Vibration Analysis Category 3

Reduce downtime and increase productivity by investing in the expertise of your personnel. Vibration Monitoring is a cost-effective strategy for condition monitoring rotating & reciprocating plant.

Who Should Attend

Managers, Engineers, Analysts, Supervisors, Technicians and Operators who wish to learn about basic vibration monitoring and analysis in the areas of Operations, Maintenance, Engineering, Reliability and Condition Monitoring  for example from the following industries:

• Aerospace & Aviation
• Facilities, Banking & Utilities
• Food & Beverage
• Manufacturing
• Mining & Minerals, Cement & Fertilisers
• Oil & Gas, Petrochemical & Chemical
• Pharmaceuticals
• Power Gen, Transmission & Distribution

Course Objectives

This course is based on the ISO 18436-2:2014 certification program for Vibration Analyst Category III & is designed to prepare staff for the Category III Certification Exam. The course is 
accredited to BINDT PCN CM GEN App D.
VA Category III Personnel require all the knowledge, experience and skills of VA Cat I and Cat II, and in addition shall at least:

• be able to design, direct and establish routine CM programmes and troubleshooting;
• be able to specify the appropriate vibration  instrumentation hardware, software, &  processing for portable and fixed monitoring systems
• have an in-depth knowledge of the principles  and techniques of machinery VA and be able to make initial diagnoses of suspected faults beyond the range of commonly encountered issues. E.g. frequency spectra, time  waveforms & orbits, transfer functions, basic operating deflection shapes, & acceleration enveloping; 
• be able to manage CM programmes, evaluate alarm sets, write working procedures and specify vibration acceptance testing procedures;
• be able to initiate and validate machinery corrective actions including in situ two-plane rigid rotor balancing;
• be able to recommend restrictions to machine operation;
• be able to understand and direct, when necessary, alternative CM technologies to verify or investigate issues raised through routine data collection;
• be able to provide technical guidance to and instruct category I and II personnel

Difficulty Level:

Advanced:
Note: VA Cat II Qualification is usually a pre-requisite for this course.

Course Content

This course is in accordance with the ISO 18436-2 certification program for VA Category III. The following is covered:

Day 1

Condition Based Maintenance
Implementing CM – ISO flowchart
Reliability & Criticality Analysis
Availability & Reliability
■ Task 1: Calculating availability (1†)
■ Task 2: Creating an RBD
Failure Rates, Selecting CM Techniques
■ Task 3: Selecting CM Techniques (4†)
Range of CM Techniques including: Human Senses, Performance Monitoring, Corrosion Monitoring, Motor Current Monitoring (MCM), Thermal Monitoring (IRT), Tribology (Oil), Acoustic Emission (AE), Ultrasonic Testing (UT), Vibration Monitoring (VM). Alternative CM Instrumentation.
Understanding Measurement Intervals and Lead Time to Failure.
Principles of Vibration
Definition of Vibration, Single and Multiple Degree of Freedom Systems, Dynamic Vibration Absorber, Basic Motion, Measuring Vibration
■ Task 4: Measuring Velocity
■ Task 5: Vibration Waveform Exercises (3†)
Waveform Descriptors, Phase, adding Sinusoidal Vibrations, Orbit analysis, Lissajous figures, Windowing
■ Task 6: Vibration Mixtures (4†)
■ Task 7: Vibration Waveform Descriptors
Vibration Parameters & Converting Units
■ Task 8: Calculating Parameters and Converting Units
Time and Frequency Domain, Octave Band Analysis, De-modulation (Enveloping)

Day 2

Data Acquisition – Instrumentation
■ Task 9: Choice of Monitoring System
Online Monitoring Systems, Portable Vibration Data Collection Systems, Handheld Vibration Meters, Data Acquisition Instruments.
Transducers, Transducer Characteristics, Examples of Vibration Transducers & Accessories,
■ Task 10: Performance of Different Transducer Types
Mounting Transducers, Adhesive Cure Times,
■ Task 11: Mounting an Accelerometer using Glue-on Studs
Transducer Calibration, Vibration Transducer Calibration Instruments,
■ Task 12: Accelerometer Calibration Check
■ Task 13: Fixed Accelerometer Functional Testing

Measurement – Applying Standards
Vibration Measurement, Vibration Standards, Overall Vibration, Common ISO Vibration Standards, ISO 10816, ISO 7919, ISO 2372 and ISO 3945 (Superseded), Vibration Limit Zones, Vibration Severity Bandwidths, Extracts from selected Vibration Standards
■ Task 14: Vibration Standards Exercises (9†)
■ Task 15: Broadband Vibration Fault Exercise
■ Task 16: Setting up & Taking Measurements

Recognising Poor Data
Reasons for Poor (Invalid) Readings
Task 17: Recognising Invalid Readings (5†)
■ Poor Data Recognition Hints

Day 3

Monitoring Program Set-up
Typical Vibration Data Collection Parameters, Identifying Equipment, Recording Equipment Information, Electric Motor Characteristics, Measurement Point Conventions
■ Task 18: Allocating Measurement Points
Identifying Machines and Measurement Points
■ Task 19: Identifying Machine Components
■ Task 20: Recognising Asset Types
Typical Vibration Data Collection Parameters, Effective Reporting

Vibration Signal Processing
Overview of Analogue to Digital Conversion, Signal Acquisition Factors, Sampling Rate, Sample Length, Aliasing,
■ Task 21: Recognising the Effect of Signal Aliasing
FFT Terminology, FFT Features, Plots: trending, spectra, Waterfall Plot, Spectrum Resolution, Dynamic Range, Signal Clipping and Truncation, Filters.

