Machinery Failure, Vibration Analysis and 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.  In this comprehensive course, the delegates will benefit from using modern methods & technologies to learn reliability basics, fault analysis and monitoring techniques. Failure analysis and Predictive Maintenance techniques, including vibration analysis, are discussed in the course with a view to optimizing the maintenance engineering effort while maximizing production.  Other techniques that will be addressed include infrared thermograph, passive ultrasonic’s, teratology and performance monitoring. 

Objectives

At the end of this seminar participants will have:

• An understanding of Machine Failure Analysis techniques.
• An understanding of why machines fail and how to identify the “bad actors”
• An understanding of a range of 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

Training Methodology

This is a highly interactive training course with opportunities to advance your opinions and ideas. Participation is encouraged in a supportive environment. To ensure the concepts introduced during the program are understood, they will be reinforced through a mix of learning methods, including lecture-style presentations, open discussion, case studies, simulations, and group work.

Who Should Attend?

This seminar is directed towards Supervisors, Team Leaders and Managers in Maintenance, Engineering and Production.  The course 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 organizations.

Course Outline

Day 1: An introduction to Reliability

• Rotating Machines
• Centrifugal pumps
• Centrifugal & rotary compressors.  Fans & blowers
• Drivers – turbines and motors
• Common problems on rotating machines
• Performance deterioration
• Vibration as an indicator
• Failure of function
• Economics of maintenance engineering
• Maintenance & asset management
• Cost of equipment failure
• Economic evaluation & financial concepts
• Life cycle costs
• Equipment Reliability
• Reliability in design
• Specifications & application
• Operational reliability, including first-line maintenance and TPM
• Maintenance reliability, including Maintenance Planning and   Management
• Maintenance strategies and their implementation

Day 2: Strategic Reliability

• Reliability Engineering
• Reliability basics
• Reliability prediction
• Reliability assessment
•  Life cycle assessment
•  FMEA & FMECA
• Reliability Maintenance
• Strategies
• CBM, RBM, RCM & PdM
• CMMS
• Maintenance roles & responsibilities
• Statistical analysis in maintenance
• MTTR, MTBF, availability & reliability
• Data collation
• Data manipulation
• Data interpretation

Day 3: Mechanical Failure Mechanisms & Troubleshooting

•  Machine Failure Analysis
• Understanding fault causes
• Wear and tribology
• Diagnosis of fatigue mechanisms – mechanical & thermal
• Bearings
• Bearing types & application
• Plain & pad bearings - hydrodynamic lubrication, failure types and identification
• Rolling element bearings – elastohydrodynamic lubrication, failure types and identification
• Pump & compressors seals
• Construction.
• Application
• Failures types – identification and analysis
• Troubleshooting techniques
• Field troubleshooting
• Engineering troubleshooting – problem-solving

Day 4: Condition Monitoring & Predictive Maintenance

• Predictive Maintenance Concepts
• Predictive Maintenance – background and history
• Predictive Maintenance Technologies – an overview
• Potential Failure Analysis – deciding which technologies to apply
• On-Line or Offline?
• Protection systems
• Monitoring systems
• Analytical systems
• 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

Day 5: Predictive Maintenance Technology

• Other Predictive Maintenance Techniques
•  Infrared Thermograph
• Thermographic applications
• Passive Ultrasonic’s - contact and non-contact
• Ultrasonic Applications
• Tribology – oil analysis
• Managing Predictive Maintenance
• Performance and Efficiency Monitoring
• Managing the Predictive Maintenance effort
• Cost Analysis
• Reporting Techniques
• Integrating Predictive Maintenance into the Maintenance Plan