Practical Machinery Vibration Analysis

and Predictive Maintenance

SUMMARY:
This practical workshop provides a detailed examination of the detection, location and diagnosis of faults in rotating and reciprocating machinery using vibration analysis. The basics and underlying physics of vibration signals are first examined. The acquisition and processing of signals is then reviewed followed by a discussion of machinery fault diagnosis using vibration analysis. Hereafter the important issue of rectifying faults that have been identified using vibration analysis is covered. The workshop is concluded by a review of the other techniques of predictive maintenance such as oil and particle analysis, ultrasound and infrared thermography. The latest approaches and equipment are discussed and several practical sessions are done in order for delegates to gain some basic practical experience in collecting and interpreting vibration data.

 

OBJECTIVES:

At the end of the workshop participants will be able to:

·         Understand the basics of vibration measurement

·         Demonstrate the basics of signal analysis

·         Understand measurement and the characteristics of vibration signals

·         Use data acquisition equipment to collect vibration signals

·         Apply vibration analysis to identify different machinery faults

·         Apply specific techniques for pumps, compressors, engines, turbines and motors

·         Apply vibration-based fault detection and diagnostic techniques

·         Diagnose machinery related problems with vibration analysis techniques

·         Apply advanced signal processing techniques

·         Detect, locate and diagnose faults in rotating and reciprocating machinery using vibration analysis techniques

·         Identify conditions of resonance and be able to rectify these problems

·         Apply allied predictive techniques such as oil analysis, infrared thermography and ultrasonics

WHO SHOULD ATTEND?

·         Instrumentation and Control Engineers                     

·         Maintenance Engineers

·         Control Technicians

·         Electrical Engineers

·         Electricians                                                            

·         Maintenance Engineers and technicians

·         Process Engineers                                                 

·         Consulting Engineers

·         Automation Engineers

PRE-REQUISITES:

A fundamental knowledge of basic electrical and mechanical concepts would be useful.

ACCREDITATION:

Satisfactory completion of this course satisfies the requirements of the International Association for Continuing Education and Training for the award of .07 Continuing Education Units for each day of attendance. The course also satisfies criteria for Continuing Professional Development according to the requirements of the Institution of Electrical Engineers and Institution of Measurement and Control in the UK, Institution of Engineers in Australia, Institution of Engineers New Zealand, and others.

WORKSHOP CONTENT SUMMARY & OUTLINE

DAY ONE:

REGISTRATION

1.0               Introduction:

1.1               Evolution of maintenance in process plants

1.2               Classification of plant machinery

1.3               Maintenance Strategies as adopted to each class of machinery

1.4               Identification of Critical Machinery and adoption of CBM

1.5               Principles of predictive maintenance - its utilisation in detection and diagnosis

1.6               Various techniques under predictive maintenance

1.7               Vibration Analysis as one of the key techniques

Review questions

2.0               Vibration Basics:

2.1               Spring Mass system – Mass, Stiffness, Damping

2.2               Wave fundamentals – concepts of amplitude, frequency, fundamental frequency, harmonics, phase, waveforms (sinusoidal, complex) – concepts of peak, peak-peak, rms.

2.3               Vibration parameters – Displacement, Velocity, Acceleration

2.4               Choice of vibration parameters

2.5               Using vibration theory to machinery fault detection

2.6               Limits and standards of Vibration

Review questions

Practical exercise

DAY TWO:

3.0               Data Acquisition Systems and techniques:

3.1               Vibration transducers and their mountings

3.2               Data acquisition equipment – Hand held meters, Data Collectors (Single, Dual Channel), Online monitoring

3.3               Equipment setup and data collection

3.4               Basic steps in Data acquisition, Overlapping, Windows

Review questions

4.0               Basics of Signal Analysis

4.1               Time Waveform Analysis

4.2               Fast Fourier Transform Analysis

4.3               Phase Measurement

4.4               Enveloping and Demodulation

4.5               Orbits

4.6               Advanced Signal Analysis

4.6.1          Triggered Data Capture

4.6.2          Synchronous Time Averaging

4.6.3          Peak holding Averaging

4.6.4          Coastdown Analysis (Bode/Nyquist)

4.6.5          Enveloped Spectras – gSE, Peakvue, SEE.

4.6.6          Modal Shape Analysis

4.6.7          Cross Channel Analysis – Coherence, FRF, TRF

4.6.8          Cepstrum

4.6.9          Torsional Vibration

Review questions

Practical introduction to vibration analyser

Practical bump test exercise

DAY THREE:

5.0               Vibration Analysis for different Machinery faults:

5.1               Unbalance

5.2               Misalignment, looseness, distortion

5.3               Bad bearings, Journals

5.4               Gears, Couplings

5.5               Critical

5.6               Resonance

5.7               Electrical

5.8               Miscellaneous

Review questions

Practical exercise

6.0               Machinery Specific Vibration Analysis:

6.1               Pumps

6.2               Compressors

6.3               Engines

6.4               Turbines

6.5               Motors

Review questions

Practical exercise

7.0               Vibration Monitoring and Analysis – Turbomachinery

7.1               Importance of Shaft vibration- usage of eddy current probes

7.2               Installation of probes on a turbomachinery train

7.3               Brief description of the turbomachinery vibration setup

7.4               Spectrum plot, Cascade plot, Waterfall plot, Bode plot, polar plot, shaft centreline plot, Wave form plot, Orbit plot, Shaft deflection plot, Data trending plot, Axial movement plot, full spectrum.

7.5               Typical problems associated with turbomachinery – Oil Whirl/whip, structural resonance, vane blade passing, Misalignment, rotor rubbing, shaft crack

Review questions

DAY FOUR:

8.0               Applications of Vibration Analysis – Balancing

8.1 Why balance?

8.2        Identifying unbalance

8.3        Practical aspects

8.4        Definitions

8.5        Single-plane balancing

8.6        Four-run method

8.7        Two-plane balancing

8.8        Overhung rotor

8.9        Balancing standards

Review questions

Practical balancing exercise with kit

9.0               Applications of Vibration Analysis – Alignment

9.1        Introduction

9.2        Identifying misalignment

9.3        Measuring misalignment

9.4        Rough methods

9.5        Reverse dial method

9.6        Face-rim method

9.8        Laser alignment

9.7        Alignment tolerances

            Review questions

Practical alignment exercise with vibration kit

DAY FIVE:

            Further practical exercises using vibration analyzer

            Case studies using analyzer and software

10.        Related condition monitoring tasks

10.1      Tighten, Lubricate, Clean (TLC)

10.2      Chemical and particle analysis

10.3      Ultrasonic inspection

10.4      Temperature monitoring

10.5      Performance monitoring

10.6      Failure analysis

11.        Managing your condition monitoring program

11.1      Baselines and trending

11.2      Which machines to monitor

11.3      Managing the data

11.4      Scheduling maintenance

11.5      Outsourcing

11.6      Selling to management: A new mindset

            Review questions

SUMMARY & OPEN FORUM

COMPLETE FEEDBACK SHEETS

CLOSING