Certification Services Division Newton Building, St Georges Avenue Northampton, NN2 6JB United Kingdom Tel: +44 (0)1604-893-811.

Fax: +44 (0)1604-893-868. E-mail: pcn@[Link]

CM/GEN APPENDIX D Issue 2 rev D

SPECIFIC REQUIREMENTS FOR QUALIFICATION AND CERTIFICATION OF CONDITION MONITORING AND DIAGNOSTIC PERSONNEL FOR VIBRATION ANALYSIS

CONTENTS
Introduction ................................................................................................................................. 2 1. Scope .................................................................................................................................. 2 2. Classification of Personnel ................................................................................................... 3 3. Eligibility for Examination and Certification .......................................................................... 5 4. Certification Available .......................................................................................................... 7 5. Qualification Examination .................................................................................................... 7 Annex A1 Training Syllabus..................................................................................................... 8 Annex A2- Detailed list of topics and hours of instruction ............................................................ 9 Annex B Reading References (normative) ..............................................................................13 Annex C- Training sub-topics- Category 2 ................................................................................17

The British Institute of Non-Destructive Testing is an accredited certification body offering personnel and quality management systems assessment and certification against criteria set out in international and European standards through the PCN Certification Scheme.

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Introduction The use of the Vibration Analysis method in condition monitoring and diagnosis of faults in machinery and structures has become a key activity in predictive maintenance programmes for many industries. The effectiveness of this technology depends on the capabilities of individuals who perform the measurements and analyse the data. This document is appended to CM/GEN (General requirements for qualification and certification of condition monitoring and diagnostic personnel). Other Appendices cover: Appendix A Appendix B Appendix C Acoustic Emission Infra-red Thermography Lubrication Management and Analysis

These other non-intrusive technologies are used as complementary condition analysis tools. Those in the manufacturing industry who have diligently and consistently applied these technologies have experienced a return on investment far exceeding their expectations. This series of documents is designed to provide comprehensive information for users of the PCN Scheme. The complete list of published PCN condition monitoring documents is detailed in publication reference PSL/8A-CM, which is posted on the Institute's web site at [Link], where all documents are available for download free of charge. It is intended, through publication of these documents, to provide industry, PCN candidates and certificate holders with all relevant information. However, if further information or advice is required on any certification matter, contact the Certification Services Division of BINDT on telephone number +44 (0) 1604 893811, or email pcn@[Link] Organisations requiring at all times to be in possession of the most up to date PCN documents may register with the "PCN Update Scheme" which, for a small annual fee, guarantees that they automatically receive all new and revised PCN documents. 1. Scope 1.1. This appendix to PCN CM/GEN sets out the specific requirements for qualification and certification of personnel engaged in Vibration Analysis Condition Monitoring. In the event of a conflict between the requirements of PCN CM/GEN and this Appendix, the PCN CM/GEN requirements shall prevail. This specification is in accordance with ISO 18436-2: Condition monitoring and diagnostics of machines-Requirements for qualification and assessment of personnelVibration Condition monitoring and diagnostics Certification to this specification will provide evidence and recognition of the qualification and competence of individuals to perform machinery vibration measurements and analysis (hereafter referred to as Vibration Analysis in this specification) using portable and permanently installed sensors and equipment. This part of CMGEN covers a four-Category certification programme that is based on the technical areas delineated herein. The scope of this programme encompasses the normative references specified in ISO 18436-2 clause 2 and those found in Annex B of this document, and incorporates the terms and definitions found in ISO 18436-2 clause 3 and CMGEN, unless otherwise stated in this document. BINDT, as a certification body accredited by UKAS in accordance with EN ISO/IEC 17024, manages this condition monitoring programme against these specifications which are derived from the relevant ISO 18436 parts, but wherever any minor regional or national modification to this adoption exists then it shall be identified as a delta and signified by text enclosed in a box, in accordance with ISO/IEC Guide 211. At no point does any minor modification diminish the specifications in ISO 18436-2. Where appropriate, the structure and format of this specification shall reflect that of all BINDT PCN specification documents for document harmonization.
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1.2.

1.3.

1.4.

1.5.

1.6.

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2.

Classification of Personnel 2.1. General 2.1.1. Individuals certificated in accordance with this specification are classified in one of four Categories depending upon their qualifications and assessment, and have demonstrated the necessary competence and skills in the concepts of machinery vibration condition monitoring and diagnostics for their classification Category as indicated in the examination syllabus at Annex A and in accordance with the standards listed in Annex B.

