Training Certificate

Prolific Consultants FZE Certificate of Course Completion will be issued to all attendees.

Course 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.

Course 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.

Suitable For

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.

Training Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos & General Discussions

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

Case Studies, Discussions, Last Day Review & Assessments will be carried out.

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