Master Advanced Vibration Analysis Techniques with CAT II Certification
This advanced course in vibration analysis is designed according to ISO 18436-2 standards, offering in-depth knowledge on diagnosing complex mechanical and electrical faults. Participants will develop the skills to effectively balance machinery, analyze signals, and perform comprehensive vibration diagnostics, including advanced techniques for electric motors, gearboxes, pumps, fans, and compressors.
Learning Objectives
- Understand advanced principles of vibration and signal processing.
- Acquire, process, and analyze complex vibration data for machinery health assessment.
- Diagnose faults such as unbalance, misalignment, and looseness, and perform machine balancing and shaft alignment.
- Analyze various components including electric motors, gearboxes, pumps, compressors, and rolling element bearings.
- Set alarm limits for early fault detection and perform acceptance testing of machinery.
Module 1: Principles of Vibration
Detailed overview of vibration theory. Importance of vibration analysis in predictive maintenance. Understanding different types of vibration signals and their sources.
Module 2: Understanding Signals
Introduction to vibration signals and data interpretation. Identifying key signal characteristics: amplitude, frequency, phase. Advanced signal recognition for fault identification.
Module 3: Signal Processing
An in-depth look at signal processing techniques for vibration analysis. Using time-domain and frequency-domain analysis. Advanced tools like FFT, envelope analysis, and filtering techniques.
Module 4: Time Waveform Analysis
Introduction to time waveform analysis for detecting faults. Interpreting waveform data for accurate machine condition assessment. Case studies on real-world applications of waveform analysis.
Module 5: Data Acquisition
Best practices for vibration data acquisition. Understanding sensor selection, placement, and data accuracy. Advanced techniques for data collection in different machine conditions.
Module 6: Vibration Analysis Process
A step-by-step guide to performing a detailed vibration analysis. Recognizing and categorizing different vibration patterns. Using historical data to improve analysis accuracy.
Module 7: Diagnosing Unbalance
Identifying and diagnosing unbalance in rotating machinery. Techniques for measuring unbalanced severity. Real-world examples of diagnosing unbalance.
Module 8: Machine Balancing
Methods for balancing machines to reduce vibration levels. On-site vs. off-site balancing techniques. Case studies on machine balancing and its impact on equipment longevity.
Module 9: Diagnosing Misalignment
Techniques for identifying misalignment in machinery. Using vibration data to detect angular and parallel misalignment. Practical examples of misalignment diagnosis and correction.
Module 10: Shaft Alignment
Principles of shaft alignment for minimizing vibration. Tools and methods for accurate shaft alignment. Effects of misalignment on machine health and performance.
Module 11: Diagnosing Looseness
Identifying signs of mechanical looseness in equipment. Analyzing vibration patterns to detect looseness issues. Solutions for correcting looseness and preventing further damage.
Module 12: Electric Motor Analysis
Vibration analysis for electric motor health monitoring. Detecting issues like rotor imbalances, electrical faults, and bearing failures. Advanced diagnostics for motor reliability and performance improvement.
Module 13: Gearbox Analysis
Techniques for diagnosing gearbox faults using vibration analysis. Identifying wear, misalignment, and gear tooth damage. Vibration analysis case studies focused on gearbox health.
Module 14: Natural Frequencies and Resonances
Understanding the role of natural frequencies in machine vibrations. Identifying and diagnosing resonances in mechanical systems. Solutions for mitigating resonance-related issues.
Module 15: Pumps, Fans, and Compressors
Vibration analysis techniques for pumps, fans, and compressors. Identifying common faults such as cavitation, impeller wear, and flow disturbances. Advanced fault diagnostics for rotating equipment.
Module 16: Belt Drive Analysis
Diagnosing issues in belt-driven machinery through vibration analysis. Identifying belt slippage, tension issues, and misalignment. Solutions for improving belt drive reliability.
Module 17: Rolling Element Bearing Analysis
Advanced techniques for analyzing rolling element bearings. Detecting early-stage bearing failures using vibration data. Preventive strategies for extending bearing life.
Module 18: Setting Alarm Limits
Establishing effective alarm limits for vibration levels. Configuring alarms to detect abnormal conditions early. Using alarm trends and data to predict machinery failure.
Module 19: Acceptance Testing
Performing vibration acceptance tests on new or repaired equipment. Setting baseline vibration levels and ensuring machinery meets performance standards. Importance of acceptance testing in quality assurance and reliability.
Who Should Attend
- Maintenance professionals seeking advanced diagnostics skills.
- Reliability engineers and condition monitoring personnel.
- Mechanical and electrical engineers responsible for machinery health.
Certification
Upon successfully completing the course, participants will receive the Vibration Analysis CAT II certification, recognized under ISO 18436-2 standards, certifying their ability to perform advanced vibration analysis and diagnostics.
