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Maintenance, Inspection, Testing, Corrosion, Painting, Turnaround & Industrial Services

Machinery Failure, Vibration & Predictive Maintenance




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 and Predictive Maintenance techniques, including vibration analysis, are discussed in the training course to optimize the maintenance engineering effort while maximizing production. Other techniques that will be addressed include infrared thermography, passive ultrasonics, tribology, and performance monitoring

Targeted Groups:

  • Supervisors
  • Team Leader
  • Professionals in Maintenance, Engineering and Production

Course Objectives:

At the end of this course the participants will be able to:

  • Understand the Machine Failure Analysis techniques
  • Understand a range of Predictive Maintenance Technologies
  • Gain knowledge of the potential contribution of each these technologies to maintenance efficiency
  • Indicate how these technologies can interact with and support each other
  • Learn hints and tips for practical application of these technologies to achieve the best results

Targeted Competencies:

  • Developing maintenance programs
  • Implementing maintenance programs
  • Different approaches for learning from failures
  • Optimizing maintenance resources
  • Implementing best practice maintenance techniques

Course Content:
Unit 1: Understanding Failures:

  • Machine Failure Analysis
  • Wear and Tribology
  • Fatigue Mechanisms
  • Plain, Tilt-pad and Anti-friction Bearing and Seal Failures

Unit 2: Reliability Fundamentals and Methods for Avoiding Failures:

  • Fundamentals of Reliability of Machinery
  • Reliability Determination and Assessment Methods
  • Statistical Analysis of Machinery Failures

Unit 3: Understanding Predictive Maintenance:

  • Predictive Maintenance Concepts
  • Introduction
  • Maintenance Strategies
  • Predictive Maintenance – Background and History
  • Predictive Maintenance Technologies – An Overview
  • Potential Failure Analysis – Deciding which Technologies to Apply
  • Vibration Analysis
  • Introduction to Vibration Analysis
  • Frequency Analysis and the Fast Fourier Transform
  • Vibration Transducers
  • Basic Failure Mechanisms with Examples

Unit 4: Using Predictive Maintenance:

  • Vibration Standards and Alarm Levels
  • Vibration Diagnostics
  • Amplitude Demodulation – 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

Unit 5: Control Mechanisms:

  • Managing Predictive Maintenance
  • Performance and Efficiency Monitoring
  • Managing the Predictive Maintenance effort
  • Cost Analysis
  • Reporting Techniques
  • Integrating Predictive Maintenance into the Maintenance Plan