PdM-202: Vibration Analysis Level II Plus TM

Transcription

1 PdM-202: Vibration Analysis Level II Plus TM Abstract A primary goal of modern condition-based maintenance programs is to maximize machinery reliability. The success of these efforts is often monitored by tracking mean-time-betweenfailures (MTBF), production uptime, product quality, maintenance costs, etc. Unfortunately, many programs fail to achieve the highest level of effectiveness because too much time is spent on the detection, rather than the analysis and prevention of problems. A key component of extending machinery life is effective analysis of the root cause of machinery failure, and using this knowledge to prevent recurrence of the failure. Level II Plus TM This seminar aims to first qualify individuals to perform the vibration data collection and analysis tasks associated with ASNT vibration level II certification, and then certify them to ASNT level II. The result of this approach is that individuals who successfully complete the seminar will be qualified to perform level II vibration tasks, such as: 1. Set up a vibration instrument and acquire spectral, phase and time waveform data for analysis purposes for common machinery applications. 2. Analyze and make suggestions for resolving the common vibration problems. This seminar focuses on use of practical vibration analysis and correction techniques. Its goal is to equip the analyst with the tools required to perform such analysis. Using our unique Activity Based Training format, analysts do not just learn the concepts of analysis, but receive detailed information on how to implement these concepts as a part of an effective machinery reliability program. The seminar addresses how to develop existing predictive technologies and interact with those in management, production and other departments. Analysts learn how much more value can be obtained by utilizing all resources available to obtain root cause solutions. Whereas many training programs are available on general vibration analysis concepts, and others on specific instrument procedures, this seminar combines the two. It also addresses the subjects from the perspective of specific machine types and components which face the analyst on a daily basis. This seminar includes over thirty (30) guided hands-on activities, designed to maximize the retention of information. This unique approach better equips the analyst to apply the seminar content and to immediately solve problems upon returning to the plant. Page 1 of 7

2 Seminar Duration The standard duration of this seminar is 32 hours. Optional ASNT Level II certification is available subsequent to the seminar. Who should attend? This seminar is designed primarily for practitioners of vibration analysis whose job functions involve or relate to maximizing machinery reliability using current condition monitoring technologies. The scope of content is appropriate for those who collect vibration data, analyze machines, perform root cause failure analysis, or investigate and resolve premature machinery failure problems. A prerequisite is to have successfully completed Level I training. Associated Task(s) 1. Set up a vibration instrument and acquire spectral and phase data for analysis purposes for common machinery applications. 2. Analyze and make suggestions for resolving the following common vibration problems: a. Unbalance b. Misalignment c. Resonance d. Bearing defects e. Looseness f. Bent shafts g. Gear defects h. Electrical defects i. Hydraulic/flow dynamics j. Rubs k. Belts and couplings l. Eccentricity m. Beats n. Soft foot Page 2 of 7

3 Seminar Objectives Upon completion of this training the student will be able to properly: 1. Explain four maintenance philosophies in use today, including the advantages and disadvantages of each. 2. Explain key elements of condition-based and precision maintenance programs. 3. Explain costs and benefits associated with precision maintenance, including: a. Impact on Energy Consumption b. Impact on Bearing Life c. Examples of overall impact on vibration, maintenance scheduling, and production 4. Explain the meaning and application of the following vibration terms: a. Machine Motion b. Period c. Displacement d. Velocity e. Acceleration f. Frequency g. Time and Frequency Domains h. Phase/Relative Motion 5. Explain and demonstrate how to determine vibration severity, including: a. Classification of Machines b. Criticality Considerations c. Common Severity Charts d. Universal Technologies Perspective on Severity 6. Explain the various steps involved in vibration analysis: a. History b. Machine Details c. Amplitude /Hand Feel d. Spectrum e. Phase/Relative Motion f. Time Waveform 7. Explain how to select the best machine locations for vibration data collection. 8. Explain the difference in operation and use of the following transducers: a. Displacement b. Velocity c. Acceleration 9. Explain mounting precautions associated with use of various transducers to collect valid vibration data. 10. Explain how to evaluate whether vibration data is valid or invalid, including: a. Warning Signs b. Confirmation Techniques c. Correction Procedures 11. Define phase 12. Explain how to acquire phase/relative motion data using a variety of techniques. 13. Explain how to interpret phase/relative motion data. 14. Explain some of the precautions associated with the acquisition of phase data. 15. Explain what unbalance is and how it is measured. 16. Explain the difference between the 3 types of unbalance. Page 3 of 7

