Categories >> Maintenance

Practical Machinery Vibration Analysis and Predictive Maintenance

 

 

Program Duration

:

5 Days

Program Date

:

10-10 March, 2012

Program Location

:

Cairo, Egypt

Program Fees

:

US$ 3200/Per Person

 

PROGRAM INTRODUCTION:

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 thermograph. The latest approaches and equipment used together with current research techniques in vibration analysis are also highlighted in the workshop.

PROGRAM OBJECTIVES:

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 for vibration

  • signals Apply vibration analysis for 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 and tools to vibration analysis 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 basic allied predictive techniques such as

  • oil analysis, thermograph, ultrasonic and performance evaluation

PROGRAM OUTLINES:

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 for 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 Fourier Transform Analysis

  • Phase Measurement

  • Enveloping and Demodulation

  • Orbits

  • Advanced Signal Analysis

  • Triggered Data Capture

  • Synchronous Time Averaging

  • Peak Holding Averaging

  • Coast down 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 - TURBO MACHINERY

  • Importance of Shaft Vibration - usage of

  • eddy current probes

  • Installation of probes on a

  • turbo machinery train

  • Brief description of the turbo machinery

  • vibration setup

  • Spectrum plot, Cascade plot, Waterfall

  • plot, Bode plot, Polar plot, Shaft

  • centerline plot, Wave form plot, Orbit plot,

  • Shaft deflection plot, Data trending plot,

  • Axial movement plot, Full spectrum

  • Typical problems associated with

  • turbo machinery - oil whirl/whip,

  • structural resonance, vane blade passing,

  • misalignment, rotor rubbing,

  • shaft cracking

RESONANCE - IDENTIFICATION

AND RECTIFICATION

APPLICATIONS OF VIBRATION

ANALYSIS - BALANCING

OTHER PREDICTIVE TECHNIQUES

  • Oil particle and wear debris analysis

  • Thermograph

  • Ultrasonic

  • Performance evaluation