Advance Vibration Analysis

Course Outline:

1. Machinery Vibration Refresh

• Understanding vibration and the importance of measuring and analyzing vibration
• Predictive/condition-based versus precision maintenance
• Vibration sources: cause and effect
• Linking vibration symptoms to common root causes encountered in the field

2. Vibration Motion

• Simple vibratory motion: Period, Frequency, Amplitude and Waveforms
• Determining machinery motion using phase relationships
• Vibration force and response, mechanical impedance and resonance
• Recognizing resonance in the field using a simple bump/impact test
• Reading natural frequency indication directly from the analyzer/software without manual calculation

3. Basics of Machinery Vibration Measurement Refresh

• How the domains of time and frequency describe vibration motion
• When to use: Displacement, Velocity, or Acceleration measurement units
• Practical use of high-frequency detection features (e.g. PeakVue / Spike Energy / Enveloping) available on modern analyzers for early fault warning

4. Instrument Types and Limitations

• Application and use of different measurement instruments
• Frequency-based versus overall readings
• Instrument selection criteria: cost, application, utility

5. Vibration Transducers

• How accelerometers, velocity transducers and proximity probes work
• Transducer applications, advantages & disadvantages
• Selection based on sensitivity, frequency range, signal distortion
• How mounting method, power supply, cable and calibration affect data quality

6. Condition Monitoring of Machineries

• Typical machinery vibration measurements for common machinery types and components
• Special field considerations for reciprocating machinery, slow-speed equipment, and gearboxes

7. Vibration Diagnosis

• Recognizing possible sources of vibration by frequency range diagnosis
• Reading gear mesh frequency and sidebands directly from spectrum to identify gear wear/backlash
• Distinguishing electrically-related vibration (1x/2x line frequency) from mechanical sources
• Root cause analysis on multi-fault field cases (combined unbalance, misalignment, looseness, pipe strain) using real case studies

8. Data Collection

• Defining effective data collection routes
• Following routes: visual inspection, transducer placement and connections
• Determining measurement quality and effectiveness
• Unloading and reviewing route data

9. Data Collection Setup

• -Measurement parameters: type, location, exception criteria, and instrument settings
• Selecting frequency ranges for detection, analysis, and overall readings
• Converting between acceleration, displacement, and velocity
• Understanding linear, logarithmic, and dB amplitude scales
• Practical effect of averaging and windowing settings on data quality

10. Unbalance

• Understanding different types of un-balance
• Using spectra to analyze unbalance
• Accurate unbalance diagnosis using phase, amplitude and frequency
• Hands-on single-plane and two-plane field balancing practice using a rotor kit

11. Misalignment

• Basic forms of misalignment: parallel, offset, and combination
• Distinguishing misalignment from unbalance and other sources
• Identifying misalignment vibration symptoms with phase and amplitude
• Using multi-point phase readings to confirm misalignment versus bent shaft or soft foot in difficult field cases

12. Detection of Rolling Element Bearing Faults

• Detecting and analyzing bearing faults in a typical failure progression
• High-frequency early warnings of impending failure
• Determining bearing condition with velocity spectra
• Reading bearing fault frequencies (BPFO/BPFI/BSF/FTF) generated by the analyzer software and matching them to spectrum peaks
• Field case studies of bearing failure caused by misalignment, lubrication, and looseness

13. Safety and Health Aspect

• Safety considerations for data collection
• Emergency health interventions

14. Report Writing & Recommendations

• Each group compiles a diagnostic report: findings, root cause, and corrective recommendations
• Short group presentation and discussion

Delivery Method:
a. Two days theory delivery in the classroom, integrating field case studies and software-based frequency reading (no manual derivation required).
b. One day hands-on practice using rotor kits: data collection, single- and two-plane balancing, bump/resonance check, and analysis with recommendation.

About The Course Leader

Ir. Sutrisno Sonto, M.Si.