Location

Date

Duration

Language

Discipline

Introduction

This is a five-day course on Rotary Machinery Preventive and Predictive Maintenance. Different maintenance strategies will be discussed; elements of each maintenance strategy, their advantages and disadvantages will be explored. The selection of the appropriate strategy that fit the mode of failure and results in the minimum time between repair and that leads to least down time and maintenance cost is one of the maintenance engineer duty that must be mastered. Tools and measurements involved in each maintenance strategy must also be recognized and deeply understood. To apply the above techniques effectively on the Rotary Machinery, one should be aware of their failure modes, and methods of troubleshooting. The above will applied on different type of Rotary Machinery like pumps, compressors, and Turbines.

Objective

• Define predictive maintenance and differentiate it from other approaches such as run-to-failure and preventive maintenance
• Describe the benefits of predictive maintenance
• Describe how equipment vibration can provide an indication of equipment condition
• Describe how impurities in equipment lubricant can provide an indication of the condition of the components being lubricated
• Describe how trends reflected in equipment records can provide an indication of equipment condition
• Describe some basic guidelines for a successful predictive maintenance program.

Audience

^{Engineers, technicians and managers responsible for selection, installation, machinery failure analysis, troubleshooting and maintenance of different rotary machines like pumps, compressors, fans, blowers, steam turbines, gas turbines will benefit from this course.}

Content

The following topics will be covered in the course over five working days:

Ch 1 Maintenance Strategies

Maintenance Strategies  

          Corrective Maintenance

          Breakdown Maintenance

          Preventive Maintenance

          Predictive Maintenance

          Corrective Maintenance

Effective Preventive Maintenance

Planning & Scheduling

Mode of Failures

Coordination with Production

Opportunity Preventive Maintenance Activities

Predictive Maintenance Techniques

Vibration monitoring

Themography

Tribology

Visual inspections

Ultrasonics

Process Parameters

Ch 2 Causes of Machinery Failure

          Improper Specifications

                   Improper Sizing

Material Deterioration

          Overstressing

          Material Corrosion

          Overheating

          Fatigue Failure

          Brittlement Failure

Misalignment

                   Cold versus Hot Alignment

                   Alignment Tolerances

          Imbalance

                   Causes of Imbalance

                   Level of Balancing

                   Vibration due to Imbalnce

          Off-design Operation

                   Range of Acceptable Operation

                   Limits of Operation

                   Controlling Systems

          Loop Oil Systems

                   Bearings

                   Seals

                   Control Systems

          Installation Problems

                   Piping Stresses

Ch 3 Root Cause and Troubleshooting

          Failure Consequences

          Failure Modes

          Age-related Failure

          Failure which are not age-related 

The Failure Process

          The Six Failure Patterns

          Technical History Data

          Failure Finding Task

Ch 4 Failure Prevention

          Proper Specifications

          Codes and Standards

          Proper Operation

          Protective and Safety Devices

          Proper Training 

Monitoring Systems

          Maintenance Planning

Ch5  Applications and Case Studies

          Pumps

          Fans and Blowers

          Compressors

          Steam Turbines

          Gas Turbines

Certificate

MAESTRO CONSULTANTS Certificate of Completion for delegates who attend and complete the training course

Methodology

Our courses are highly interactive, typically taking a case study approach that we have found to be an effective method of fostering discussions and transferring knowledge. Participants will learn by active participation during the program through the use of individual exercises, questionnaires, team exercises, training videos and discussions of “real life” issues in their organizations.
The material has been designed to enable delegates to apply all of the material with immediate effect back in the workplace.

Fees

$4000