2.1.2. Personnel classified at a higher Category shall require the competence, knowledge and skills expected of personnel at all lower Categories 2.2. Vibration Analysis Category 1 PCN certificated Vibration Analysis Category 1 personnel are qualified to perform a range of simple single channel machinery vibration condition monitoring and diagnostics of machines activities in accordance with ISO17359 and ISO13373-1. They shall not be responsible, for example, the choice of sensor or for any analysis to be conducted, nor for the assessment of test results, except for identifying alert conditions against a pre-established alert setting or settings. Category 1 personnel shall be qualified to: 2.2.1. 2.2.2. 2.2.3. 2.2.4. 2.2.5. 2.2.6. 2.2.7. operate portable instrumentation on pre-assigned or pre-programmed routes; acquire readings from permanently installed instrumentation; input results into a data base and download routes from a computer; conduct testing under steady-state operating conditions following predefined procedures; compare overall or single value vibration measurements against preestablished alert settings; recognise that no signal is present verify the integrity of collected data and prevent or control poor data;

2.2.8. evaluate and report test results in accordance with instructions. 2.3. Vibration Analysis Category 2 Individuals certificated as Vibration Analysis Category 2 are qualified to perform industrial machinery vibration measurements and basic vibration analysis using single-channel measurements, with or without phase trigger signals, according to established and recognised procedures. Category 2 personnel shall be qualified to: 2.3.1. 2.3.2. 2.3.3. 2.3.4. 2.3.5. 2.3.6. 2.3.7. 2.3.8. 2.3.9. select the appropriate machinery vibration measurement technique; set up instruments for basic resolution of amplitude, frequency and time; perform basic vibration analysis of machinery and components such as shafts, bearings, gears, fans, pumps and motors using spectrum analysis; maintain a data base of results and trends; perform basic (single channel) impact tests to determine natural frequencies; classify, interpret and evaluate the test results (including acceptance tests) in accordance with applicable specifications and standards; recommend minor corrective actions; understand basic single-plane field balancing concepts; be aware of some of the causes and effects of bad measurement data;

2.3.10. recommend the use of alternative CM technologies with an awareness of the basic principles of all four condition monitoring (CM) technologies specified in CM/GEN at least to Category 1;

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2.3.11. carry out, supervise and instruct all Category 1 duties; 2.3.12. provide technical direction for personnel at or below Category 2. 2.4. Vibration Analysis Category 3 Individuals certificated as Vibration Analysis Category 3 are qualified to perform and/or direct, and/or establish, programmes for vibration condition monitoring and diagnostics of machines in accordance with ISO 17359 and ISO 13373-1. Category 3 personnel shall be qualified to: 2.4.1. 2.4.2. 2.4.3. select the appropriate machinery vibration analysis technique; specify the appropriate vibration instrumentation hardware and software for both portable and permanently installed systems; measure and perform diagnosis of single-channel frequency spectra, as well as time domain plots such as waveforms and orbits, under bother steadystate and unsteady operating conditions, with or without a phase trigger; establish vibration monitoring programmes including determination of machines for periodic /continuous monitoring, frequency of testing, route plans;

2.4.4.

2.4.5. establish acceptance and severity criteria for in service and faulty machinery;

2.4.6. 2.4.7. 2.4.8. 2.4.9.

establish programmes for specification of acceptance criteria for new machinery; perform prognostics for fault conditions;

vibration Categories and

measure and analyse basic operating deflection shapes; use acceleration enveloping (demodulation);

2.4.10. perform basic single-plane balancing; 2.4.11. report to management regarding programme objectives, budgets, cost justification and personnel development; 2.4.12. provide instructions and technical direction to vibration trainees Category; 2.4.13. prepare reports for appropriate personnel on machine condition, recommend corrective action and report on the effectiveness of repairs; 2.4.14. understand and interpret Standards, Codes, specifications and procedures; 2.4.15. Category direct the use of alternative CM technologies with an understanding of the principles of all four condition monitoring (CM) technologies specified in CM GEN at least to Category 1 2.4.16. provide instructions and technical direction to vibration trainees Category; 2.4.17. carry out, manage and supervise PCN CM qualification examinations on behalf of the British Institute of NDT, if so appointed.

