Course Details
PREVENTIVE & PREDICTIVE MAINTENANCE OF ROTATING EQUIPMENT
Location
Dubai, UAE Date
Duration
5 days Language
EnglishDiscipline
MECHANICAL ENGINEERINGIntroduction
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
Upon successful completion of this course, the delegates will be able to:
üRecognize the aspects of maintenance today through the various types of maintenance including maintenance strategy development and productive maintenance
üApply maintenance business model, maintenance organization, and business elements and identify the different equipment failure patterns and the reasons why equipment fails
üDetermine the process of developing maintenance objectives in accordance to the business plan, R&M policy and maintenance strategy, discuss the significance of equipment plans in maintenance planning and identify several equipment plans development, approaches and plan options
üEmploy the methods of preventive maintenance and condition monitoring such as vibration monitoring, equipment monitoring frequency and infrared thermography
üImplement the procedure of work selection in accordance with work screening procedure, work request requirements, prioritization systems and cost benefits
üCarryout various strategies of work planning and scheduling by identifying the planning effectiveness, planners and staffing, routine maintenance planning and use of various planning tools and specify the different proven turnaround practices in accordance with success factors and management practices
üRecognize the purpose of work execution & job completion and characterize its advantages and disadvantages, implement the methods of maintenance quality assurance and continuous improvement and employ the method of Root Cause Failure Analysis (RCFA)
üApply the various stewardship and performance metrics such as performance work management, KPIs, maintenance effectiveness metrics and work force utilization metrics
üDistinguish the factors of human reliability through classification of human error and human reliability analysis, familiarize the different reliability tools using life cycle cost analysis and life data analysis and discuss the key elements of reliability engineering and how to manage assets in projects
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 Imbalance
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.