These Plants consist of both static and rotating equipment, including piping. These pieces of equipment must not fail suddenly while in operation. Sudden breakdown failures not only cause huge production and the associated monetary losses but also find a company unprepared as to how to bring them back on stream, apart from safety, health, and environmental issues.Modern inspection and maintenance strategists believe in Predictive Maintenance which provides sufficient warning about the deteriorating conditions of equipment/machines in advance through Vibration Analysis and Condition Monitoring.While vibration analysis and condition monitoring are important for all machines/equipment to plan maintenance without surprises, online Vibration Analysis is critical for large rotating machines which don’t have standbys in the plant e.g., Turbo-compressors, Turbo-generators, etc.

By the end of this training course, participants should be able to:

• Understand the basic concepts of Predictive Maintenance, Vibration Analysis, and Condition Monitoring of Machines/Equipment
• Learn the fundamentals and advantages of Predictive Maintenance
• Learn the components and methodology of vibration monitoring, including hardware items such as probes and data processing instruments, and the associated software for analysis
• Comprehend various types of condition monitoring such as metal integrity checks, rotating machine bearing checks, condition trending using internal process parameters, and analysis of the composition of fluids at the outlet of processes, equipment, and machines (e.g., ferrography, temperature rise, pressure fluctuation, etc.)

• Appreciate the importance of, and planning around Predictive Maintenance,Vibration Analysis, and Condition Monitoring in oil, gas, and process plants, including their execution
• Grasp the Assessment of remainder life and preparation for repair/ replacement/ maintenance
• Understand some non-destructive testing techniques, aiding in condition monitoring and predictive maintenance
• An understanding of Machine Failure Analysis techniques
• An understanding of a range of Predictive Maintenance Technologies
• Knowledge of the potential contribution of each these technologies to maintenance efficiency
• Guidelines indicating how these technologies can interact with and support each other
• Hints and Tips for practical application of these technologies so as to achieve the best results

• Supervisors
• Team Leader
• Professionals in Maintenance, Engineering and Production
• Engineering, Fire & Safety, Maintenance, Operation, Inspection personnel at all levels, including trainees/interns
• Insurance, Regulatory, and lending agencies
• Middle level and Top management personnel with an introductory version of this course
• Those who provide contractual services on Predictive Maintenance, Vibration Analysis and Condition Monitoring of Machines

This Machinery Failure, Vibration & Predictive Maintenance training course will be conducted along workshop principles with formal lectures, case studies and interactive worked examples. Relevant case studies will be provided to illustrate the application of each tool in an operations environment. Each learning point will be re-enforced with practical exercises. There will be ample opportunities for discussion and sharing experiences.

Concepts 

• Machines/Equipment in the Plants
• Understanding Failures
• Machine Failure Analysis

• Wear and Tribology
• Fatigue Mechanisms
• Plain, Tilt-pad and Anti-friction Bearing and Seal Failures

Reliability Fundamentals and Methods for Avoiding Failures

• Fundamentals of Reliability of Machinery 
• Reliability Determination and Assessment Methods 
• Statistical Analysis of Machinery Failures
• Workshop and Case Study

CONDITION MONITORING

• What conditions can deteriorate machines/equipment?
• Variations in conditions in machines/equipment in the running plant
• Condition variations as an indication of the trend of deterioration
• Technologies to capture variations
• Baseline condition
• Online condition
• Risk-based condition
• Risk-based monitoring

Understanding Predictive Maintenance

• Predictive Maintenance Concepts

• Introduction
• Maintenance Strategies
• Predictive Maintenance – Background and History
• Predictive Maintenance Technologies
• Infrared Thermography
• Thermographic Applications
• Passive Ultrasonics -Contact and Non-contact
• Ultrasonic Applications
• Tribology –Oil Analysis

Control Mechanisms

• Managing Predictive Maintenance
• Performance and Efficiency Monitoring
• Managing the Predictive Maintenance effort
• Cost Analysis
• Reporting Techniques
• Integrating Predictive Maintenance into the Maintenance Plan

Vibration 

• Vibration Analysis

• Introduction to Vibration Analysis
• Frequency Analysis and the Fast Fourier Transform
• Vibration Transducers
• Basic Failure Mechanisms with Examples

• Cause of Vibration/Basic Physics behind it
• The vibration of rotating and static equipment: Relative comparison
• Detecting vibration: Probes – Displacement, Velocity, and Acceleration
• Threshold limits of vibration/Acceptance criteria
• Portable and fixed tools and sophisticated instrumentation
• Data collection, Analysis, and Monitoring
• Consequences of Ignoring vibration
• Case studies on Vibration
• Lack of timely maintenance may give rise to vibration
• Balancing the rotating parts in machines
• Industry advancements
• Vendors providing instruments and tools
• Service providers on data collection and problem diagnostics with troubleshooting

Global industry trends

• Culture of machine monitoring vis-a-vis human health monitoring by medical doctors
• The analogy between industry and medical condition monitoring
• Predictive maintenance is a lifeline and currently globally accepted strategy
• Condition monitoring and diagnostics as a respected profession

Case Studies

• Study of incidents as a result of ignorance of predictive maintenance, vibration analysis, and condition monitoring
• Analysis of problem areas, root cause analysis, and corrective actions
• Presentation of solutions by the participants

A RECTUS attendance certificate will be awarded to all participants who complete at least 80% of the total course duration.