2.5

Vibration Analysis Category 4 Individuals certificated as Vibration Analysis Category 4 are qualified to perform and/or direct vibration condition monitoring and diagnostics of machines in accordance with ISO17359 and ISO 13373-1 and all types of machinery vibration measurements and analysis. Category IV personnel shall be qualified to: 2.5.1 apply vibration theory and techniques, including measurement and interpretation of multi-channel spectral results such as frequency response functions, phase and coherence; understand and perform signal analysis, including understanding of frequency and time domain processing, including orbits and their limitations;

2.5.2

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2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.5.8 2.5.9

determine the natural frequencies, mode shapes and damping of systems, components and assemblies; determine the operating deflection shapes of machines and connected structures and recommend means for correction; use generally recognised advanced techniques for vibration analysis, parameter identification and fault diagnosis; apply basic principles of rotor-bearing dynamics to vibration diagnosis; conduct basic two-plane field balancing; recommend advanced two-plane influence coefficient or static/couple balancing; recommend corrective actions and/or modifications, including component change or repair, isolation, damping, change of stiffness and change of mass;

2.5.10 provide technical guidance to vibration trainees: 2.5.11 interpret and evaluate published ISO codes of practice, International Standards and specifications; 2.5.12 recognise vibration caused by gas pulsation in machines such as reciprocating machines and screw compressors, and to measure the necessary parameters and recommend means for correction; 2.5.13 recommend corrective actions for resilient mounting and other holding-down and foundation problems; 2.5.14 2.5.15 2.5.16 2.5.17 design, write procedures; and manage and Test planning and Test condition monitoring

design, implement programmes;

manage

undertake all forms of equipment testing, diagnostics and prognostics; carry out, manage and supervise PCN CM qualification examinations on behalf of the British Institute of NDT, if so appointed

3.

Eligibility for Examination and Certification 3.1. General 3.1.1. Candidates shall have a combination of education, training and experience to ensure that they understand the principles and procedures applicable to machinery vibration measurement and analysis. Candidates shall affirm adherence to the code of ethics contained in ISO18436-1 and BINDT document CP27- Code of Ethics.

3.2.

Education 3.2.1. Candidates seeking certification do not need to provide evidence of formal education to establish eligibility. However, it is recommended that Category 1 and 2 candidates have at least a secondary school graduation diploma or its equivalent. Category 3 and 4 candidates shall be able to manipulate simple algebraic equations, use a basic scientific calculator (including trigonometric and logarithmic functions), and be familiar with the operation of personal computers. Successful completion of two or more years of mechanical technology or mechanical engineering at an accredited college, university or technical school is highly recommended for candidates seeking certification to Category 3 and 4.

3.3.

Training 3.3.1. To be eligible to apply for examination based on this Specification, the candidate shall provide documentary evidence of successful completion of a
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BINDT approved or recognised course of formal training, which will be based on the requirements of Annex A2. Sources of technical information are listed in Annex B. The minimum duration of training required shown in Table 1. BINDT allows a maximum of 50% self study or on line training for topics consistent with Annex A2 and as specified by the approved trainer (CMGEN refers). 3.3.2 Approved training should be in the form of lectures, demonstrations and practical exercises. The approved training shall include examinations to ensure that the subject matter has been understood and that they have successfully completed the training. To achieve certification from BINDT the candidate must also provide evidence of required experience as specified below. The training syllabus indicated includes a requirement for practical knowledge and practical skills training and evaluation by the trainer at Category 1.

Table 1. Minimum Cumulative Duration of Training (hours) Category 1 32 Category 2 70 Category 3 110 Category 4 174

The hours shown represent cumulative totals of training hours. 3.3.2 It is recommended that candidates attend additional training on machine knowledge, covering machinery and component training, of at least half the time shown in Table 1. This additional training should cover design, manufacture, installation, operation and maintenance principles and include failure mechanisms associated with each principle.

3.3.3

3.4.

Experience 3.4.1. To be eligible to apply for certification based on this specification, the candidate shall provide evidence of experience in the field of machinery vibration analysis condition monitoring and diagnostics appropriate to the Category sought. The minimum experience requirements are shown in Table 2, and the figures shown represent cumulative months of experience for each Category. Work experience is based on 175 hour/month. At each higher Category, the breadth and depth of experience is expected to be greater than at the previous lower Category.

3.4.2. Certification at Category 2 Category 3 and Category 4 requires previous certification at the lower Categories. 3.4.3. Candidates must maintain a log of hours and nature of work on PCN document CP16 for Category 1 and 2 and CP17 for Category 3 and 4.

Table 2 Minimum Experience Requirements (months) Category 1 Category 2 Category 3 Category 4 6 18 36 60

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4.

