MD1 MD2 MD3 MD4

Machine Monitoring & Diagnostics Courses

Vibration Analysis; Rotordynamics and Balancing Rigid and Flexible Rotors in-situ

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MD1 - Basic Protection and Condition Monitoring

Description: Learn the basics of vibration monitoring of balance-of-plant machines (using rolling element bearings). You will learn about basic machine faults, measurements for detecting and diagnosing the faults, and the different types of systems for monitoring these faults from a machine protection and condition monitoring perspective.

Course Format: Public classroom (and live stream over the internet) course in Darmstadt (Germany) or Gardnerville (Nevada – USA). Private and on-site courses for a single company (min. 5 students) are available.

Detailed topic list: Vibration and Condition Monitoring

• Introduction to Maintenance Practices

• Introduction to Vibration

• Types of Vibration Measurement Systems

• Machine type and monitoring

Principles of Vibration

• Review of Basics

• Understand Static and Dynamic Data

• Fault Characteristic Frequencies

• Vibration units

• Introduction to Phase

Understand the Required Measurements

• Understand the setup Basic

• Overall & Trends

• Spectrum

• Time waveform

• Envelope spectrum

• Phase Measurements

Understand the Required Measurements

• Understand the setup Basic

• Overall & Trends

• Spectrum

• Time waveform

• Phase Measurements

• Envelope spectrum

Data Acquisition

• How to correctly measure vibration

• Best Location for the Vibration Sensor

• Mounting the Sensor on the Machine

• Naming Conventions

Setting Alarms

• Standards and Guidelines

• Types of Alarms

Fault analysis

• Analysis Process

▪ Unbalance; Misalignment; Looseness

▪ Rolling Element Bearings

▪ Gears

▪ Electric motors

▪ Pumps Fans and Compressors

Corrective action

• Reports

• Recommendation

• Basic of Balancing

MD1 MD2 MD3 MD4

Machine Monitoring & Diagnostics Courses

Vibration Analysis; Rotordynamics and Balancing Rigid and Flexible Rotors in-situ

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MD2 - TurboMachinery Diagnosis & Rotordynamics

Description: This course provides a deeper insight into vibration on fluid-film bearings machines and rotor response, stiffness, instabilities, etc. You will learn how to interpret diagnostic plots such as orbit, polar, Bode, shaft centreline and full and half spectra.

Course Format: Public classroom (and live stream over the internet) course in Darmstadt (Germany) or Gardnerville (Nevada – USA). Private and on-site courses for a single company (min. 5 students) are available.

Private courses attended remotely can be split in several days of 90-minute remote sessions.

Detailed topic list:

Machine Diagnostics and Vibration

• Introduction to Machine Diagnostics

• Machinery Vibration Basics

• Diagnostic Vibration Measurements

• Operating modes of rotating machinery

• Terminology

Timebase

• Structure of a time-based plot

• Timing mark (speed/phase reference)

• Information in the time waveform

• Waveform compensation

Phase

• What is phase

• Why phase is important

• Absolute and Relative phase

• Rules of phase measurement

• Vector compensation

Orbits

• How orbit is constructed

• Information contained in the orbit

• Direct and filtered orbits

• Slow roll compensation

• Phase trigger

• Sub-synchronous or super-synchronous

• Orbit shape

• Orbit precession

• Absolute orbits

Bode and Polar Plots

• Bode and polar plots

• Uncompensated vs. compensated plots

• Slow roll compensation

• Balance and other resonances

• SAF – Synchronous amplification factor

• Heavy spot location

• APHT trend plots

Fundamental Rotor Response FSR

• 1X rotor vibration

• Understanding Dynamic Stiffness

• Rotor System model

• Sources of spring stiffness

• Equation of rotor motion

• 1X vibration below, at, and above resonance

• Changes in stiffness affect response

Average Shaft Centreline

• Eccentricity ratio

• The good, bad and the ugly ASC

• Preload

• Using ASC plots in the diagnosis

Spectrum and Full Spectrum

• Frequency and Period

• FFT spectrum & Full spectrum

• Waterfall and Cascade

• Information not included in the spectrum

Single Plane Balance Response

• Synchronous perturbation

• Unbalance force

• The symptoms of unbalance

• Balancing methodology

• Balancing by vectors

• Trial weights

• Influence coefficient vector

• Splitting and combining weights

Malfunction That Modify Stiffness

• Rubs

• Tight rub and Excessive clearance

• Partial rub

• Full annular rub

• Continuous contact rub

• Normal-Tight and Normal-Loose

• Rub symptoms (orbit; time waveform; spectrum)

