Analytical Prevention of Machinery Failure, PM & Troubleshooting of Plant Rotating Equipment

This advanced course for industry aims to convey the latest thinking and best practice of machinery vibration monitoring and analysis via lectures, case studies, video films, and friendly software and program activities. The program gives a detailed advanced treatment of the detection, location and diagnosis of faults in rotating and reciprocating machinery, using vibration analysis. Industrial case study examples are used throughout the program to emphasize key points and to underline the relevance and applicability of the topics being addressed.

The course will provide a refreshment of knowledge for existing condition monitoring practitioners and it will provide a solid foundation for technologists moving into a machine monitoring and diagnostic role.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

• Apply knowledge on analytical prevention of machinery failure, pm & troubleshooting of plant rotating equipment
• Acquire a detailed understanding of advanced time and frequency analysis techniques
• Assess accurately machinery condition
• Use accurate diagnosis of antifriction bearings
• Apply accurate evaluation of gear problems
• Carryout structural troubleshooting
• Obtain knowledge of predicting remaining machine life

Who Should Attend?

This course is intended for engineers and technicians working in application and management of predictive maintenance as well as for designers and production managers and engineers working in technical and design modification roles within industries.

Course Outline

Day 1
Vibration Signal Processing and Assessing Condition

• Sampling, Aliasing, Digitizing
• Time, frequency and modal domains
• Time & Frequency Representation
• Frequency domain instrumentation
• Fast Fourier transforms
• Windowing
• Filtering
• Averaging
• Amplitude Scales
• Transmission Path Effects
• Harmonic, periodic, random motion
• Generated and excited frequencies
• Frequencies caused by electronic phenomena
• Relationship between velocity, displacement and acceleration
• Band selectable analysis and real time bandwidth
• Speed and load adjusted sensitivity
• Identifying imbalance
  • Bent shaft
  • Soft foot
  • Looseness
  • Horizontal
  • Vertical
  • Offset
  • Angular
  • Misalignment
  • Noise
  • Resonance
  • Rubs
  • Oil whirl
• Case studies

Day 2
Advanced Analytical Techniques

• Principles of the envelope
• Pulse trains and line spectra
• Loaded element modulation
• Definitions of the Cepstrum
• The autocorrelation function and coding the cepstrum
• Comparison with spectrum and phase sensitivity
• Transmission path effects
• Zoom cepstra and noise level effects
• Dynamic range limitations and the effect of filter bandwidth
• Other demodulation techniques
• Use of phase in diagnostics
• Case studies

Day 3
Advanced Troubleshooting of Anti-Friction Bearings

• Data collection and transducer selection
• Frequency calculation
• Identifying (inner and outer race; multiple defects; defect severity; nature of defect; deep fatigue spalls; shallow flaking; frosting; acid etching/corrosion; fluting) defects
• Defects on balls/rollers and cage
• Inadequate lubrication
• Looseness
  • Excessive internal clearance
  • Turning on the shaft
  • Loose in the housing
• Case studies

Day 4
Advanced Troubleshooting of Gearboxes

• Transducer selection
• Gear vibration theory
• Gearmesh frequency; harmonics and subharmonics
• Hunting tooth frequency
• Planetary gears
• Gear life expectancy
• Identifying eccentric gears
  • Out-of-round
  • Bent shaft
  • Loose
  • Worn
  • Misaligned
  • Backlash problems
  • Oscillating gears
  • Broken
  • Cracked or chipped teeth
• Case studies

Day 5
Advanced Diagnostics and Structural Troubleshooting

• Vibration Control
  • Transmissibility
  • Excitation
  • Design charts
• Fundamentals of isolator selection/damping applications
• Structural supports Considerations
• Critical Shaft Speeds
• Vibration in Ducts
• Vibrational control via structural modification
• Electric motor analysisOut-of-magnetic centre
  • Broken rotor bars
  • Turn to-turn shorts
  • Siren effect
• Steam turbines
• Pumps, starvation and cavitation
• Special tests
  • Start-up/Coast down
  • Bump tests
  • Noise recording
  • Synchronous time averaging (STA)
  • Relative motion measurements (RMM)
• Dual-channel impact testing
• Modal analysis
  • Natural frequency
  • Mode shape
  • Damping
• Start-up/coast-down testing
• Critical speeds/damping
• Operational deflection shapes

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

Course Fees

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Course Timings

Daily Course Timings
08:00 - 08:20       Morning Coffee / Tea
08:20 - 10:00       First Session
10:00 - 10:20       Coffee / Tea / Snacks
10:20 - 12:20       Second Session
12:20 - 13:30       Lunch Break & Prayer Break
13:30 - 15:00       Last Session