Certification Available 4.1 4.2 4.3 4.4 Category 1 (General- Vibration analysis condition monitoring) Category 2 (General- Vibration analysis condition monitoring) Category 3 (General-Vibration analysis condition monitoring) Category 4 (General-Vibration analysis condition monitoring)

5.

Qualification Examination 5.1. Application for qualification examinations 5.1.1 Application for qualification examinations is made on PCN form PSL/57-CM and supported with PSL30 and PSL33 where required.

5.2.

Examination content (Theory and practical knowledge) 5.2.1. For each certification Category, the candidates shall be required to answer the number of multiple-choice questions indicated in Table 3. 10% of the number of questions on the Category 3 and 4 examination papers will consist of narrative questions. On each Category 3 and 4 paper there will be ten narrative questions offered, and only six need to be answered. Each narrative question will be worth 5 marks. Table 3 qualification examination content Categories Category 1 Category 2 Category 3 Category 4 Number of Questions 60 100 100 60 Time (Hours)* 2.0 3.5 4.0 4.0 Passing Grade % 75 75 75 75

* Examination times include a 30-minute reading period Category to assist candidates with English as a second language or any disability in accordance with CMGEN clause 9.3.

5.2.2.

The content of the examination paper shall contain multiple-choice questions for each subject in Annex A2, and in the same weighting as indicated by the percentage of time spent on each subject indicated in Annex A2, together with the indicated narrative questions (if applicable). Questions will be of a practical nature and test the candidates knowledge of concepts and principles required to conduct machinery vibration testing and analysis. Questions will include the interpretation of practical data, charts, plots or images, and simple mathematical calculations using a basic scientific calculator may be required.

5.2.3.

5.2.4.

5.2.5. BINDT examinations do not provide a summary of common formulae with the examination questions. 5.2.6. Detail of BINDT examination, re-examination, renewal procedure is given in CMGEN.

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Annex A1 Training Syllabus

Hours of SUBJECT 1. Principles of Vibration 2. Data Acquisition 3. 4. 5. 6. 7. Signal Processing Condition Monitoring Fault Analysis Corrective Action Equipment Knowledge 6 8 2 2 2 2 8 2 0 0 0 0 0 32 4 4 4 4 4 4 4 2 2 2 2 2 0 38

training 2 2 3 3 8 6 4 2 3 2 2 3 0 40 4 2 8 1 6 16 0 0 4 2 4 3 14 64

Category 1 Category 2 Category 3 Category 4

8. Acceptance Testing 9. Equipment Testing and Diagnostics 10. Reference Standards 11. Reporting and Documentation 12. Fault Severity Determination 13. Rotor /Bearing Dynamics Total Hours

It is recommended that the trainer allocates up to 2 hours for their required training examination at all Categories, while at Category 1 only, an additional 2 hours for the BINDT specified practical skills evaluation exercises should be considered.

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Annex A2- Detailed list of topics and hours of instruction

SUBJECT Category 1 Hours 6
*

Category 2 Hours 4 * * * * * *

Category 3 Hours 2 * * * * * * *

Category 4 Hours 4

1. Principles of Vibration 1. Basic Motion 2. Period, Frequency 3. Amplitude: Peak, Peak-to-Peak, rms 4. Parameters: Displacement, Velocity, Acceleration 5. Units, Unit Conversions 6. Time and Frequency Domains 7. Vectors, Modulation 8. Phase 9. Natural Frequency, Resonance, Critical Speeds 10. Force, Response, Damping, Stiffness 11. Instabilities, Non-linear Systems 2. Data Acquisition 1. Instrumentation 2. Dynamic Range, Signal-to-Noise Ratio 3. Transducers 4. Sensor Mounting, Mounted Natural Frequency 5. Fmax, Acquisition Time 6. Proximity Sensor Conventions (API) 7. Triggering 8. Test Planning 9. Test Procedures 10. Data Formats 11. Computer database upload/download 12. Recognition of poor data 3. Signal Processing 1. RMS/Peak Detection 2. Analog/Digital Conversion 3. Analog Sampling, Digital Sampling 4. FFT Computation 5. FFT Application 6. Time Windows: Uniform, Hanning, Flat Top 7. Filters: Low Pass, High Pass, Band Pass, Tracking 8. Anti-aliasing 9. Bandwidth, Resolution

