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Topics include reliability basics; maintenance philosophies & strategies, their relationships to each other & their effective application; machinery condition monitoring; machinery condition assessment & asset management; effective fault diagnosis...


 
Course Outline

After participating in this course, you will be able to:

  • Discover how to monitor the condition of rotating machinery and how to diagnose problems using state-of-the-art technology including thermal, lubricant and vibration-based fault detection and diagnostic techniques
  • Gain a working knowledge of the techniques of reliability engineering and the ability to apply them effectively in improving the maintenance, maintainability, and reliability of rotating machinery
  • Develop the principles and practice of reliability-centered maintenance and of condition monitoring, how to interpret the measurements and symptoms, and how to diagnose associated faults
  • Add to your ability to evaluate the economic impact of reliability improvement activities and to achieve cost-effective maintenance of your plant equipment
  • Broaden your technical knowledge base leading to increased contributions in plant reliability, integrity and reduced downtime as well as enhance your career advancement potential

Description

Reliable operation of the rotating equipment in any plant is its life blood.  Engineers must have an integrated viewpoint focusing on it through design, operation and maintenance.  This seminar comprehensively presents from such an integrated viewpoint state-of-the-art techniques and methodologies for improving reliability of rotating equipment.

Topics include reliability basics; maintenance philosophies and strategies, their relationships to each other, and their effective application; machinery condition monitoring; machinery condition assessment and asset management; effective fault diagnosis techniques; failure mode and causal analysis;  life-cycle strategies to promote increased reliability; reliability improvement program development and implementation including structure and personnel considerations; and business ramifications of reliability improvement.

The course will comprise lectures and workshop to maximize your benefits. Additionally, an optional "Question and Answer" period is included to provide you with opportunity to get expert answers on your specific questions.

Objective

To provide a comprehensive understanding of the fundamentals and techniques underlying the assessment of rotating machinery reliability, detection and diagnosis of faults, and best practices for cost-effective reliability improvement.

Who Should Attend

Design, maintenance, machinery and plant engineers, supervisors and technicians as well as operations personnel involved in operation, condition assessment, troubleshooting and maintenance of rotating equipment in the manufacturing, chemical processing, pharmaceutical, petrochemical, power, mining, pulp and paper, food, and other process industries. Recent graduates will benefit within the short period of two days from years of experience of the instructor.

Program Outline

Instructor: Faculty: Nabil Al-Khirdaji, Kappa Associates International

Day I

8:00      Registration and Coffee

8:20      Welcome, Introduction, Workshop Preview, Learning Outcomes and the Assessment Method

8:30      Reliability Engineering

  • Reliability basics
  • Elements of world-class reliability 
  • Reliability prediction models 
  • Traditional approach to reliability prediction
  • Failure mode and effect analysis
  • Machinery reliability assessment
  • Ascertaining the functionality and remaining life of rotating equipment

9:30      Maintenance Methods and Strategies

  • Breakdown, preventive, predictive and proactive maintenance
  • Reliability-centered maintenance (RCM) 
  • Precision maintenance
  • Computerized maintenance management systems (CMMS)

10:30    Refreshments and Networking

10:45    Reliability Improvement Program Development and Implementation 

  • Program definition and development: structure, objectives, impact on business        
  • Reliability action teams: structure, training, mandate, and resources
  • Identify and rank reliability deficiencies and associated lost production costs
  • Critical poor performers (bad actors) identification and tracking

11:30    Reliability Analysis Software Review 

12:00    Lunch

1:00      Economics of Machinery Failures and Reliability         

  • Improvement 
  • Cost impact of machinery failure
  • Justification and economic evaluation of reliability improvement projects
  • Financial concepts: capital assets, time value of money, life cycle costs and risk
  • Life cycle costs methodology 

1:30      Effectiveness of Reliability Deficiency Corrections

  • Reliability performance indicators 
  • MTBF, MTTR
  • Lost production cost
  • Direct failure information
  • Reporting