• Newkirk effect

MD1 MD2 MD3 MD4

Machine Monitoring & Diagnostics Courses

Vibration Analysis; Rotordynamics and Balancing Rigid and Flexible Rotors in-situ

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MD2 - Detailed topic list cont.:

Instabilities

• The source of fluid instability

• Fluid velocity profile

• Hydraulic instability symptoms

• Whirl & Whip mode of vibration

• Other sub-synchronous vibration faults

• Eliminating fluid induced instability

Anisotropic Stiffness

• Isotropic vs. Anisotropic

• Sources of anisotropic stiffness

• Effects of anisotropic stiffness

• When dealing with anisotropic stiffness

Multiplane Balance Response

• Synchronous rotor response

• Modes of vibration and mode shapes

• Support stiffness and mode shape

• Rigid vs. flexible rotors

• Unbalance

• Balancing two modes

Shaft Crack

• Stress field orientation

• Types of shaft crack

• Shaft crack symptoms

• Operating recommendations

• Monitoring recommendations

Art of Machinery Diagnosis

• Diagnosis process

• Data formats to Examine

• Organizing and verification of data

• Data highlights to look for

• The machine train diagram

• Data correlation

• Report

• Diagnostic pitfalls

MD1 MD2 MD3 MD4

Machine Monitoring & Diagnostics Courses

Vibration Analysis; Rotordynamics and Balancing Rigid and Flexible Rotors in-situ

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MD3 – Balancing in-situ (2 options)

Description Option 1: Rigid rotor balancing course, you will learn about the different types of unbalance, both 1 and 2 plane balancing, no phase (four run) balancing and overhung rotor balancing methods.

Description Option 2: The flexible rotor balancing, you will learn about rotor’s mode response, rotor non-linearity, thermal vector and 2 plane balancing.

Course Format: Public classroom (and live stream over the internet) course in Darmstadt (Germany) or Gardnerville (Nevada – USA). Private and on-site courses for a single company (min. 5 students) are available.

Private courses attended remotely can be split in several days of 90-minute remote sessions.

Rigid Rotor (option 1) topic list:

Introduction

• Introduction to Balancing

• Quantify the unbalance

Why Balancing

• Why balancing is important

• Causes of Unbalance

Introduction to vibration

• Understand vibration & phase

• Phase conventions

• Understanding vibration units

• Understand vectors and Polar plots

In-situ Balancing considerations

• Safety concerns

• General considerations for balancing

• Types of unbalance

• In-situ balancing job preparation

• Information for balancing

• Trial weight selection

Rigid rotor Balancing methods

• In-situ single plane balancing procedure

• In-situ two planes balancing procedure

• In-situ overhung rotors balancing procedure

• No-phase balancing procedure

Inability to Balance

• Inability to balance

• Split/combine weights

Assessing the Balancing Condition

• Assessing the balancing based on vibration amplitude

• Assessing the balancing based on residual unbalance

MD1 MD2 MD3 MD4

Machine Monitoring & Diagnostics Courses

Vibration Analysis; Rotordynamics and Balancing Rigid and Flexible Rotors in-situ

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Flexible Rotor (option 2) topic list:

Introduction

• Introduction to Balancing

• Quantify the unbalance

• Why balancing is important

• Causes of Unbalance

Introduction to vibration

• Understand vibration & phase

• Phase conventions

• Heavy spot & High spot

• Understand vectors

• Bode and Polar plots

• Runout compensation data

In-situ Balancing considerations

• Safety concerns

• General considerations for balancing

• Information for balancing

Flexible rotor Balancing methods

• Balancing flexible rotors

• Modes of vibration and mode shapes

• Support stiffness and mode shapes

• Trial weight selection

• In-situ balancing flexible rotors with vectors

• Balancing two modes

• Influence coefficient vector

Inability to Balance

• Inability to balance

• Split/combine weights

Assessing the Balancing Condition

• Assessing the balancing based on vibration amplitude

• Assessing the balancing based on residual unbalance (ISO)

