VCAT-III CANDIDATE PROFILE
This course is intended for the vibration analyst who will:
- Have a minimum of 3 years of experience
- Have a senior role in the condition monitoring team
- Have others report to them to verify diagnoses
- Be responsible for the most complex fault conditions (with the possible exception of sleeve bearing, flexible rotor machines)
- Need to perform complex tests to validate fault conditions (e.g., resonance) and find a solution
- Want to be a leader of the vibration team or take a leading role in diagnosing faults and making repair recommendations
- Want to understand all data collector options, special test capabilities, all analysis tools and understand the widest range of fault conditions
- Seek to become certified to international standards (ISO-18436) by an accredited certification body
- Want to understand all condition monitoring technologies, how and when to apply them
- Want to understand machine dynamics (natural frequencies, resonance, ODS), how to perform resonance testing and how to correct resonance problems
- Use the training and certification as the next step in a rewarding career as a vibration analyst
Duration
38 hours, typically over five days
Compliance
- Training: ISO 18436-2
- Certification: ISO 18436-2, ISO/IE 17024
Exam
- 4 hours
- 100 multiple-choice questions
- 70% passing grade
- Can be taken online or in-person at the course
Certification requirements
- Training course completed
- 36-months of practical vibration analysis work experience, verified by supervisor/manager
- Have previously been certified to VCAT-II by a MIBoC-approved certification body
- Pass the exam
- Valid for 5 years
What will you gain from taking this course?
There is a great deal to learn, but it will help you to perform your role with confidence. The topics covered in this course include:
- Review of condition monitoring technologies
- Signal processing and data acquisition
- Time waveform analysis
- Phase analysis
- Dynamics (natural frequencies and resonance)
- Testing for natural frequencies
- Operating Deflection Shape (ODS) analysis
- Modal analysis and introduction to FEA
- Correcting resonances
- Rolling element bearing fault detection
- Journal bearing fault detection
- Electric motor testing
- Pumps, fans, and compressors
- Gearbox fault detection
- Corrective action
- Acceptance testing
The key is that with the VCAT-III course, you will transition from being a vibration analyst who should be supervised to a person who is capable of running the program, being a senior consultant, solving difficult problems, and taking a leadership role.
Pre-study
- Access to the “Learning Zone” upon registration and payment
- Complete set of videos covering every topic
- An excellent way to be prepared and get the most from the course
Post-study
- Continue to access the Learning Zone 4 months after the course completion or upgrade for a lifetime with Lifelong Learning (LLL)
- Continue learning for free on WWW.MOBIUSCONNECT.COM with online forums, webinars, tutorials, etc.
TOPICS COVERED - CATEGORY II
Signal processing
- Filters: Low pass, band pass, high pass, band stop
- Sampling, aliasing, dynamic range
- Signal-to-noise ration
- Resolution, Fmax, data collection time
- Averaging: linear, overlap, peak hold, time synchronous
- Windowing and leakage
- Order tracking
- Cross-channel measurements
- Correlation and coherence
Time waveform analysis
- Collecting data - ensuring you have the correct setup
- When should you use time waveform analysis?
- Diagnosing unbalance, misalignment, bent shaft, eccentricity, cocked bearing, resonance, looseness, and other conditions
Phase analysis
- Collecting data
- Bubble diagrams
- Diagnosing unbalance, misalignment, bent shaft, eccentricity, cocked bearing, resonance, looseness, and other conditions Dynamics (natural frequencies and resonance)
- Natural frequencies and resonances
- Mass, stiffness, and damping
- SDOF and MDOF
Testing for natural frequencies
- Run-up coast down tests
- Bode plots and Nyquist (polar) plots
- Impact and bump tests
Operating Deflection Shape (ODS) analysis
- Can we prove the existence of a natural frequency?
- Visualizing vibration
- Setting up the job
- Collecting phase readings correctly
- Interpreting the deflection shape
- Using Motion Amplification
Modal analysis and intro to FEA
- How does modal analysis differ from ODS?
- How does Finite Element Analysis (FEA) differ from modal analysis
- A quick review of the modal testing process
Correcting resonances
- The effect of mass and stiffness
- Beware of nodal points
- Adding damping
- A “trial and error” approach
- A “scientific” approach
- Isolation
- Tuned absorbers and tuned mass dampers
Rolling element bearing fault detection
- Why do bearings fall?
- Cocked bearing, sliding on the shaft or inside the housing, looseness
- EDM and DC motors and VFDs
- Bearing frequencies and what to do when you don’t have all the details
- The four stages of bearing degradation
- Ultrasound
- High-frequency detection techniques
- Shock Pulse, Spike Energy, Peak vue, and other techniques
- Demodulation/enveloping
- Selecting the correct filter settings
- Spectrum analysis
- Time waveform analysis
- Low-speed bearings
Journal bearing fault detection
- What are journal bearings?
- Measuring displacement
- Introduction to orbit plots
- Using your analyzer to acquire orbit plots
- Introduction to centerline diagrams
- Eccentricity ratio
- Glitch removal
- How the orbit changes with pre-load, unbalance, misalignment, instabilities, oil whir and whip
Electric motor testing
- How do motors work?
- Diagnosing a range of fault conditions: eccentric rotor, eccentric stator, soft foot, phasing, broken rotor bars, rotor bar, and stator slot pass frequencies
- Motor current analysis
Pumps, fans, and compressors
- Unique fault conditions
- Flow turbulence, recirculation, cavitation
Gearbox fault detection
- Spectrum analysis versus time waveform analysis
- Wear particle analysis
- Gearmesh, gear assembly phase frequency (and common factors)
- Tooth load, broken teeth, gear eccentricity and misalignment, backlash and more
Corrective action
- General maintenance repair activities
- Review of the balancing process and ISO balance grades
- Review of shaft alignment procedures
Running a successful condition monitoring program
- Defining the program
- Setting baselines
- Setting alarms: band, envelope/mask, statistical
- Setting goals and expectations (avoiding common problems)
- Report generation
- Reporting success stories
Review of relevant ISO standards