4 17. Explain the main vibration analysis symptoms of unbalance, including how to confirm the analysis using phase data. 18. Explain the main vibration analysis symptoms of misalignment, including how to confirm the analysis using phase data. 19. Explain what resonance is and its effect on machinery. 20. Explain the main vibration analysis symptoms of resonance, including: a. Speed Sensitivity b. Hand feel c. Curling d. Cracking e. Bump test f. Phase shift 21. Explain the advantages and disadvantages of FFT data and time waveform data for specific applications. 22. Explain the principles of the frequency and time relationship, F=1/p. 23. Select an appropriate measurement unit for particular applications. 24. Set up a vibration instrument to acquire appropriate time waveform data for any given application. 25. Select an appropriate transducer location and mounting method. 26. Identify and explain the fundamental patterns that comprise a time waveform, including: a. Sine Waves b. Symmetry of Amplitude Scale/Truncation c. Symmetry of Time Scale d. Impacts 27. Explain the effect of relative phase on the summation of waveform data. 28. Recognize typical time waveform patterns for the following common machinery problems: a. Unbalance b. Misalignment c. Eccentricity d. Looseness e. Bearings f. Gears g. Missing/cracked/broken teeth h. Beats 29. Develop the ability to detect common problems/root cause failures associated with the following machines: a. Motors b. Turbines c. Pumps d. Air Handlers e. Compressors (Centrifugal and Reciprocating) f. Gearboxes g. Belt Driven Machines h. Couplings 30. Explain the purpose of special processing techniques. 31. Explain and properly select the correct filter, including: a. Low Pass Filter Page 4 of 7

5 b. High Pass Filter c. Band Pass Filter 32. Explain the main sources of impacts and high frequency noise. 33. Explain the theory of: a. High Frequency Detection (HFD) b. Amplitude Demodulation c. Peakvue 34. Data collection guidelines Seminar Outline 1.0 Explain four maintenance philosophies in use today, including the advantages and disadvantages of each. 1.1 Run to fail 1.2 Preventative 1.3 Condition based 1.4 Precision 1.5 Explain key elements of condition-based and precision maintenance programs. 1.6 Explain costs and benefits associated with precision maintenance, including: Impact on Energy Consumption Impact on Bearing Life Examples of overall impact on vibration, maintenance scheduling, and production 2.0 Basic Terminology of vibration analysis 2.1 Basic motion 2.2 Period, frequency 2.3 Measurement Units 2.4 Displacement 2.5 Velocity 2.6 Acceleration 2.7 Time and Frequency domains 2.8 Phase 3.0 Vibration Fundamentals 3.1 Amplitude 3.2 Frequency 3.3 Phase 3.4 Severity 4.0 Practical Phase Analysis 4.1 Phase Acquisition Optical Strobe light Channel 4.2 Instrument Setup Dataline Datapac CMVA CSI 2115/2120 Page 5 of 7

6 4.3 Analyzing Basic Machine Faults with Phase Unbalance Misalignment 5.0 Resonance Analysis 5.1 Analysis Techniques Mode Shape Plot Bump Test Coast down / Startup 5.2 Instrument setup 6.0 Time Waveform Analysis 6.1 Introduction 6.2 Principles 6.3 Instrument setup 7.0 Review of Machinery Basics 7.1 Motors Construction Principles of Operation Common Failure Modes 7.2 Pumps Construction Principles of Operation Common Failure Modes 7.3 Gearboxes Construction Principles of Operation Common Failure Modes 7.4 Air Handlers Construction Principles of Operation Common Failure Modes 7.5 Compressors Construction Principles of Operation Common Failure Modes 7.6 Turbines Construction Principles of Operation Common Failure Modes 8.0 Vibration Symptoms of Common vibration problems 8.1 Bearings 8.2 Looseness 8.3 Gears 8.4 Electrical 8.5 Flow related 8.6 Belts 9.0 Safety and Health 9.1 Mechanical 9.2 Electrical 9.3 Environmental 9.4 Regulations Page 6 of 7

7 9.5 Equipment 10.0 Special Processing Techniques 10.1 High Frequency Detection 10.2 Enveloping 10.3 Peakvue 11.0 Qualification and Certification Activities 11.1 Written Test 11.2 Practical Hands-on Examination Page 7 of 7