* * * * *

* * * * *

* * *

* * *

8 *

4 * *

2 * * * * * * * * * *

2 * *

* * * *

* * * * * *

* *

* *

* * 2 * 4 * 3 8 * * * * * * * * * * * * * * * * * * * *

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SUBJECT

Category 1 Hours

Category 2 Hours

Category 3 Hours

Category 4 Hours *

10. Noise Reduction 11. Averaging: Linear, Synchronous Time, Exponential 12. Dynamic Range 13. Signal-to-Noise Ratio 14. Spectral maps 4. Condition Monitoring 1. Computer data base set-up 2. Computer database maintenance 3. Equipment Evaluation and Prioritisation 4. Monitoring programme design 5. Alarms set-up: Narrowband, Envelope 6. Baseline Assessments, Trending 7. Route Planning 8. Alternate Technologies: Lubrication management, Infrared Thermography, motor current analysis and acoustic emission 9. Fault recognition 5. Fault Analysis 1. Spectrum Analysis, Harmonics, Sidebands 2. Time Waveform Analysis 3. Phase Analysis 4. Transient Analysis 5. Orbit Analysis 6. Shaft centreline analysis 7. Enveloping 8. Mass Unbalance 9. Misalignment 10. Mechanical Looseness 11. Rubs, Instabilities 12. Bearing Defects: Rolling Element, Journal 13. Electric Motor Defects 14. Flow Induced Vibration, Aerodynamics and Liquids 15. Resonance and Critical Speeds 16. Gearbox analysis 17. Turbo machinery 18. General fault recognition 6. Corrective Action 1. Shaft Alignment
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* *

* *

* * *

* 2 4 3 * * * * * * * * * * * * * 2 * 4 * 8 * * * * * * * * * * * * * * * * * * * * * * * * 2 4 * 4 *

* 1

6 * * * * * * *

* * * * *

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SUBJECT

Category 1 Hours

Category 2 Hours *

Category 3 Hours * * * * *

Category 4 Hours * *

2. Field Balancing 3. Flow Control 4. Replacement of machine parts 5. Isolation and damping 6. Resonance control 7. Basic maintenance action 7. Equipment Knowledge 1. Electric Motors: Generators and Drives 2. Pumps, Fans 3. Steam Turbines, Gas Turbines 4. Compressors 5. Reciprocating Machinery 6. Rolling Mills, Paper Machines and other equipment 7. Machine Tools 8. Structures, Piping 9. Rolling Element Bearings 10. Journal Bearings 11. Gearing 12. Couplings, Belts 8. Acceptance Testing 1. Test procedure 2. Specifications and Standards 3. Reporting 9. Equipment Testing and Diagnostics 1. Impact Testing 2. Forced Response Testing 3. Transient Analysis 4. Transfer Functions 5. Damping Evaluation 6. Cross Channel Phase, Coherence 7. Operating Deflection Shapes 8. Modal Analysis 9. Torsional vibration 10. Reference Standards 1. Relevant National Standards/IEC/ISO 11. Reporting and Documentation 1. Condition Monitoring Reports 2. Vibration Diagnostics Reports
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* *

* 8 * *

* 4 * * *

* 4 * * * * * * * * * * * * 2 0 0

* *

* * *

* * * * * * *

2 *

2 * * *

* * 3 * * * 4 * * * * * * * * * *

2 * *

2 *

2 * 2 * *

2 * 4

2 * *

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SUBJECT

Category 1 Hours 0

Category 2 Hours 2 *

Category 3 Hours 3 * *

Category 4 Hours 3 * *

12. Fault Severity Determination 1. Spectrum Analysis 2. Time Waveform Analysis, Orbit Analysis 3. Categories: Overall, Narrowband, Component 4. Severity Charts; Graphs and Formula 13. Rotor/Bearing Dynamics 1. Rotor Characteristics 2. Bearing Characteristics 3. Rotor Balancing Total hours

* * 0 0

* * 0 * 14 * * *

32

38

40

64

Notes: 1. The symbol * indicates the subject to be covered within the time allotted. 2. Category 2 includes the knowledge of Category 1 3. Category 3 includes the knowledge of Categories 1 and Category2. 3. Category 4 includes the knowledge of Categories 1, 2 and 3.

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Annex B Reading References (normative)

Applicable International Standards and essential reading Essential reading (material from which BINDT specified examination questions can be developed) The essential reading for each Category is specified in Tables 1 and 2. For example, at Category 1 the essential reading includes the nine Standards in Table 2 and the three textbooks listed in Table 1.

