ICTD International Centre for Training and Development

Practical Machinery Vibration Monitoring, Analysis & Predictive Maintenance

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About the course

This training course is designed to give 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 course 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 course.

Course Objectives

Upon successful completion of this course, the delegates 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 allied predictive techniques such as oil analysis, thermography, ultrasonic and performance evaluation

Course Outline

Day 1

Predictive Maintenance Techniques: Predictive Maintenance Basics

  • Maintenance philosophies
  • Evolution of maintenance philosophies
  • Plant machinery classification and recommendations
  • Principles of predictive maintenance
  • Predictive maintenance techniques
  • Vibration analysis – a key predictive maintenance technique

Predictive Maintenance Techniques: Vibration Basics

  • Spring-mass system: mass, stiffness, damping
  • System response
  • What is vibration?
  • The nature of vibration
  • Harmonics
  • Limits and standards of vibration

Day 2

Data Acquisition

  • Introduction
  • Collection of vibration signal – vibration transducers, characteristics and mountings
  • Conversion of vibrations to electrical signal
  • Conclusion

Signal Processing, Applications and Representations

  • The fast Fourier transform (FFT) analysis
  • Time waveform analysis
  • Phase signal analysis
  • Special signal processes
  • Conclusion

Day 3

Machinery Fault Diagnosis Using Vibration Analysis

  • Introduction
  • Commonly witnessed machinery faults diagnosed by vibration analysis

Correcting Faults That Cause Vibration

  • Introduction
  • Balancing
  • Alignment
  • Resonance vibration control with dynamic absorbers

Day 4

Oil and Particle Analysis

  • Introduction
  • Oil fundamentals
  • Condition-based maintenance and oil analysis
  • Setting up an oil analysis program
  • Oil analysis – sampling methods
  • Oil analysis – lubricant properties
  • Oil analysis – contaminants in lubricants
  • Particle analysis techniques
  • Alarm limits for various machines (source: National Tribology Services)
  • Conclusion

Day 5

Other Predictive Maintenance Techniques

  • Introduction
  • Ultrasound
  • Infrared thermography
  • Conclusion

Course Methodology

A variety of methodologies will be used during the course that includes:

  • (30%) Based on Case Studies
  • (30%) Techniques
  • (30%) Role Play
  • (10%) Concepts
  • Pre-test and Post-test
  • Variety of Learning Methods
  • Lectures
  • Case Studies and Self Questionaires
  • Group Work
  • Discussion
  • Presentation

Who should attend

This course is intended for mechanical engineers, automation engineers, process engineers, consulting engineers, electrical engineers, instrumentation and control engineers, maintenance engineers, electricians, control technicians and other technicians.

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