Level II certification available
Format: 5 day with the test in the afternoon of day 5
Since Update International started teaching vibration analysis in the mid ‘60s, we have always kept our focus on giving practical information. Our 45 years of training experience have given us insights into how to get concepts across in a truly effective manner. To enhance the learning experience we have added our unique computer-based learning environment to the seminar. This allows some “hands-on” type experiences and practice sessions to the classroom training. Using the vibration simulator, self-paced practice ‘homework’ will allow the students to get practice using the concepts they learn in the classroom right away.
As technology has developed in the vibration field, many training courses have put more and more emphasis on the technical details of the instruments, theory and mathematics of vibration. The amount of information necessary for the trainee to learn, and in some cases to be certified on, can be overwhelming. As a result, for a majority of vibration analysts, their daily activities consist mostly of monitoring with very little analyzing. Typically, they pick out the “bad” machines from the “good” machines and then generate work orders for repairs (usually change out parts). Little is done to determine the root cause of the problem and prevent it from occurring again.
Update International has always taught analysts to determine the causes of vibration problems and eliminate them, not only making “bad” machines into OK machines, but also making OK machines into precision machines. In recent years, we have gone even further by making the goal to eliminate the problems before the machine is turned over to operations – before they do damage to the machine.
We begin the seminar with introducing the course instructor and the attendees (their backgrounds and goals for the seminar), who are all encouraged to share their experiences to add to the knowledge being offered. The philosophies of maintenance are discussed as a vibration program must work within that program and cannot be separate from the overall maintenance program.
The basic concepts of vibration are reviewed (some introduction to vibration is preferred) such as the types of amplitudes and when to use each. Moving right to analysis, the four types of data needed are introduced: history, amplitude, frequency and phase. The importance of each with simple examples of how they are used in analysis is shown.
History is often a neglected area which often reflects a communication gap in the plant. We address this concern throughout the seminar as it is a very important element in an effective program. The concept of amplitude analysis (comparing amplitudes at various positions and directions) is demonstrated and practiced. Even at this early stage the concept of resonance is introduced, as it can affect even the most basic analysis.
The introduction of waveforms and spectra are shown with hands on exercises on the simulator. Frequency analysis is then introduced with a unique understanding. At the same time we can lay a foundational understanding of the concept of phase. The limitations of some of the rules of thumb that many heavily rely on are explained with an understanding of vectors. Finally, there is an introduction to the under used practice of phase analysis.
At this point we look again at the financial implications of the vibration program and how to quantify it. The job of a vibration analyst includes justifying the program to management and effectively communicating what is working and what can be improved. Training in this area is seldom given to the analyst who often expects the fruit of his labor to just be noticed by management.
A generic overview of the types of vibration instruments and transducers is covered with an emphasis is on the setting and parameters that must be addressed with each instrument, such as resolution, low frequency cutoff and sampling rate. We will be using Update’s virtual instrument to demonstrate in the classroom but only the generic concepts, applicable to all instruments, will be taught. The focus with transducers will be on proper mounting techniques.
Beginning spectral analysis starts with definition of terms and clearing up common misconceptions. An overview shows what symptoms show up in each area of a spectrum. What can create vibration at frequencies less than 1x RPM, at running speed, in the lower harmonics, and at higher frequencies. This will show the typical pattern for most vibration problems. Later, each problem is addressed in depth, including the exceptions to the rules.
Three very important concepts need to be understood in order to do effective analysis without confusion. Truncation of a waveform which creates harmonics in a spectrum, modulation of a waveform which creates sidebands in a spectrum, and beats, created by two frequencies going in and out of phase with each other. Knowing why these occur will provide a better understanding of the conditions that produce symptoms.
The most common distinction that the analyst will have to make is that of separating imbalance from misalignment. This subject is covered in depth using spectra and vectors, including why the simple rules don’t always apply. Later we will apply phase analysis to enhance the analysis.
In turn, we examine the topics of vibration from looseness and rubs, electrical hum and rotor bar problems, identifying the various stages of bearing failure, flow related problems in pumps, problems in belt driven machines and gear problems. Case histories and exercises help the student learn these subjects.
Resonance is a major concern for the vibration analyst as there are usually more machines with at least a partial resonance amplifying vibration a source. While the concept of resonance is introduced earlier, this is the point where it is studied in depth. A number of very effective, practical techniques for detecting and eliminating resonance are covered. Many of these techniques can be performed by non-analysts (such as mechanics and operators) with just minimal training. Topics of special interest include foot related resonance and resonant whirl. Again, case histories add to the student’s knowledge.
While the concept of phase is applied in a number of vibration courses and is used in balancing, too few analysts use phase analysis in their work. This is a very powerful tool to accurately separate misalignment from imbalance, which sometimes looks similar in spectra. Exercises practice the application right away.
An in-depth look at the causes of the two most common machine problems, imbalance and misalignment, are taken here. The analyst’s job is not just finding the problems but helping prevent them from occurring again. We begin by understanding balancing tolerances and their origin, what it considered true precision. Understanding the difficulties of balancing narrow and overhung rotors and how to get past them gives the analyst the ability help create proper specifications and procedures. All the proper balancing, however, will not result in a precision balanced machine unless precision assembly is done in the field. A review of the common assembly errors that affect balance addresses this issue.
Many mechanics are led to believe that just using a precision alignment tool will assure that the alignment job will be precision. We look at the many things that can make an alignment difficult as well as inaccurate.
The final topic is the direction the best programs are evolving to. The most effective way to avoid problems is a system to prevent them from happening in the first place. We cover unique procedures to spot and eliminate problems before the machine is put into service, most of which can be performed by others with minimal vibration training.
This brings us to about noon on Friday. The afternoon is reserved for those who wish to take the optional certification test. The test fee is $200US.