Course Details
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Course Description
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 with a view to optimising the maintenance engineering effort while maximising production. Other techniques that will be addressed include infrared thermography, passive ultrasonics, tribology and performance monitoring.
Vibration Monitoring employs things from simple portable vibration data collectors to the complex in-built online Vibration Monitoring and Diagnostics Systems. Online condition monitoring tools include bearing analysers, machinery stethoscopy, temperature sensors and profilers, acoustics emissions techniques, ultrasonic testing for integrity, etc.
These Plants consist of both static and rotating equipment, including piping. These pieces of equipment must not fail suddenly while in operation. Sudden breakdown failures not only cause huge production and the associated monetary losses but also find a company unprepared as to how to bring them back on stream, apart from safety, health, and environmental issues.Modern inspection and maintenance strategists believe in Predictive Maintenance which provides sufficient warning about the deteriorating conditions of equipment/machines in advance through Vibration Analysis and Condition Monitoring.While vibration analysis and condition monitoring are important for all machines/equipment to plan maintenance without surprises, online Vibration Analysis is critical for large rotating machines which don’t have standbys in the plant e.g., Turbo-compressors, Turbo-generators, etc.
The Training Course Will Highlight ?
Training Objective
Target Audience
- Supervisors
- Team Leader
- Professionals in Maintenance, Engineering and Production
- Engineering, Fire & Safety, Maintenance, Operation, Inspection personnel at all levels, including trainees/interns
- Insurance, Regulatory, and lending agencies
- Middle level and Top management personnel with an introductory version of this course
- Those who provide contractual services on Predictive Maintenance, Vibration Analysis and Condition Monitoring of Machines
Training Methods
This Machinery Failure, Vibration & Predictive Maintenance training course 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.
Daily Agenda
Concepts
- Machines/Equipment in the Plants
- Understanding Failures
- Machine Failure Analysis
- Wear and Tribology
- Fatigue Mechanisms
- Plain, Tilt-pad and Anti-friction Bearing and Seal Failures
Reliability Fundamentals and Methods for Avoiding Failures
- Fundamentals of Reliability of Machinery
- Reliability Determination and Assessment Methods
- Statistical Analysis of Machinery Failures
- Workshop and Case Study
CONDITION MONITORING
- What conditions can deteriorate machines/equipment?
- Variations in conditions in machines/equipment in the running plant
- Condition variations as an indication of the trend of deterioration
- Technologies to capture variations
- Baseline condition
- Online condition
- Risk-based condition
- Risk-based monitoring
Understanding Predictive Maintenance
- Predictive Maintenance Concepts
- Introduction
- Maintenance Strategies
- Predictive Maintenance –Background and History
- Predictive Maintenance Technologies
- Infrared Thermography
- Thermographic Applications
- Passive Ultrasonics - Contact and Non-contact
- Ultrasonic Applications
- Tribology – Oil Analysis
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
Vibration
- Vibration Analysis
- Introduction to Vibration Analysis
- Frequency Analysis and the Fast Fourier Transform
- Vibration Transducers
- Basic Failure Mechanisms with Examples
- Cause of Vibration/Basic Physics behind it
- The vibration of rotating and static equipment: Relative comparison
- Detecting vibration: Probes – Displacement, Velocity, and Acceleration
- Threshold limits of vibration/Acceptance criteria
- Portable and fixed tools and sophisticated instrumentation
- Data collection, Analysis, and Monitoring
- Consequences of Ignoring vibration
- Case studies on Vibration
- Lack of timely maintenance may give rise to vibration
- Balancing the rotating parts in machines
- Industry advancements
- Vendors providing instruments and tools
- Service providers on data collection and problem diagnostics with troubleshooting
Global industry trends
- Culture of machine monitoring vis-a-vis human health monitoring by medical doctors
- The analogy between industry and medical condition monitoring
- Predictive maintenance is a lifeline and currently globally accepted strategy
- Condition monitoring and diagnostics as a respected profession
Case Studies
- Study of incidents as a result of ignorance of predictive maintenance, vibration analysis, and condition monitoring
- Analysis of problem areas, root cause analysis, and corrective actions
- Presentation of solutions by the participants
Accreditation
BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.
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