Training Course Outline

Day 1
Maintenance Techniques and Strategies

• What are Maintenance Techniques?
• Why Choose Particular Maintenance Techniques.
• Matching Technique to Failure Mode and Criticality.
• Reliability Centred Maintenance Methodology,
• CBM Implementation Methodology.
• Failure Rates - Classic Failure Rates & Real Failure Rates.
• Failure Rate Profiles.
• Maintenance Strategies,
• Feasibility of Application,
• Summary of Techniques
• Task 1: Matching Maintenance Strategy to Failure Rate Profiles
• Task 2: Comparison of benefits & drawbacks of 4 strategies
• Task 3: Matching Failure Modes to Strategies for 12 examples

Introduction to Condition Monitoring

• What is condition based maintenance (CBM).
• Condition monitoring techniques including:
• Human Senses,
• Performance Monitoring,
• Corrosion Monitoring,
• Thermal Monitoring,
• Oil Analysis & Wear Debris Monitoring,
• Current Monitoring,
• Vibration Monitoring,
• Acoustic Emission,
• Ultrasonic Monitoring.
• Selecting techniques
• Task 1 to 3: applying CBM techniques to selection of example machines: E.g. Pump, Fan & Centrifugal Compressor examples.

Condition Monitoring Standards

• History of standardisation, and current procedures for developing standards.
• Overview of Condition Monitoring International Standards.
• Overview of Condition Monitoring Training and Certification Standards.

Introduction to Vibration Monitoring

• Setting up a vibration condition monitoring program, equipment audit, identifying measurement points.
• Choosing appropriate technique, overall & spectral monitoring.
• Online or portable systems, cost comparison of VM, program set-up, asset types, practical data collection & reporting.
• Task 1: Setting up system - choosing asset types & setting up points
• Task 2: Practical Data Collection

Vibration Severity Measurement

• Using overall vibration,
• vibration limit zones from ISO 10816,
• broadband vibration bandwidth,
• alert levels,
• typical severity guidelines,
• recording overall vibration,
• using overall vibration for fault finding,
• trending vibration
• Task 1-6 Vibration Severity Examples

Day 2

Principles of Vibration Analysis

• Vibration units & descriptors,
• basic motion,
• time & frequency domains.
• Frequency and amplitude,
• Fmax, filters, phase relationships,
• typical spectra,
• vibration mixtures,
• quantifying the vibration
• Task 1 to 3 – Vibration Displacement, Velocity & Acceleration graphs
• Task 4: – Frequency, Amplitude and Phase
• Task 5 & 6: – Vibration Mixtures (odd & even harmonics)

Applying Vibration Standards

• Range of vibration standards including ISO 10816, ISO 7919, ISO 14694.
• Examples of vibration limit tables.
• Applying limits.
• Transducer requirements.
• Applying limits.
• Task 1-6 Applying Appropriate Vibration Limit Examples

Vibration Data Acquisition

• Instrumentation,
• Permanently installed & Portable systems.
• Transducers,
• Response Types,
• Accelerometers,
• Velocity Transducers,
• Displacement Transducers,
• Mounting Transducers.
• Measurement Point Schematics.
• Task 1: Identifying components for example machine
• Task 2: Allocating measurement points on example machine

Vibration Spectral Analysis

• 32 actual vibration spectra with brief details about the equipment.
• The examples show key frequencies, shape of peaks, harmonics, relative amplitude
• Tasks: 16 machines to diagnose

Vibration Analysis & Fault Finding

• Diagnostics & Fault Finding.
• Vibration Monitoring Fault Finding Process.
• Typical Maintenance Actions.
• FFT Range & Resolution.
• Bearing Faults
• Task 1: Case History – Rotating Machine Fault Frequencies
• Task 2: Case History – Rotating Machine Fault Diagnosis

Workshop on Data Collectio

• Task 1: Setting up example machine measurement points
• Task 2: Taking measurements, reviewing overall measurements
• Task 3: Reviewing spectra and time traces

Day 3

Introduction to Shock Pulse Monitoring

• Function of a shock pulse transducer,
• Processing shock pulse signals.
• Effect of:
• external conditions,
• Lubricant film thickness.
• Quantifying the shock pulse measurement,
• dBm/dBc,
• Carpet value dBc,
• Maximum value dBm,
• Common sources of interference