Table 1 Essential reading includes: Category 3, 4 1,2,3,4 1,2,3,4 Title Handbook of Rotor Dynamics Vibration Analysis Pocket Guide Vibration monitoring and Analysis Handbook Author F. F. Ehrich, 1998 RMS Ltd S R W Mills Publisher Kreiger BINDT BINDT ISBN 1-5755240882 0-903132-36-2 0903132397

Recommended reading: Category 1, 2, 3 2, 3 2, 3 2, 3 2, 3 1, 2, 3 Title Vibration Monitoring Handbook Infrared ThermographyTheory & Practice Acoustic emission and ultrasonics The wear debris analysis handbook Oil Analysis The Simplified Handbook of Vibration Analysis- Vols. 1 and II Machinery Malfunction Diagnosis and Correction Basic machinery vibrations: An introduction to machine testing, analysis and monitoring Modal testing- Theory and nd Practice, 2 Edn Vibration Testing- Theory and Practice Author C. W. Reeve, 1998 N Walker T Holroyd B J Roylance & T M Hunt Evans and Hunt A. R. Crawford, 1992 R.C. Eisenmann, 1998 R. L. Eisenmann, 1999 Publisher Coxmoor BINDT Coxmoor Coxmoor, 1999 Coxmoor CSI ISBN/Publ No 190189200X 0903132338 1901892077 1901892026 1901892050 Library of Congress 9272682 013240946-1 0966950003

1, 2, 3, 4 1, 2, 3

Prentice Hall Clarendon Hills Press, ILL,

1, 2, 3, 4 1, 2, 3

D. J. Ewins, 2000 K. G. McConnell, 1995

McGraw-Hill, Inc John Wiley & Son

0863802184 047130435-2

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Table 2 Applicable International Standards (material from which BINDT specified examination questions can be developed) The current published version of each standard applies. Standard ISO 1925: Mechanical vibration- BalancingVocabulary ISO 1940-1: Mechanical vibration- Balance quality requirements of rigid rotors- Part 1: Determination of permissible residual unbalance ISO 1940-2: Mechanical vibration- Balance quality requirements of rigid rotors- Part 2: Balance errors ISO 2017: Vibration and shock isolatorsProcedure for specifying choice ISO 2041: Mechanical vibration and shockVocabulary. ISO 2954: mechanical Vibration of rotating and reciprocating machines-Requirements for instruments for measuring vibration severity ISO 5348: Mechanical vibration and shock Mechanical mounting of accelerometers. ISO 7919-1: Mechanical vibration of nonreciprocating machines- Measurement on rotating shafts and evaluation criteria-Part 1: General Guidelines ISO 7919-2: Mechanical vibration of nonreciprocating machines- Measurement on rotating shafts and evaluation criteria-Part 2: Large Land-based steam turbine generator sets ISO 7919-3: Mechanical vibration of nonreciprocating machines- Measurement on rotating shafts and evaluation criteria-Part 3: Coupled industrial machines ISO 7919-4: Mechanical vibration of nonreciprocating machines- Measurement on rotating shafts and evaluation criteria-Part 4: Gas turbine sets ISO 7919-5: Mechanical vibration of nonreciprocating machines- Measurement on rotating shafts and evaluation criteria-Part 5: Machine sets in hydraulic power generating and pumping plants ISO 8528-9: Reciprocating internal combustion engine driven alternating current generating sets-Part 9: Measurement and evaluation of mechanical vibrations ISO 8569, Mechanical vibration and shockCM_VA Issue 2 rev D 14 of 20

Category 1

Category 2

Category 3

Category 4

* *

* *

* *

* * * * *

* * *

* *

* *

*
1st January 2012

Standard Measurement and evaluation of shock and vibration effects on sensitive equipment in buildings ISO 10816-1: Mechanical vibration-Evaluation of machine vibrations by measurements on non-rotating parts- Part 1: general guidelines ISO 10816-2: Mechanical vibration-Evaluation of machine vibrations by measurements on non-rotating parts- Part 2: Land-based steam turbines and generators in excess of 50MW with normal operating speeds of 1500 r/min, 1800 r/min, 3000 r/min and 3600 r/min ISO 10816-3: Mechanical vibration-Evaluation of machine vibrations by measurements on non-rotating parts- Part 3: Industrial machines with nominal power above 15kW and nominal speeds between 120r/min and 15000 r/min when measured in situ ISO 10816-4: Mechanical vibration-Evaluation of machine vibrations by measurements on non-rotating parts- Part 4: Gas turbine sets excluding aircraft derivatives ISO 10816-5: Mechanical vibration-Evaluation of machine vibrations by measurements on non-rotating parts- Part 5: Machine sets in hydraulic power generating and pumping plants ISO 10816-6: Mechanical vibration-Evaluation of machine vibrations by measurements on non-rotating parts- Part 6: Reciprocating machines with power ratings above 100kW ISO 11342: Mechanical Vibration- methods and criteria for the mechanical balancing of flexible rotors ISO 13372: Condition monitoring diagnostics of machines: Vocabulary and

