COURSE OVERVIEW:

Machinery failure diagnostics and vibration analysis represent the pinnacle of proactive asset management, allowing for the detection of internal defects long before they result in catastrophic failure. This course provides a deep dive into the digital signal processing and mechanical theory required to interpret the complex "language" of rotating machinery. Participants will explore how various mechanical faults—such as unbalance, misalignment, and bearing defects—manifest as specific frequencies and patterns within a vibration spectrum.

The scope of this training extends from the physical installation of sensors to the advanced interpretation of time waveforms and FFT spectra. Coverage includes the use of accelerometers, proximity probes, and velocity transducers, alongside the data acquisition hardware needed to capture high-fidelity signals. Emphasis is placed on the diagnostic process, teaching participants how to differentiate between structural resonance and component-specific malfunctions, ensuring that maintenance interventions are targeted and effective.

Furthermore, the course integrates these diagnostic techniques into a comprehensive predictive maintenance (PdM) framework. Trainees will learn how to establish alarm baselines, trend data over time, and use cross-functional tools such as thermography and oil analysis to validate vibration findings. By mastering these diagnostic skills, plant personnel can transition from reactive repair cycles to a precision maintenance culture that significantly enhances the reliability and safety of industrial operations.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Interpret Fast Fourier Transform (FFT) spectra to identify common mechanical faults.
• Differentiate between synchronous and non-synchronous vibration peaks.
• Execute professional data collection routes using portable vibration analyzers.
• Diagnose unbalance and misalignment using phase analysis techniques.
• Identify the four stages of rolling element bearing failure through high-frequency detection.
• Evaluate structural resonance issues using bump tests and ODS analysis.
• Set up effective narrowband and broadband vibration alarms for critical assets.
• Relate vibration signatures to specific internal components like gears and vanes.
• Apply time waveform analysis to detect impacting and looseness.
• Integrate vibration data with thermographic images for comprehensive diagnostics.
• Determine the severity of machinery faults using ISO 10816 standards.
• Recommend specific maintenance actions based on diagnostic findings.
• Calculate the financial impact of a successful predictive maintenance program.

TARGET AUDIENCE:

This course is intended for Vibration Analysts, Reliability Technicians, Rotating Equipment Engineers, and Maintenance Supervisors responsible for the condition monitoring of critical plant machinery.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.