Recognition of Poor Data

• Takes real examples of measurements with faults.
• Discusses main reasons for bad or poor readings.
• Task 1: Readings with fault(s) for Air Replacement Plant
• Task 2: Readings with fault(s) for Air Replacement Plant
• Task 3: Readings with fault(s) for Re-circulation Fan

Vibration Fault Finding using Phase

• Use of phase in vibration fault finding
• Task 1 – Close coupled machine phase diagnosis example
• Task 2 – Open drive machine phase diagnosis example
• Task 3 – Gearbox drive machine phase diagnosis example

Introduction to Balancing

• Effects of Unbalance, Types of Rotor, Causes of Unbalance.
• Types of Unbalance - Static, Couple, Quasi-static, Dynamic.
• When to Balance, Balancing Methods.
• Quantifying Unbalance, Unbalance and Eccentricity, Balance Quality.
• Task 1: Specifying Balance Quality – Exhaust Fan
• Task 2: Actual Permissible Unbalance – Exhaust Fan
• Task 3: Specifying Balance Quality – Gas Turbine
• Task 4: Actual Permissible Unbalance – Gas Turbine

Practical Balancing

• Carrying out one plane balancing.
• Checklists, equipment requirements, procedures and tips for practical site balancing.
• Task 1: Single plane balancing exercise without phase
• Task 2: Single plane balancing exercise with phase
• Review of day 3 and Course wash up / test questionnaire on days 1 – 3.

Day 4

Vibration Signal Processing

• Data display & processing;
• FFT,
• time waveform,
• linear averaging,
• time synchronous averaging,
• exponential averaging,
• overlapping data,
• acquisition time,
• dynamic range influence,
• clipping,
• truncation,
• anti-aliasing,
• picket fence effect,
• noise elimination
• Task 1: Showing effect of sampling and averaging
• Task 2: Showing effects of applying different filters
• Task 3: Showing effects of dynamic range and noise

Bearing Fault Diagnosis

• Rolling Element Bearing fault diagnosis showing examples of Fatigue Failure,
• Misalignment,
• Incorrect Fitting Methods and other failure causes.
• Includes Corrosion when Stationary,
• False Brinelling Lubrication Failures,
• Wear,
• Fretting
• Damage & Electrical Damage
• Task 1: Selection of damaged bearing photographs to diagnose

Vibration Time and Spectral Examples

• 32 actual measurements with time, spectral and or trend data with brief details about the equipment.
• The examples show time traces, key frequencies, shape of peaks, harmonics, relative amplitude etc.
• Tasks: 16 machines to diagnose

Vibration Transducer & Calibration Workshop

• Calibration of vibration measurement systems.
• Task 1: Demonstration of calibration of accelerometer and vibration analyser using calibrator
• Task 2: How to fitting accelerometer to glued screw stud mounting

Single Degree of Freedom Systems

• Introduces single degrees of freedom systems, shows effect of parameters including mass, and damping.
• Task 1: Demonstration of varying parameters on spreadsheet example

Day 5

Vibration Acceptance Testing

• Benefits of Acceptance Testing.
• Contractual Matters and Project Planning.
• Vibration Acceptance Testing.
• Acceptance Testing Requirements.
• Vibration Severity Measurements.
• Performance & Testing Standards References

Structural Resonances

• Identifying Resonance,
• Hammer Test,
• Self Excitation,
• Exciter Testing,
• Reducing Resonance - Effects of Frequency, Stiffness, Mass, Damping, Isolation
• Task 1 Hammer Test
• Task 2 Run Down (Coast Down) Test
• Task 3 Machine Excitation at Fixed Speed
• Task 4 Exciter Test
• Case History 1 – Engine Test Pallet
• Case History 2 – Circulation Pump

Vibration Isolation

• Why do we need to isolate?
• Useful Web sites.
• Explaining Vibration Isolator Characteristics.
• Typical Procedure for Selecting Isolators including Finding Forcing frequencies
• Task 1: Example of selecting Isolators for Large Exhaust Fan
• Task 2: Case History of Engine Test Pallet

SpectrumPDA Vibration Data Collection

• Practical use of data collection system.
• Creating assets, loading sites, measuring assets, analysis functions, reporting, modification of hierarchy.

Training Examination

• Post-test multiple choice training examination designed to cover days 1 - 5.
• Note: Success in test is pre-requirement for eligibility for sitting PCN Level 2 examination.

Course Wash-up

• Review of course and candidates assessment of trainers