Category 1

Category 2

Category 3

Category 4

* *

* *

* *

* *

ISO 13373-1: Vibration condition monitoring of machines; Part 1: Vibration condition monitoring. General procedures ISO 13379: Condition monitoring and diagnostics of machines- Data interpretation and diagnostic techniques which use information and data related to the condition of the machine- General guidelines ISO 14694: Specification for balance quality and vibration Categories (Industrial Fans) ISO 14695: vibration Method of measurement of fan

* *

* * *

ISO 17359: Condition monitoring and diagnostics of machines- General guidelines

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Standard ISO 18436-1: Condition monitoring and diagnostics of machines: Requirements for qualification and assessment of personnel: part 1 Requirements for assessment bodies and the assessment process

Category 1

Category 2

Category 3

Category 4

BINDT specified additional standards ISO 13374-1. Condition monitoring and diagnostics of machines- Data processing, communication and presentation: Part 1: General Guidelines ISO 281: Rolling bearing: Dynamic load ratings and rating life ISO 15: Rolling bearingsdimensions: general Plan radial bearings boundary

* * *

* * * *

* * * *

ISO 13381-1: Condition monitoring and diagnostics of machines; Prognostics: Part 1 General Guidelines ISO 18431-2: Mechanical vibration and shock -- Signal processing -- Part 2: Time domain windows for Fourier Transform analysis ISO 18436 2: Condition monitoring and diagnostics of machines: Requirements for qualification and assessment of personnel. Part 2: vibration condition monitoring and diagnostics ISO 13373-2: Vibration condition monitoring of machines; Part 2: Processing, presentation and analysis of vibration data *

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Annex C- Training sub-topics- Category 2Category

This Annex is additional to the specifications of ISO18436-2 and is provided by the certifying body as an additional guide to the trainer for Category 2. Category 2 training should satisfy Annex A2 but it is suggested that it also incorporates these sub-topics, which are not exhaustive. Topic 1. Principles of Vibration 1. Basic Motion Superposition of sinusoidal vibrations; pink, selfexcited, steady state and transient vibration; damped free vibration; definitions; Beat frequency/definitions; double integration; shaft orbits; pk-pk/calculation; basic definitions; Formulae (integral/derivatives); absolute vibration; pk-pk, displacement and rms calculations; Modulation; crest factor; enveloping bandpass filters; Definition; Units; phase reference position; Fundamental natural mode; critical speeds; resonance fundamentals; Sub-topics

2. Period, Frequency 3. Amplitude: Peak, Peak-to-Peak, rms 4. Parameters: Displacement, Velocity, Acceleration 5. Units, Unit Conversions 6. Time and Frequency Domains 8. Phase 9. Natural Frequency, Resonance, Critical Speeds 2. Data Acquisition 1. Instrumentation 2. Dynamic Range, Signal-to-Noise Ratio 3. Transducers

Definitions; absolute vibration; Noise signal definition; double integration; Seismic; transducer function; accelerometer integration; transducer frequency ranges; evaluation parameters; ISO measurement guidelines; axial measurements; transducers sensitive axis; transducer mounting methods; cement mounting resonance; adhesive curing times; stud mountings; Zoom function; resolution calculations; Field calibration checks; proximity probes; Eddy current probes; clamps Mounting surfaces; cables

4. Sensor Mounting, Mounted Natural Frequency

5. Fmax, Acquisition Time 6. Proximity Sensor Conventions (API) 7. Triggering 8. Recognition of poor data 3. Signal Processing 1. Analog Sampling, Digital Sampling

FFT; minimum multiples of frequency interest; synchronous sampling/key phasor; sampling rates; analog/digital converters; equipment not part of signal conditioning; Enveloping; definitions Definition; zoom FFT;

2. FFT Computation 3. FFT Application 4. Time Windows: Uniform, Hanning, Flat Top 5. Filters: Low Pass, High Pass, Band

Basic types of vibration filters; low pass; high pass;

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Topic Pass, Tracking 6. Anti-aliasing 7. Bandwidth, Resolution

