasangan Sensor Vibrasi Cooling Tower Fan D 1 8.33

6 Pemasangan Sensor Vibrasi Cooling Tower Fan E 1 8.33

7 Wiring cable dari Sensor menuju Junction Box 5 41.67
8 Commissioning 1 8.33
Total Volume 12 100
Metodologi
4. Jadwal Pekerjaan
Jadwal Pekerjaan 21-29 November 2019
Day-1 Day-2 Day-3 Day-4 Day-5 Day-6 Day-7 Day-8
8.33
4.17 4.17
4.17 4.17
4.17 4.17
4.17 4.17
4.17 4.17
13.89 13.89 13.89
8.33

• Pekerjaan dilakukan pada saat Outage (Turn Around) berlangsung.

Metodologi
5. Organisasi Tim dan Penugasan
• Project Leader - Bertanggung jawab atas seluruh aktivitas proyek
dimulai saat site survey, kick off meeting, eksekusi hingga serah
terima pekerjaan.
• Engineer Pengawas Proyek dan Commisioning - Mengawasi semua
aktivitas dan kegiatan proyek yang dilaksanakan oleh teknisi.
• Teknisi - Melakukan pemasangan sensor vibrasi di lapangan sesuai
dengan prosedur dan instruksi kerja yang telah diberikan.
• HSSE Field - Mengurus administrasi terkait aturan K3L yang berlaku di
Perusahaan owner dan memastikan semua personel di lapangan
bekerja dengan aman.
Metodologi
6. Kajian K3L

Safety Rules
1. Safety Induction – mematuhi semua aturan-aturan K3L yang berlaku di
tempat bekerja, mengetahui tempat eskavasi ketika terjadi bahaya yang
mengaharuskan semua pekerja meniggalkan pekerjaannya.
2. Pre-Job Safety Meeting – berkomunikasi dengan baik sehingga semua
rencana pekerjaan bisa dilaksanakan dengan baik dan tetap
mengutamakan keselamatan, keamanan, kesehatan kerja, dan
memperhatikan dampak terhadap lingkungan.
Metodologi
6. Kajian K3L
Hazard Mapping and Risk Assessment
1. Tersengat listrik – memastikan sumber listrik telah di LOTO
2. Tersandung dan terjepit – menggunakan alat pelindung diri yang sesuai
dan menjauhi semua objek atau benda yang menghalangi pekerjaan.
3. Jatuh dari ketinggian – menggunakan full body harness yang sesuai
serta memiliki kompetensi dalam bekerja di ketinggian.
4. Manual Handling – berkomunikasi dengan baik dan menyesuaikan posisi
badan saat melakukan pengangkatan barang secara manual.
5. Bekerja langsung di bawah terik matahari – membawa air mineral agar
terhindar dari dehidrasi.
6. Housekeeping – memastikan semua area kerja selalu bersih dari
material atau benda kerja yang bisa menimbulkan potensi bahaya.
Pelaksanaan dan Hasil
1. Kurva-S Progres Pekerjaan

KURVA-S PROGRES PEKERJAAN

100,00

82,77

68,88
Bobot Realisasi Komulatif (%)
100,00
45,82
77,78 Bobot Rencana Komulatif (%)
37,49
29,16 63,89
20,50 45,83
37,50
12,00 29,17
20,83
12,50
0,00 0,00
Pelaksanaan dan Hasil
2. Hasil Pengujian
Hasil dari pengujian menunjukkan bahwa sensor berfungsi dengan
baik dimana sensor masih berada diantara nilai DC operating (bias)
voltage sesuai dengan standar spesifikasi yaitu 4-16 VDC

No Sensor Location Bias Voltage (Volt DC) Remarks

1 CTF 1 A 11.9 Ok
2 CTF 1 B 11.9 Ok
3 CTF 1 C 11.8 Ok
4 CTF 1 D 11.9 Ok
5 CTF 1 E 11.9 Ok
Pelaksanaan dan Hasil
3. Dokumentasi Tahapan Pekerjaan
Analisa Biaya dan Keuntungan
A. Analisa Biaya

1. Biaya instalasi termasuk material per 5 unit = $14.833

2. Biaya Tenaga Kerja $800 x 4 Orang = $3.200
3. Total Biaya Instalasi $14.833 + $3.200 = $18.033
4. Perhitungan Keuntungan (Margin 50%)
Keuntungan = Biaya instalasi per 5 unit × 0,50 = 14.833 × 0,50 = $7.416,50
5. Perhitungan harga ke pelanggan (tidak termasuk pajak):
Total Harga = $18.033 + $7.416,50 = $25.449
6. Perhitungan Pajak (11%):
Total Pajak = $25.449 × 0,11 = $2.799
7. Struktur Harga Akhir (Termasuk Pajak)
Total dengan Pajak = $25.449 + $2.799 = $28.242
Analisa Biaya dan Keuntungan
B. Keuntungan

Terhitung secara komersil, total keuntungan yang didapatkan dalam proyek

ini adalah sebesar $7.416,5 atau Rp 112.688.896,78. Selain keuntungan
secara komersil yang diperoleh oleh Perusahaan pelaksana tugas,
Perusahaan pemberi tugas dalam hal ini PLTU Tenayan akan memperoleh
keuntungan sebagai berikut:
1. Pihak owner bisa terhindar dari kegagalan pada gearbox cooling tower
fan secara fungsi (functional failure) yang tentunya apabila terjadi akan
menyebabkan kerugian yang sangat besar dikarenakan penurununan
rate kapasitas power yang tersedia.
2. Pemasangan sensor vibrasi ini diharapkan bisa menjadikan PLTU
semakin handal dalam melayani kepentingan publik untuk menyuplai
listrik dalam negeri.
Kesimpulan
1. Pelaksanaan pekerjaan harus dikerjakan oleh pekerja yang memiliki
kompetensi di bidangnya, menggunakan alat ukur yang sesuai, dan
membuat laporan secara objektif serta sesuai dengan berdasarkan fakta
di lapangan.
2. Pemasangan sensor dilaksanakan sesuai dengan jadwal
perencanaan dan mendapatkan hasil yang baik menurut standar DC
operating (bias) voltage yaitu antara 4-16VDC.
3. Tim enjiniring condition based maintenance (CBM) PLTU Tenayan
saat ini dan seterusnya bisa mengimplementasikan program
pengambilan data vibrasi untuk mengetahui kondisi teraktual dari
gearbox cooling tower fan.
Referensi
James E. Berry., 1997. Concentrated Vibration Signature Analysis and Related Condition
Monitoring Techniques. Second Edition.
Mobius Institute. 2016. Vibration Analysis Training Manual Category I. 4.1 Version.
International Standard. 2009. Mechanical Vibration Measurement and Evaluation of Machine
Vibration., Second Edition., ISO-10816-3. Switzerland.
CTC Product Datasheet., dari [Link]
Terima kasih
Rizfian1927@[Link]