Practical Machinery Vibration Analysis and Predictive Maintenance

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 Topamax 100 mg
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

Ordering Cialis 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


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