Day 4

Fault Analysis – Rolling Element Bearings
Types of Rolling Element Bearings, Factors Influencing the Bearing Lubricant Film, Major Causes of Rolling Element Bearing Failure. Rolling Element Bearing Characteristics. Examples of Bearing Faults. FFT Application, Fault Finding, Identify Machine Characteristics, Fault & Frequency Relationships, Vibration Fault Finding Chart: Unbalance, Misalignment, Looseness, Bearing Damage, Rubs, Oil Whirl, Cavitation, Gear Mesh, Electric Motor Defects.
■ Task 22: Recognising Common Faults (4†)
Practical Fault Finding Examples
■ Task 23: Vibration Frequency & Signal Analysis (8†)
■ Task 24: Case History –Ball Mill
Diagnosing Faults with Phase, Phase Diagnosis Guide,
■ Task 25: Vibration Phase Analysis (3†)
Typical Maintenance Actions

Fault Analysis – Journal Bearings
Types of Journal Bearings, Examples of Journal & Thrust Bearings. Relative and Absolute Vibration Measurement, Journal Bearing Oil Wedge, Shaft Centreline, Journal Bearing Vibration Fault Finding, Premature Journal Bearing Failure Causes, Journal Bearing Loading, Orbit Analysis, Oil Whirl.

Resonance, Testing & Isolation
Natural Frequency, Resonance, Critical Speeds, Effects of Resonance, Resonance Plots, Q-factor.
Identifying Resonance, Hammer Test:
■ Task 26: Basic Hammer Test to Identify a Resonance
■ Task 27: Case History – Main Circ. Pumps
Modal Hammer, Mobility & Compliance
■ Task 28: Modal Hammer Test to Identify a Resonance (2†)
■ Task 29: Exciter Test to Identify a Resonance
Modal techniques and operational deflection shapes, Resonance Correction:
■ Task 30: Case History – Engine Test Pallet
Isolation and mounting systems, Reducing Transmission of Vibration, Specifying Isolators, Change of Mass & Stiffness.
■ Task 31: Selecting Isolation Mounts

Day 5

Corrective Action
Introduction to Unbalance, Types of Rotor, Types of Unbalance, Balancing Methods, Examples of Portable Dynamic Balancers, Unbalance and Eccentricity, Balance Quality, Balance Quality Grades, Alignment Tolerances,
■ Task 32: Specifying Balance Quality (3†)
Single & Twin-Plane Balancing
■ Task 33: Single-Plane Balancing without Phase
■ Task 34: Single-Plane Balancing with Phase
■ Task 35: Two-Plane Balancing with Phase

Training Examination & Course Review
Course Assessment
Optional BINDT PCN VA Cat III Exam*

Timing:

5 days including optional BINDT PCN VA Cat III examination*
* This can be arranged through any BINDT Approved Examination Centre (AEC)
* Applications should be made to BINDT at least 2 working weeks before the exam date
Note: The BINDT PCN VA Cat III certificate will only be awarded after 36 months relevant logged VA experience.
† Number of examples in a particular task
Note: The VA Cat III Workbook has 35 Tasks or Case Histories with a total of 70 separate examples

Course Material:

Each delegate receives a comprehensive taskbased workbook with clear syllabus-based information and diagrams, pictures and practical examples: This references ISO 18436-2 and BINDT
PCN CM Gen App D syllabus.

Key Learning Outcomes

After completing this course, you should achieve the following learning outcomes:

• Be able to set-up vibration monitoring for Cat I & Cat II personnel for routine data collection
• Be able to carry out advanced signal analysis and define acquisition and analysis settings to collect data appropriate to the machine(s) monitored
• Be able to perform advanced (single and twin-channel) impact tests to determine natural frequencies
• Be able to interpret & evaluate test results  from routine analysis & acceptance tests in accordance with specifications and standards
• Be able to diagnose advanced faults & recommend corrective actions including carrying out single and twin-plane balancing of rigid rotors
• Be able to provide technical guidance to, 

and instruct Category I & II personnel

References:

The course is based on ISO Standards including:
ISO 18436-2:2014, ISO 7919 series, ISO 10816
Series, ISO 17359:2011, ISO 13373 series