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Vibration Analysis Category III
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
Course Content:
This course has a dedicated workbook based on the ISO 18436-2:2014
certification program for vibration analyst category III & is designed to prepare staff for the BINDT Cat III Certification Exam. The course is accredited to BINDT PCN CM GEN App D. The following is covered:
Day 1
Condition Based Maintenance
Implementing CM – ISO flowchart
Reliability & Criticality Analysis, Availability & Reliability, Series & Parallel Reliability Networks
Failure Rates, Selecting CM Techniques
● Task 1: Calculating availability (1†)
● Task 2: Creating an RBD
● Task 3: Selecting CM Techniques (6†)
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
Basic Motion, Definition of Vibration, Single and Two Degree of
Freedom Systems, Dynamic Vibration Absorber, Measuring Vibration
● Task 4: Measuring Velocity
● Task 5: Vibration Waveform Exercises (3†)
Waveform Descriptors, Phase, adding Sinusoidal Vibrations
● 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, Handheld Vibration Data Collection Systems, Handheld Vibration Meters, Data Acquisition
Instruments.
Transducers, Transducer Characteristics & Response, Examples of Vibration Transducers & Accessories
● Task 10: Performance of Different Transducer Types
Accelerometer Mounting Response, Adhesive Cure Times,
● Task 11: Mounting an Accelerometer using Glue-on Studs
Transducer Calibration, Examples of 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 Severity Exercises (11†)
● 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 (6†)
Poor Data Recognition Hints
Day 3
Monitoring Program Set-up
Typical Vibration Data Collection Parameters, Identifying Equipment, Recording Equipment Information, Machinery Types, 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
Effective Reporting
Vibration Signal Processing
Overview of Analogue to Digital Conversion, Signal Processing
Key Steps, Signal Acquisition Factors, Sampling Rate, Sample Length, Aliasing,
● Task 21: Recognising the Effect of Signal Aliasing
Time Waveforms, FFT Terminology, FFT Features, Waterfall Plot,
Spectrum Resolution, Dynamic Range, Signal Clipping and Truncation, Filters.
Day 4
Fault Analysis – Rolling Element Bearings (REB)
Types of Rolling Element Bearings (REB), Factors Influencing the Bearing Lubricant Film, Major Causes of REB Failure. REB Life, 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. REB Severity Chart.
● Task 22: Recognising Common Faults (4†)
● Task 23: Vibration Frequency & Signal Analysis (9†)
● 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
Common Machine Types with Journal Bearings, Types
of Journal Bearings & Thrust Bearings, Examples of Journal & Thrust Bearings. Relative and Absolute Vibration Measurement, Journal Bearing Oil Wedge, Shaft Centreline, Journal Bearing Vibration Fault Finding
Chart, 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 Testing, Examples of Modal Hammers. Exciter (Shaker) Test, Examples of Exciters.
● Task 28: Modal Hammer Test to Identify a Resonance (2†)
● Task 29: Exciter Test to
Identify a Resonance
● Task 30: Case History – Engine Test Pallet
Machine Self-excitation. Isolation, Reducing Transmission of Vibration, Examples of Isolation Mounts.
● Task
31: Selecting Isolation Mounts
Day 5
Corrective Action - Balancing
Introduction to Unbalance, Types of Rotor, Types of Unbalance, Balancing Methods, Examples of Portable Dynamic Balancers, Unbalance and Eccentricity, Balance Quality,
Balance Quality Grades, Estimating Permissible Unbalance, estimating a test mass
● Task 32: Specifying Balance Quality (4†)
Assessing Rotor Balancing Requirements, Measuring and Correction Planes.
● Task 33: Single-Plane Balancing without Phase
Detecting Amplitude and Phase, One Plane & Two Plane Balancing Checklist, In-situ Balancing Requirements.
● Task 34: Single-Plane
Balancing with Phase
Checking Linearity, Example Indexing Exercise
● Task 35: Rotor Indexing
● Task 36: Two-Plane Balancing with Phase
Polar & Component Correction
Corrective Action – Alignment
Shaft Alignment, Types of Misalignment, Factors
Influencing Alignment, Alignment Tolerances, Practical Alignment, Alignment Check-Off Sheet, Expansion of Materials due to Temperature, Examples of Shaft Alignment Instruments & Tools.
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. The VA Cat III Workbook has 36 Tasks or Case Histories with a total of 78 separate examples
Course Material:
Each delegate receives a comprehensive task-based workbook
(362 pages) with clear syllabus-based information and diagrams, pictures and practical examples:
This includes clear references to ISO 18436-2, BINDT PCN CM Gen App D syllabus & the BINDT Vibration
Monitoring & Analysis Handbook.
Difficulty Level: Advanced:
Note: VA Cat II Qualification is a pre-requisite for this course.
Candidates are recommended to have a good understanding of basic maths. For example: Algebraic formulae, calculating ratios, squares & square roots, geometric relationships e.g. cosine and sine rules.
ISO 18436-2 states: Successful completion of two or more years of mechanical technology or mechanical engineering at an accredited college, university or technical school is highly recommended for candidates
seeking certification to categories 3 and 4
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