Sub-topics band pass; tracking; discrete frequency range/filter; Anti-aliasing filter; aliasing; Bandwidth of bandpass filter; FFT resolution; signal duration; lines of resolution; analyser sample time; FFT collection time; calculations; white, pink, transient and periodic random vibration; frequency resolution; response function; distortion; average mobility magnitude; Gaussian, random, ideal, Blast; triboelectric noise causes; Exponential/Linear frequency domain averaging; synchronous time domain averaging; Exponential averaging; averaging; Digital dynamic range calculation; digital dynamic 16bit analysers;

8. Noise Reduction 9. Averaging: Linear, Synchronous Time, Exponential 10. Dynamic Range 4. Condition Monitoring 1. Computer data base set-up 2. Computer database maintenance 3. Equipment Evaluation and Prioritisation 4.4 5. Alarms set-up: Narrowband, Envelope 6. Baseline Assessments, Trending 7. Route Planning 8. Alternate Technologies: Lubrication management, Infrared Thermography, motor current analysis and acoustic emission 9. Fault recognition 10. Procedure writing 5. Fault Analysis 1. Spectrum Analysis, Harmonics, Sidebands 2. 3 4 5 6 7 8. Mass Unbalance 9. Misalignment 10. Mechanical Looseness 11 12. Bearing Defects: Rolling Element,
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Alarm triggers; envelope techniques

Evaluation; rotating shafts/asymmetrical;

B/C boundary; gas turbine alarm set-up; mechanical integrity; Baselines;

Basics of IRT; AE; LM (tribology and wear debris analysis); motor current; magnetic resonance; performance monitoring; causes of bearing wear; Rubs; mass loss; sidebands; Not applicable at Category 2

Asynchronous vibration; waterfall/cascade diagrams; oil whirl; zoom spectrum;

1x rpm; static unbalance; residual, initial, resultant and delta unbalance; Definition; Bearing tightness;

Transducer mounting on rolling element bearings; rub

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Topic Journal 13. Electric Motor Defects 14. Resonance and Critical Speeds 15. Gearbox analysis 6. Corrective Action 1. Shaft Alignment 2. Field Balancing

Sub-topics and sub-syncronous definitions; Poles and line frequency; thermal affects; rotor/stator bars; Resonance; critical speed in flexible rotors; Time domain averaging; sidebands and gear mesh frequency;

Couple unbalancing; defining unbalance (fans etc); balance weight arrangement; minimum runs; offset balancing;

3. Basic maintenance action 7. Equipment Knowledge 1. Electric Motors: Generators and Drives 2. Pumps, Fans Eddy current probes; stiffness dissymmetry; thermal dissymmetry; rotor construction; drive belt vibration; Pump flow conditions; industrial fans-oil seals and oil analysis, basic fan construction/installation/operation; sub-synchronous frequencies; eccentric impellers; Alarm Category triggers (steam/gas turbines); condenser vacuum; temperature affects on gas turbine generators;

3. Steam Turbines, Gas Turbines

4. Compressors 5. Reciprocating Machinery 6. Rolling Mills, Paper Machines and other equipment 7. Machine Tools 8. Structures, Piping 9. Rolling Element Bearings 10. Journal Bearings 11. Gearing 12. Couplings, Belts 8. Acceptance Testing 1. Test procedure 2. Specifications and Standards 3. Reporting 9. Equipment Testing and Diagnostics 1. Impact Testing 2. Forced Response Testing 10. Reference Standards 1. Relevant National Standards/IEC/ISO Relevant standards to country of training; Running speed frequency ranges; multiple frequency vibrations, mode balance tolerance, multi-plane balance; sensitivity to unbalance; phase couple angle of and amount of unbalance; fault/failure definitions; see all
1st January 2012

Large diesel engine construction; piston velocity; Pulp refining machinery measurements; Acoustic emissions; torque controlled machining; Natural resonances;

Oil whirl; Gear teeth and shaft speed calculations;

Resonance; Evaluation zones;

Ring testing; impact testing, transmissibility; transfer functions;

CM_VA Issue 2 rev D

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Topic

Sub-topics ISO in Annex B Table 2 for Category 2

11. Reporting and Documentation 1. Condition Monitoring Reports 2. Vibration Diagnostics Reports 12. Fault Severity Determination 1. Spectrum Analysis Bode plots; rotating aerodynamic stall; rotor/stator bar defects; gear mesh and sideband frequencies; sum and difference frequencies; Evaluation criteria Polar plots; Campbell and Nyquist diagrams; FMECA; interpretation; statistics; Format and content; results interpretation; Future actions;

3. Categories: Overall, Narrowband, Component 4. Severity Charts; Graphs and Formula

CM_VA Issue 2 rev D

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1st January 2012