Practical Machinery Vibration Analysis and Predictive Maintenance

THE WORKSHOP

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 reviewed followed by a discussion of machinery fault diagnosis using vibration analysis, and rectifying the unidentified faults. 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 used together with current research techniques in vibration analysis are also highlighted in the workshop.

WHAT IS INCLUDED?

  • Receive a certificate of attendance in support of your continuing professional commitment
  • All workshops include the associated hardcopy technical manual
  • Printed workshop handouts
  • Lunch and refreshments
  • Interact and network with workshop attendees and experienced instructors
  • Practical, industry driven content to assist you in your continuing professional development (CPD)
  • Attendees automatically become IDC subscribers and receive exclusive deals and technical content every month

WHO SHOULD ATTEND?

  • Automation engineers
  • Consulting engineers
  • Control technicians
  • Electrical engineers
  • Electricians
  • Instrumentation and control engineers
  • Maintenance engineers and technicians
  • Process engineers

CONTENT SUMMARY

INTRODUCTION

  • Evolution of maintenance in process plants
  • Classification of plant machinery
  • Maintenance strategies as adopted to each class of machinery
  • Identification of critical machinery and adoption of CBM
  • Principles of predictive maintenance, its utilisation in detection and diagnosis
  • Various techniques under predictive maintenance
  • Vibration analysis as one of the key techniques

VIBRATION BASICS

  • Spring mass system – mass, stiffness, damping
  • Wave fundamentals – concepts of amplitude, frequency, fundamental frequency, harmonics, phase, waveforms (sinusoidal, complex) – concepts of peak, peak-peak, rms
  • Vibration parameters – displacement, velocity, acceleration
  • Choice of vibration parameters
  • Using vibration theory to machinery fault detection
  • Limits and standards of vibration

DATA ACQUISITION SYSTEMS AND TECHNIQUES

  • Vibration transducers and their mountings
  • Data acquisition equipment – hand held meters, data collectors (single, dual channel), online monitoring
  • Equipment setup and data collection
  • Basic steps in data acquisition, overlapping, windows

BASICS OF SIGNAL ANALYSIS

  • Time waveform analysis
  • Fast courier transform analysis
  • Phase measurement
  • Enveloping and demodulation
  • Orbits
  • Advanced signal analysis
    • Triggered data capture
    • Synchronous time averaging
    • Peak holding averaging
    • Coastdown analysis (bode/Nyquist)
    • Enveloped spectras – gSE, Peakvue, SEE
    • Modal shape analysis
    • Cross channel analysis – coherence, FRF, TRF
    • Cepstrum
    • Torsional vibration

VIBRATION ANALYSIS FOR DIFFERENT MACHINERY FAULTS

  • Unbalanced
  • Misalignment, looseness, distortion
  • Bad bearings, journals
  • Gears, couplings
  • Critical
  • Resonance
  • Electrical
  • Miscellaneous

MACHINERY SPECIFIC VIBRATION ANALYSIS

  • Pumps
  • Compressors
  • Engines
  • Turbines
  • Motors

VIBRATION MONITORING AND ANALYSIS – TURBOMACHINERY

  • Importance of shaft vibration - usage of eddy current probes
  • Installation of probes on a turbomachinery train
  • Brief description of the turbomachinery vibration setup
  • 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
  • Typical problems associated with turbomachinery – oil whirl/whip, structural resonance, vane blade passing, misalignment, rotor rubbing and shaft crack

RESONANCE IDENTIFICATION AND RECTIFICATION

APPLICATIONS OF VIBRATION

ANALYSIS - BALANCING OTHER PREDICTIVE TECHNIQUES

  • Oil particle and wear debris analysis
  • Thermography
  • Ultrasonics
  • Performance evaluation

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