Condition Based Maintenance Course

Improving Reliability through Condition Monitoring

The Condition Based Maintenance Course is a combination of reliability improvement (through precision maintenance practices), condition monitoring, and root cause failure analysis and provides the best all-round approach to reducing maintenance costs and improving availability.

Delivered in a two days (or three if appropriate) course, it is possible to give attendees a more thorough understanding of these important topics.  This course is ideal for Reliability Engineers and Condition Monitoring program leaders.

Duration

2 days (3 if appropriate)

Course Description

The Condition Based Maintenance Course is ideal for any person who is considering starting a condition monitoring program or who wishes to improve reliability at the plant.  The first step in implementing such a program is to understand the goals and benefits.  The second step is to understand the practical steps that can be implemented to improve reliability.  And the third step is to understand the condition monitoring technologies, and how they can provide early warnings about possible machine failure. (The fourth step is to have a plan to implement a successful program.  This is summarised in this course, but it is available as a two day course: “Establishing and Operating and Successful Condition Monitoring Program”.)  Thanks to the Mobius Institute animations and simulators, you will be surprised at how much you learn and understand about the condition monitoring technologies.

Who should attend?

Reliability engineers; condition monitoring team leaders; plant managers, maintenance managers and others in the maintenance and production departments who wish to understand why reliability should be improved, and how to improve it.  If you already have a reliability or condition monitoring program, this course will help to better understand what it is all about.  If you manage such a program, this course will help you to inject new life and ideas into that program.

What is unique about this course?

RMS makes it unique.  We spent a lot of time, effort and money to generate modern slides, illustrations, 3D animations, and software simulators to make these topics very easy to understand, and to captivate you during the course.  There is nothing surer; if you are bored or confused you won’t learn a thing and you will have wasted your precious time.  Our presentations and instructors are lively and animated, and you will understand, and remember, the topics we teach.  You will go back to your plant feeling energized and prepared to take on all the challenges.

Topics

Understanding maintenance philosophies

• Breakdown or run-to-failure maintenance
  • When is it economically justifiable?
• Scheduled or calendar-based maintenance
  • Is there a significant flaw in this method?
  • Do machines fail when you expect them to fail?
  • MTBF and MTBR
  • The P-F curve
• Predictive or condition-based maintenance
  • The benefits
  • Planned maintenance versus unplanned
  • Is your plant ready for it?
• Precision or reliability centred maintenance
  • The philosophical difference
  • The benefits
  • Is your plant ready for it?
  • Understanding OEE
• Understanding risk
  • Minimising risk
  • Reliability, condition monitoring and insurance
• Improving the bottom line
• Cut maintenance costs or improve OEE?

Improving reliability

• Taking care of the simple things
• Bearing and seal installation
  • A quick review of the importance of correct installation and operation of bearings and seals
• Precision shaft and belt alignment
  • The importance of precision alignment
  • What is misalignment?
  • How can you tell if a machine is not aligned
  • An overview of shaft and belt alignment techniques
    • Using dial indicators
    • Using laser-based systems
    • Correcting soft foot
    • Dealing with thermal growth
• Precision balancing
  • The importance of balancing
  • What is unbalance?
  • How can you tell if a machine is not balanced
  • An overview of the balancing process
    • Single-plane balancing
    • Two-plane balancing
    • In-situ versus shop balancing
    • Balance grades (ISO standards)
• Resonance control
  • What is resonance?
  • How common is resonance?
  • An overview to detecting resonance
  • An overview to correcting resonance

• Improving lubrication
  • Understanding lubrication
  • The importance of lubrication
  • Contamination control
• Acceptance testing, FMECA and Root cause failure analysis
  • Create a good plan with FMECA, and close the loop with RCA

Condition monitoring overview

• Overview of condition monitoring
• Is condition monitoring still necessary if you improve reliability?
• Vibration analysis
  • A quick review of the fundamentals
    • The time waveform, spectrum analysis, overall level measurements
    • How to collect vibration readings
• A quick introduction to diagnosing unbalance, misalignment, resonance, looseness, rolling element and journal bearing faults
  • Implementing a simple program to get started
  • Using portable analysers, on-line monitoring systems, and protection systems
• Oil analysis
  • What information can be revealed?
  • What do the different tests mean?
  • Contamination, oil cleanliness, particle counting, elemental analysis, and more
• Wear particle analysis
  • Why is it needed?
  • Relating particle size, shape, and color to machinery components
• Infrared analysis or thermography
  • Understanding thermography
    • Spot temperature and the flawed measurement techniques
    • Infrared image analysis
    • Being aware of emissivity and environment conditions
    • Understanding resolution and focal length
  • Applying thermography to mechanical and electrical systems
• Ultrasound or acoustic emission
  • How does it work?
  • Applying ultrasound to mechanical and electrical systems
• Electric motor testing
  • A quick introduction to how vibration analysis and motor current analysis can detect faults in electric motors
  • Rolling element bearing testing
  • A quick introduction to how ultrasound testing, vibration analysis, and oil analysis can be used to detect bearing faults
• Performance monitoring
  • Integrating performance monitoring into the condition monitoring program
  • Incorporating plant inspections into the condition monitoring program
• Condition monitoring technologies and ISO and ASNT standards
  • Training and certification
  • The importance of plant-wide training
• An overview to running a successful program
  • Selecting the appropriate technologies
  • Why programs succeed
  • Why programs fail

Case studies will be presented throughout the course that demonstrate the financial benefits of predictive maintenance and reliability, and they demonstrate how each technology can be implemented in order to detect fault conditions and diagnose the severity and nature of the fault condition.

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