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RE01

Analytical Prevention of Machinery Failure, PM & Troubleshooting of Plant Rotating Equipment

Introduction

Machines deteriorate as they get older so we can expect a certain amount of performance falloff and general deterioration of the machine.  If we understand the failure mechanisms that are in place we can identify which parameters best indicate the deterioration of the machine. 

Failure analysis, Troubleshooting and Predictive & Planned Maintenance techniques, including vibration analysis, are discussed in the course with a view to optimising the maintenance engineering effort while maximising production.

Target Audience

This seminar is directed towards Supervisors, Team Leaders and Managers in Maintenance, Engineering and Production.  The seminar will also benefit anyone who wishes to update themselves on Predictive Maintenance Technologies and Failure Analysis techniques, as well as those who have to judge the suitability of these technologies for their needs, and learn how to implement them for the benefit of their organisations.

Objectives

At the end of this seminar participants will have:

• An understanding of Machine Failure Analysis and Troubleshooting techniques
• An understanding of a range of Planned & Predictive Maintenance Technologies
• Knowledge of the potential contribution of each these technologies to maintenance efficiency
• Guidelines indicating how these technologies can interact with and support each other
• Hints and Tips for practical application of these technologies so as to achieve the best results
• A practical approach to developing an action plan to utilise these technologies in their own areas of responsibility, fitting them into the overall maintenance strategy, and measuring benefits

Key Benefits

The knowledge gained in this seminar will:

• Allow the delegate to carry out analysis of machine failures
• Enable the delegate to develop a proactive maintenance regime within the organisation.
• Give the delegate confidence to carry out failure analyses thereby avoiding repetitive failures.
• Allow tighter control of maintenance budgets by the avoidance of unplanned equipment failures in service.

Training Methodology

The seminar will be conducted along workshop principles with formal lectures, case studies and interactive worked examples. Relevant case studies will be provided to illustrate the application of each tool in an operations environment. Each learning point will be re-enforced with practical exercises. There will be ample opportunities for discussion and sharing experiences.

Organisational Impact

Analysis of machine failures and predictive maintenance of rotating plant is vital to the budgetary success of the operations organisation.  On completion of this seminar the delegate will be able to critically analyse the methodologies employed within the organisation and instigate improvements where required.

Personal Impact

Technical knowledge is key to effective control and peer respect within any maintenance organisation; when this is achieved personal satisfaction follows.  This seminar will give the delegate the required level of technical knowledge and skill to achieve that personal satisfaction.

Competencies

·         Analytical competency to analyse machine failures

·         Ability to put in place measures to avoid repetitive machine failures.

·         Understanding of vibration analysis techniques as applied to rotating equipment.

·         Ability to put in place predictive maintenance measures to quantify equipment condition.

·         Ability to organise Planned Maintenance activities.

Seminar Content

      Day 1        UNDERSTANDING FAILURES

      Machine Failure Analysis

      Wear and tribology

      Fatigue mechanisms

      Plain, tilt-pad and anti-friction bearing and seal failures

      Day 2        AVOIDING FAILURES

        Analysis and identification of failures

        FMEA and FMECA to identify failure modes and criticality analysis

        Trouble shooting techniques

        Statistical analysis of failures

      Reliability, availability and maintainability

      Day 3        UNDERSTANDING PLANNED MAINTENANCE

      Planned Maintenance Concepts

      Introduction

      Maintenance Strategies

      Planned Maintenance – background and history

      Planned Maintenance Technologies – an overview

      CMMS – an overview

      Potential Failure Analysis –

      Deciding which technologies to apply to avoid failures

      Day 4        USING PREDICTIVE MAINTENANCE

      Vibration Analysis

      Introduction to Vibration Analysis

      Frequency Analysis and the Fast Fourier Transform

      Vibration Transducers

      Basic Failure Mechanisms with examples

      Vibration Standards and Alarm Levels

      Vibration Diagnostics

      Amplitude Demodulation – aka Enveloping, SSE, HFD, Peak-Vue

      Vibration on Rolling Element Bearings

      Resonance – identification & cure

      Other Predictive Maintenance Techniques

      Infrared Thermography

      Thermographic applications

      Passive Ultrasonics - contact and non-contact

      Ultrasonic Applications

      Tribology – oil analysis

      Day 5        CONTROL MECHANISMS

      Managing Planned Maintenance

      Performance and Efficiency Monitoring

      Managing the Planned Maintenance effort

      Cost Analysis

      Reporting Techniques

      Integrating Predictive Maintenance into the Maintenance Plan