2:00      Vibration in Rotating Machinery

  • Vibration fundamentals
  • Vibration in condition monitoring
  • Vibration monitoring and analysis methods - benefits and limitations
  • RMS broad-band vibration meters
  • Shock-pulse technology
  • Diagnostic screening technology
  • Narrow band vibration analysis
  • Cepstrum analysis
  • Automated diagnostic system for vibration analysis
  • Intelligent (smart) machines
  • Data interpretation

3:00      Refreshments and Networking

3:20      Industrial Lubrication 

  • Lubrication theory and practice 
  • Plant lubrication systems and programs   
  • Wear particle analysis technology; Ferrography techniques and instruments
  • Bearing failures - Detection, diagnosis and prevention guidelines and tips

4:20      Stretch Break / Adjournment

4:30      Question and Answer Session with Instructor
               This one hour optional session will provide an opportunity to get expert answers to your specific questions on course or related topics.
               The adjournment will be at 5:30 pm but participants may leave when they feel the instructor has answered all their questions.

5:30      Adjournment

Day II

8:30      Machinery Component Failure and Analysis

  • Common causes of component failures: bearings, seals, shafts, couplings, controls
  • Design, application, materials, and installation factors
  • Operating practices
  • Maintenance practices and quality
  • Wear failure models
  • Troubleshooting guidelines
  • Metallurgical failure analysis methodology
  • Reliability of standby equipment
  • Periodic exercising program
  • Best industry practices, guidelines and tips.
  • Impact of equipment standby practices on reliability and maintenance costs

10:00    Refreshments and Networking

10:15    Fault Causes, Detection, and Diagnosis 

  • Failure evolution process
  • Bases for the detection of faults in rotating machinery
  • Principles of rotor dynamics and balancing
  • Mass unbalance
  • Bent shafts - thermal distortion, large unbalance force
  • Cracked shafts - vibration caused by fatigue-induced cracks 
  • Shaft misalignment
  • Bearing lubrication, misalignment, and rubbing
  • Excessive forces and moments by connected piping
  • Equipment base plate grouting

11:30    Machinery Condition Monitoring 

  • On-line condition monitoring strategies
  • Protection systems vs. diagnostic systems
  • Parameters measured and measurement locations
  • Typical field data collection processes and systems
  • Remote monitoring and diagnostics
  • Expert systems - smart machines
  • Enhancements to CBM technologies
  • Interpretation of measurements, trend analysis and diagnostics 

12:30    Lunch

1:30      Machinery Failure Analysis and Prevention

  • Troubleshooting rotating machinery
  • Failure mode and effect analysis
  • Failure investigation process
  • Root cause failure analysis methods
  • Corrective action: continue, repair, redesign, replace 

2:30      Refreshments and Networking

2:50      Workshop 
              Work on machinery failure case studies and your own examples under the guidance of the instructor.

4:10      Questions and Answers and Feedback to Participants on Achievement of Learning Outcomes

4:30      Concluding Remarks and Final Adjournment


Prerequisites & Certificates
Pre-Requisites

Certificates offered

1.2 CEU / 12 PDH


Cancellation Policy
To withdraw from a course, you must send a request, in writing, with the official receipt to our office. Fifteen or more business days in advance: full refund less $50.00 administration charge. Five to fifteen business days in advance: non-refundable credit of equal value for any future EPIC seminar within one year. Credits are transferable within your organization. In case of an unexpected event occurring after this time, you may send someone else to take your place without any additional cost.
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Here are some reviews of the training vendor.
The course was very well presented and the course instructor was absolutely amazing.
Reviewed by 2013
Our instructor, Stephen Lamming, was outstanding and a true expert in his field. He was able to complement the technical air monitoring information with practical real life examples which was highly beneficial. He is an excellent communicator and was highly interactive with the course attendees. This course was recommended to me because Stephen Lamming does an outstanding job. I was very impressed with this course and have subsequently recommended it to my colleagues.
Reviewed by 2012
Would have liked more interactive problem solving.
Reviewed by 2011
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