Rotating Equipment Reliability Optimization and Continuous Improvement

Introduction

The problem of reliability allocation and optimization of Rotating Equipment has been widely investigated by world-class process companies during the last decade. Instead of concentrating exclusively on redundancy allocation as per the old fashion maintenance, the minimum required reliability for each component of the equipment are now estimated in order to achieve the equipment reliability goal with minimum cost. Thereafter, the engineer can decide whether this minimum required component reliability will be achieved via fault avoidance or redundancy. This new philosophy allocates reliability to a component according to the cost of increasing its reliability.

Continuous improvement of plant reliability by optimizing predictive maintenance for rotating equipment is one of the most important challenges plants face today. To know how to effectively prevent equipment failures, conduct a successful root cause failure analysis and improve condition monitoring for pumps, turbines and compressors are continuing challenges for engineers. Proper analysis and solving of chronic problems at the source saves time and money.
This course is designed to explain the effective method of component condition monitoring for use as both a predictive maintenance and root cause analysis tool. It also details the major failure causes, the world-class proven root cause analysis procedure with exercises and case histories, installation, pre-commissioning planning, functional testing and commissioning, preventive maintenance strategies and more.

Objectives

The course will concentrate on the problems and solutions surrounding equipment failures, diagnostics and effective methods to prevent them. This results in more efficient plant maintenance, increased operational efficiency, lower operating costs and improved plant availability. Upon the successful completion of the course,

participants will be able to:-

• Recognize the concept of organizing for world class operations particularly the characteristics and steps used toward pacesetter performance
• Explain equipment failure patterns by distinguishing repairable from non-repairable equipment, identifying the types of equipment failure, reviewing why equipment fails and employing actions to minimize failure effect
• Develop in-depth understanding on the maintenance affect on reliability and recognize how maintenance influences equipment performance
• Heighten awareness and understanding on root cause failure analysis (RCFA) including the various types and approaches used in rotating equipments
• List down and describe the step by step process of root cause failure analysis (RCFA)
• Know the principle of predictive maintenance and be able to employ the various predictive maintenance techniques and strategies used in rotating equipments
• Identify the various types and components of conditioning monitoring techniques and recognize their importance in rotating equipment reliability optimization and continuous improvement
• Understand the concept of optimizing reliability particularly conditioning monitoring and predictive maintenance and be able to identify its components and importance  

Training Methodology

The training methodology is interactive with group exercises and is suitable for all employees involved in functions management. The pace and level of the training workshop is customized to the understanding of the delegates. Ongoing back-up and support is available after the training on request to the supplier, and the training course is also available for in-house presentation as well as for “competency transfer

Who Should Attend?

Managers, Section Heads and Planners Maintenance, Reliability, Machinery and Plant Engineers Maintenance, Reliability, Machinery and Plant Superintendents/Supervisors Maintenance, Plant and PMV Foremen Operations Managers, Engineers and Supervisors

Course Outline

Day 1

Understanding Failures Machine Failure Analysis Wear And Tribology Fatigue Mechanisms Plain, Tilt-Pad And Anti-Friction Bearing And Seal Failures

Day 2

 Avoiding Failures Analysis And Identification Of Failures Fmea And Fmeca To Identify Failure Modes And Criticality Analysis Trouble Shooting Techniques Statistical Analysis Of Failures Reliability, Availability And Maintainability

 Day 3

Understanding planned maintenance. Planned Maintenance Concepts Introduction Maintenance Strategies Planned Maintenance – background and history Planned Maintenance Technologies – an overview CMMS – an overview Potential Failure Analysis Deciding which technologies to apply to avoid failures

Day 4

Using predictive maintenance vibration Analysis Introduction to Vibration Analysis Frequency Analysis and the Fast Fourier Transform Vibration Transducers Basic Failure Mechanisms with examples Vibration Standards and Alarm Levels Vibration Diagnostics Amplitude Demodulation – aka Enveloping, SSE, HFD, Peak-Vue Vibration on Rolling Element Bearings Resonance – identification & cure Other Predictive Maintenance Techniques Infrared Thermography Thermographic applications Passive Ultrasonics - contact and non-contact Ultrasonic Applications Tribology – oil analysis

Day 5

Control mechanisms. Managing Planned Maintenance Performance and Efficiency Monitoring Managing the Planned Maintenance effort Cost Analysis Reporting Techniques Integrating Predictive Maintenance into the Maintenance Plan