ICTD International Centre for Training and Development

Machinery Failure, Vibration Analysis and Predictive Maintenance

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About the course

Machines deteriorate as they get older so we can expect a certain amount of performance fall-off 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 and 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 thermography, passive ultrasonic, tribology and performance monitoring.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

  • Understand and gain knowledge on machinery failure, vibration analysis and predictive maintenance
  • Determine why machines fail and how to identify the “bad actors”
  • Determine range of Predictive Maintenance Technologies
  • Recognize the potential contribution of each these technologies to maintenance efficiency
  • Use the guidelines indicating how these technologies can interact with and support each other
  • Illustrate the hints and tips for practical application of these technologies so as to achieve the best results
  • Apply practical approach to developing an action plan to utilize these technologies in their own areas of responsibility, fitting them into the overall maintenance strategy, and measuring benefits

Course Outline

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

  • Trouble shooting techniques
  • Statistical analysis of machinery failures

Day 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

Day 4

Using Predictive Maintenance

  • Vibration Standards and Alarm Levels
  • Vibration Diagnostics
  • Amplitude Demodulation – a.k.a Enveloping, SSE, HFD, Peak-Vue
  • Vibration on Rolling Element Bearings
  • Resonance – identification & cure
  • Other Predictive Maintenance Techniques
  • Infrared Thermography
  • Thermographic applications
  • Passive Ultrasonic - contact and non-contact
  • Ultrasonic Applications
  • Tribology – oil analysis

Day 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

## Course Methodology

A variety of methodologies will be used during the course that includes:

  • (30%) Based on Case Studies
  • (30%) Techniques
  • (30%) Role Play
  • (10%) Concepts
  • Pre-test and Post-test
  • Variety of Learning Methods
  • Lectures
  • Case Studies and Self Questionaires
  • Group Work
  • Discussion
  • Presentation

Who should attend

This course 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.

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