Upon completion of the course, the trainee will be able to:

• • Consolidate and update understanding of the Terminology used in measuring and analysis.
  • Provide methods to improve equipment through the prediction and the avoidance of Equipment Failure.
  • Understanding the critical necessities and priorities associated for maintaining machinery
  • Key procedure for the implementation of risk based failure analysis
  • Equipment critically and functional failure
  • How to reduce the overall life cycle cost of owning a piece of equipment.
  • Maximize component life by avoiding the cause of failure.
  • Be familiar with condition based maintenance rather than corrective maintenance.
  • Implement real improvements in machinery reliability and plant performance.
  • Use case studies based on both technical and non technical situations.

Machinery Failure Analysis and Prevention course is designed for Operation Engineers, Design Engineers, Maintenance Engineers, Supervisors, and Planning Engineers working in refineries, petrochemical plants and power stations.

The Machinery Failure Analysis and Prevention training course will utilize a variety of proven learning techniques to ensure maximum understanding, comprehension and retention of the information presented. This includes lecture with active delegate participation including discussions, real life problems, case studies and relevant videos. The course instructor may modify the above training methodology during the course for technical reason.

Pre & Post course assessments will be used to measure the effectiveness of this training.

Achieving Customer Service Excellence training course will be presented with the aid of highly motivating presentations together with videos and case studies to enhance learning. Discussions, skills practice and group work will allow delegates to get fully involved, participate, experience and understand the practical implications.

Pre & Post course assessments will be used to measure the effectiveness of this training.

Module 1 - Concept of Failure

• Key Topics:
  • Introduction to Failure Analysis and Troubleshooting Systems
  • Causes of Machinery Failure
  • Machinery Design Properties
  • Equipment Failure
  • Types of Failure Causes
  • Affect of Failure
  • Failure Cascading
  • Failure Modes
  • Chronic vs. Sporadic Failures
  • Failure Reporting
  • Failure Reduction Programs

Module 2 - Root Cause Failure Analysis Process

• Key Topics:
  • What RCFA is?
  • Why it is done?
  • Types of Root Causes
  • SEVEN Generic Steps in an RCFA
  • Challenges in Setting up RCFA
  • Sustaining an RCFA Process
  • Application on RCFA (Exercises)

Module 3 - Failure Analysis & Investigation Tools

• Key Topics:
  • Brainstorming
  • Flow Charts
  • Histograms
  • Fishbone Diagrams
  • Pareto Charts
  • Fault Tree Analysis
  • Failure Mode and Effect Analysis (FMEA)
  • Applications (Exercises)

Failure Mode and Effect Analysis (FMEA)

• • Failure Analysis Methods
  • Common Failure Analysis Techniques
  • Implementing FMEA
  • FMEA Procedure
  • Application on FMEA (Exercises)

Module 4 - Machinery Troubleshooting

• Key Topics:
  • Condition Monitoring
  • Machine Failure Modes
  • Equipment Performance
  • Methods of Detection
  • Applications (Machine Failure)

Structured Problem Solving Techniques

• • Win – Win Problem Solving
  • Development of Problem Solving Skills
  • Alternative Solution Training
  • Formulate Alternative Strategies
  • Guidelines for Decision Making
  • Priority Setting

Module 5 - Machine Reliability

• KeyTopics:
  • Reliability, availability, maintainability
  • Risk Assessment and Management
  • Life Cycle Management
  • Reliability & Maintainability
  • Techniques & Analysis of Reliability
  • Human and System Reliability
  • Human Performance Approach
  • Reliability Centered Maintenance
  • Centrifugal Pump Reliability Improvement
  • Machinery Reliability Audits and Reviews

Case Studies

• • Journal and Tilt-Pad Thrust Bearings failure causes
  • Mechanical Seal Failure Modes
  • Lubricant of Pumps and Motors Problems
  • Causes of Shaft Failure
  • Causes of Coupling Failure
  • Causes of Gear Failure

BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.