• Understand the basics of vibration measurement
  • How a well designed program, and the reliability centered maintenance approach (with precision balancing, alignment, lubrication and resonance control), will improve the OEE and therefore the bottom line.
  • How to select the correct measurement location and axis, and collect good, repeat able measurements.
  • What the Fmax, resolution, averaging and other analysis settings mean, and how to select the optimum settings for a wide variety of machine types.
  • How to analyse vibration spectra, time waveforms, envelope (demodulation), and phase measurements.
  • How to diagnose a wide range of faults conditions: unbalance, eccentricity, misalignment, bent shaft, cocked bearing, looseness, rolling element bearings faults, journal bearing faults, gearbox faults, resonance, and other conditions.
  • How to set alarm limits manually and with statistics
  • How to balance and align a machine, and correct a resonance condition

The Workshop

Do you already have an understanding of vibration fundamentals and want to become more confident and accurate in your diagnoses? Then you will enjoy this course!

As a Category II analyst you are expected to know how to test machines correctly, how to diagnose faults accurately (and perform additional tests to verity your diagnosis), how to set vibration alarm limits, and how to correct certain types of faults. Now it is time to understand what those analyser settings mean so that you can take the best measurement. Now it is time to understand why the vibration patterns change the way they do – and how to use time waveform analysis and phase analysis to verify faults condition.

We are offering you the opportunity to not learn topics, but to truly understand the analyser and machine so that you feel confident in the decisions you make.

Course Outline

  1. I. Vibration principles:
    • Basic motion
    • Period Frequency
    • Amplitude (peak, peak-to-peak, RMS)
    • Measurements (Displacement, Velocity, Acceleration)
    • Units, unit conversions
    • Time orbital and frequency domains
    • Vectors, modulation
    • Phase
    • Natural frequency, resonance, critical speeds
    • Shaft and casing vibration
  2. Data Acquisition:
    • Instrumentation (and acquire readings)
    • Transducers
    • Sensor mounting, mounted natural frequency
    • Fmax Acquisition Time
    • Proximity Sensor Conventions
    • Triggering
    • Test Planning
    • Test Procedures
    • Recognition of poor data
    • Vibration system calibration
  3. Signal Processing:
    • Analogue and Digital; Sampling
    • FFT Application
    • Windows (Uniform, Hanning, Flat-top)
    • Filter (Low pass, High Pass, Band Pass, Tracking)
    • Anti-aliasing
    • Band-width, Resolution
    • Noise Reduction
    • Averaging (Linear, Synchronous time, exponential)
    • Dynamic range
    • Run-out Compensation
  4. Condition Monitoring:
    • Vibration Severity
    • Alarm set-up (Narrowband, Envelope)
    • Baseline Assessments, Trending
    • Route/ Task Planning
    • Alternate Technologies (e.g. Oil Analysis, Wear Debris Analysis, Infrared Thermography, Motor Current Analysis, Acoustic Emission)
    • Recognition of Baseline Variations
    • Alarm and trip Level Determination
    • Integrated Health Analysis
  5. Fault Analysis:
    • Basic Spectrum Analysis
    • Special Harmonics and sidebands
    • Time Waveform Analysis
    • Phase analysis
    • Transient Analysis
    • Orbital Analysis
    • Shaft Centre-line Analysis
    • Enveloping
    • Mess Unbalance
    • Misalignment
    • Concentricity Errors
    • Mechanical Looseness
    • Rubs
    • Instabilities
    • Shaft bow
    • Bearing (rolling, element, journal) Defects
    • Electric motor Defects
    • Gearbox Defects
    • Resonance and Critical speeds
  6. Corrective Action Recognition:
    • Shaft Alignment
    • Concentricity
    • Balancing
    • Basic Maintenance Action
    • Lubrication
  7. Acceptance Testing:
    • Test Procedures
    • Specifications and Relevant standards
    • Acceptance test Report
  8. Equipment Testing & Diagnostics:
    • Impact testing
    • Forced response testing (e.g. coherence. Transfer Function)
    • Model analysis
    • Process safety
  9. Reference Standards:
    • Relevant international (ISO, IEC), National and Regional Standards
  10. Reporting and Documentation:
    • Vibration CM Reports
    • Machine History Records
    • Decision Making and Recommend Action
  11. Faults Severity Determination:
    • Levels (Overall, Narrowband, Component0
    • Spectrum Analysis
    • Time Waveform and Orbit analysis
    • Severity charts, Graphs, Formulae
  12. Theoretical Rotor and Bearing Dynamics
    • Rotor characteristics
    • Bearing characteristics
  13. Field Balancing:
    • Single-plane
    • Two-plane

Who should Attend

If you have been performing vibration analysis for more than six months, and feel that you have a good understanding of the fundamentals, then you are ready to step up to the category II course. (Note that you require 18 months experience to be certified.) Anyone who wants to be confident and capable of diagnosing a wide range of faults conditions, correct certain conditions. And taking accurate measurements needs to take this course. Many plant sites require contractors to be certified. And many employers require employees to be certified. The vibration institute course and certification program follows the ISO 18436-2 Standard and accredited the American National Standards Institute.

Job Titles

  • Maintenance Manager
  • Engineering Manager
  • Reliability Manager
  • CBM Engineer
  • Facility Engineer

Coming from the following industries

  • Power Generation
  • Petrochemicals
  • Transportation
  • Automotive Manufacturing
  • Pulp & paper
  • Earth-moving (Mining)
  • Primary metals (steel Manufacturing / smelting)
  • General manufacturing
  • Process manufacturing

Vibration Analysis is used in the following objectives:

Early Detection of mechanical fatigue or breakdown

  • All rotating equipment vibrates to some degree, but as older bearings and components reach the end of their product life they begin to vibrate more dramatically, and in district ways
  • Ongoing monitoring of equipment allows these signs of wear and damage to be identified well before the damage becomes an expensive problem

Accurately monitor health of your plant machinery

  • It is a useful tool to identify unbalance, misalignment, eccentricity, bent shaft crack, mechanical looseness, journal bearings faults, rolling elements. Bearing faults, rotor rub, cavitation, electrical motor problems and gear faults.

Decrease downtime and increase savings

  • This process is generically known as ‘condition monitoring’. When used correctly, it can result in huge cost savings when compared to traditional maintenance methods
  • Traditional maintenance methods are preventive components are replaced on a fixed schedule whether worn or not and reactive maintenance in which components are repaired only after they have broken down.
  • Neither of these methods is ideal, although both are very common throughout the heavy industry sector, and both tend to incur much higher costs than those methods that use vibration analysis.