• Assessing the balancing based on residual unbalance (API)

MD1 MD2 MD3 MD4

Machine Monitoring & Diagnostics Courses

Vibration Analysis; Rotordynamics and Balancing Rigid and Flexible Rotors in-situ

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MD4 – Hands-on Diagnostic Seminar

Description: This comprehensive course provides best practice techniques for diagnosing turbomachinery faults with fluid-film and rolling-element bearings. You will learn how to interpret data plots and to do root cause analysis. There are many case studies and there will also be exercises.

Course Format: Public classroom (and live stream over the internet) course in Darmstadt (Germany) or

Gardnerville (Nevada – USA). Private and on-site courses for a single company (min. 5 students) are available.

Private courses attended remotely can be split in several days of 90-minute remote sessions.

Detailed topic list:

Monitoring and Diagnostic Jobs

• Monitoring and Ad-hoc Jobs

• Condition Monitoring

• Acceptance Tests

• Diagnostic Job

• Certification of Personnel

• ISO & API Standards

Alarms

• Alarming Data

• Hardware and Software Alarms

• Implementing Alarms

• Alarms in Different Plots

Available Data

• Machine Specs and History

• Vibration Data

▪ Static

▪ Dynamic

• Process Data

• Environmental Conditions

Machine & Bearing Type

• Bearing types

▪ REB

▪ FFB

• Machine type

• Orientation & Installation

Monitoring Process

• Phases

• Detection

• Analysis

• RCA

• Verification

Vibration Analysis Process

• Data Validation and organization

• Machine train

• Forcing Frequencies

• Data Highlights

• Data Correlation

• Interpretation and Diagnosis Plots

Vibration Analysis Process cont.

• Spectrum

• Waveform

• Orbits

• Average Shaft Centerline

• Bode and Polar

• Slow Roll

Data Formats

• Introduction

• Steady State Operation

• Transient Condition

• Slow Roll

• Stopped

Diagnostic Faults in REB machines

• Machine malfunction diagnosis

▪ Unbalance

▪ Misalignment

▪ Eccentricity; Bent Shaft

▪ Cocked Bearing

▪ REB

▪ Looseness

▪ Flow problems (turbulence; cavitation)

▪ Vane Pass

▪ Electrical related faults

▪ Gears

▪ Resonances

▪ Belts

MD1 MD2 MD3 MD4

Machine Monitoring & Diagnostics Courses

Vibration Analysis; Rotordynamics and Balancing Rigid and Flexible Rotors in-situ

Brüel & Kjær Vibro GmbH Brüel & Kjær Vibro A/S Brüel & Kjær Vibro A/S 64293 Darmstadt 2850 Nærum Gardnerville, NV 89410 Germany Dänemark USA Phone: +49 (0) 6151 428 0 Phone: +45 7741 2500 Phone: +1 775 552 3110 info@bvkibro.com https://www.bkvibro.com/service-and-support/training/machine-diagnostics-and-rotor-dynamics-training/

© 2020 – Brüel & Kjær Vibro - Contents alterations reserved! | 7

MD4 – Detailed topic list cont.:

Process Review in JB machines

• Recognize basic vibration signal “building blocks”

• Reduce data

• Organize data

• Verify data

• Examine key vibration highlights

• Examine key machinery highlights

• Correlate vibration with key process data

• Analyze data

• Attack root cause, not just symptom

• Info analysis process – match malfunctions with observed symptoms

• Hypothesize & test…

• Special considerations:

• Limited data

• Multiple simultaneous symptoms

• Final Report

Diagnostic Faults in JB machines

• Machine malfunction diagnosis

▪ FSRR

▪ ASC and Preloads

▪ Instabilities

▪ Anisotropic stiffness

▪ Shaft crack

▪ Rubs

▪ Looseness

▪ Thermal bow

Exercise – Real case studies

• Journal bearing Machine (2 examples)

• Rolling Element Bearing machine (2 examples)