By the end of this course, participants will be able to:
- Analyze machinery failures using advanced diagnostic techniques to identify root causes and prevent recurrence.
- Understand the principles and applications of predictive maintenance to optimize equipment reliability and performance.
- Evaluate the effectiveness of various predictive maintenance technologies, including vibration analysis, infrared thermography, and oil analysis.
- Integrate predictive maintenance strategies into broader maintenance plans to enhance operational efficiency and reduce downtime.
- Apply best practices for managing maintenance efforts, including performance monitoring, cost analysis, and reporting.
- Develop a comprehensive understanding of how predictive maintenance tools complement one another to create a cohesive and efficient maintenance strategy.
DAY 1
Understanding Machinery Failures
- Principles of Failure Analysis:
- Key causes and contributors to machinery failure.
- Insights into wear mechanisms and tribology.
- Fatigue processes and prevention strategies.
- Analysis of Component Failures:
- Common failure modes of bearings (plain, tilt-pad, and anti-friction) and seals.
- Techniques for identifying root causes of failures.
DAY 2
Reliability Foundations and Preventing Failures
- Core Concepts of Machinery Reliability:
- Fundamental principles of reliability in machinery design and operation.
- Techniques for assessing and improving reliability.
- Failure Prevention Techniques:
- Statistical methods for analyzing failure trends.
- Tools for identifying early indicators of potential failure.
- Interactive Workshop and Case Study Analysis:
- Practical exercises to apply failure analysis techniques in real-world scenarios.
DAY 3
Introduction to Predictive Maintenance
- Foundations of Predictive Maintenance:
- Overview of maintenance strategies and their evolution.
- Historical background and advancements in predictive maintenance.
- Selecting the right predictive technologies based on failure analysis.
- Vibration Analysis Essentials:
- Introduction to vibration analysis and its role in maintenance.
- Fundamentals of frequency analysis and Fast Fourier Transform (FFT).
- Overview of vibration sensors and transducers.
- Key failure mechanisms illustrated with examples.
DAY 4
Application of Predictive Maintenance Techniques
- Advanced Vibration Diagnostics:
- Interpreting vibration standards and alarm thresholds.
- Diagnostic techniques such as amplitude demodulation (e.g., enveloping, SSE, HFD, Peak-Vue).
- Analysis of rolling element bearing vibrations.
- Identifying and resolving resonance issues.
- Complementary Predictive Technologies:
- Infrared Thermography:
- Basics of thermography and its applications in maintenance.
- Ultrasonics:
- Applications of passive ultrasonics in identifying faults.
- Differentiating between contact and non-contact methods.
- Tribology and Oil Analysis:
- Techniques for evaluating lubrication, wear, and oil conditions.
DAY 5
Managing Predictive Maintenance Systems
- Optimizing Predictive Maintenance Programs:
- Techniques for monitoring system performance and operational efficiency.
- Strategies for effectively managing predictive maintenance initiatives.
- Cost-benefit analysis of implementing predictive maintenance.
- Reporting and Integration:
- Developing clear and actionable maintenance reports.
- Incorporating predictive maintenance strategies into broader maintenance plans.
