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  Rotating Machinery Health Management and Rotating Equipment Maintenance and Reliability Training Course Content 4-Day Rotating Machinery Excellence Introductory and Advanced Course Content Get the latest version at www.lifetime-reliability.com   –   the maintenance and reliability growth experts    Rotating_Machinery_Management_Course_Content .docx 22 April 2009 Page 1 of 7 Course Content Day 1 - Machinery Health and Reliability Excellence - Introduction COURSE OVERVIEW First day  –  Cause of Rotating Machinery failures Second day  –  Standards, condition monitoring and top-class maintenance Third day  –  Shafts, bearings and seals for reliability excellence, Maintenance for reliability Fourth day  –  Improving machinery reliability, reducing maintenance cost, sustaining RE integrity What is ‘Rotating Machinery Excellence’?   PLANT AND MACHINERY DOWNTIME COSTS The True Cost of Failure Where Profit is Lost in Business Processes The Purpose of Business Maintenance is an Economic Decision Impact of Defects and Failures Defect and Failure True (DAFT) Costs go Company-wide Failure Costs Surge thru the Company Separate the True Downtime Costs so you can see them for what they are Calculating the True Downtime Costs MACHINERY RISK MANAGEMENT Understanding Risk and Its Consequences Risk Calculations The Shape of Risk Risk Relationships What Risk Means Determine Your Acceptable Failure Domain Maintenance is Used to Manage Risk Benefits of Reducing Operating Risk VARIATION, DEFECTS AND FAILURES Defects and Failures Enter Your Business Everyday Normal Ways to Control Defects and Failures Preventing Defects and Failures The Trouble with Accepting a Defect Defects Lead to Failures and High Costs  Act to Control the Defects and Risks Problems, Defects and Failures start with Variation Effects of Process Condition Disruptions Special and Common Cause Variation Preventing Process Condition Disruptions MACHINERY DESIGN ISSUES The Unforgiving Nature of Machine Design  Activity 1 - Design Shaft Rotor and Material Selection The Slow Destroyers Good Process Control Prevents Rapid Internal Equipment Changes Supporting Structure and Foundation Strength and Rigidity Vibration Basics  Rotating Machinery Health Management and Rotating Equipment Maintenance and Reliability Training Course Content 4-Day Rotating Machinery Excellence Introductory and Advanced Course Content Get the latest version at www.lifetime-reliability.com   –   the maintenance and reliability growth experts    Rotating_Machinery_Management_Course_Content .docx 22 April 2009 Page 2 of 7 Course Content Continued Forced Vibration Natural Frequency  Attenuation of Vibration Dissipating Loads and Forces Preventing Equipment Deformation Preventing Deformation from Pipe Stress  Activity 2 - Soft Foot Case Study Soft Foot Case Study Soft Foot Distorts Motor Armature Air Gap ROTATING MACHINERY PARTS FAILURE Causes of Shaft Failures Causes of Roller Bearing Failures Calculating L10 Lifetime Effects of Fluctuating Loads and Forces Lubrication Contamination Lubrication Contamination Control Tell-tale Bearing Failure Signs Causes of Contact Shaft Seal Failures ROTATING MACHINERY RELIABILITY The Payoff is Reliability, Availability, Maintainability, Safety (RAMS) Equipment Degradation Cycle Equipment Life Extension Valuable Precision Maintenance Rotating Equipment Precision Maintenance Precision Maintenance of Rotating Equipment is …   Accuracy Controlled Enterprise (ACE) Procedures  Activity 3 - Develop an ACE procedure Day 2 - Machinery Health and Reliability Excellence - Introduction MECHANICAL EQUIPMENT AND MACHINERY STANDARDS 6 Mechanical Equipment Care Standards to Set, Use and Keep Using Balanced Rotors and Balancing Standards Rotating Equipment Balancing Shaft Coupling Problems  Appropriate Key Length for Assembly Coupling Bolts and Washers Specification for Coupling Assembly Burred Shaft Either on end or next to bearing face  Activity 1 Balancing Case Study Effects of Shaft Misalignment Causes of Shaft Misalignment Coupling Flexing Points Locations  Accuracy and Limits for Alignment Precision Alignment Practice . Pre-Alignment Checks . Rough-In Alignment . Precision Alignment  Rotating Machinery Health Management and Rotating Equipment Maintenance and Reliability Training Course Content 4-Day Rotating Machinery Excellence Introductory and Advanced Course Content Get the latest version at www.lifetime-reliability.com   –   the maintenance and reliability growth experts    Rotating_Machinery_Management_Course_Content .docx 22 April 2009 Page 3 of 7 Course Content Continued . Alignment Records Off-line to Running (OL2R) Machine Movement Case Study 2  –  Important Factors when Doing Shaft Alignments CONDITION MONITORING METHODS FOR ROTATING MACHINERY Range and Choice of Condition Monitoring Methods Condition Monitoring Degradation Selecting Condition Monitoring using the Three Point Inspection Frequency Machine Shape Deflection VIBRATION ANALYSIS Rotating Machinery Vibration Causes of Vibration Bearing Vibration Causes ISO Standards for Vibration Evaluation  Allowable Vibration Severity Vibratory Condition Based Monitoring Rotating Shaft Vibration Measurement The Value of a Baseline Vibration Signature Rotating Bearing Vibration Displays TRIBIOLOGY AND LUBRICATION ANALYSIS Wear Particle Analysis  Analysing Properties of Lubricants Sustaining Lubricant Health Lubricant Management Programs THERMOGRAPHY ROTATING EQUIPMENT NON-DESTRUCTIVE TESTING Radiography (X-Ray, Gamma Ray) Magnetic Particle Inspections Dye Penetrant Procedures Ultrasonic Scanning (thickness, cracks, inclusions, etc) Visual Inspections (human eyes, borescope, etc) Performance Monitoring (human senses, temperature, pressure, pH, etc) RELIABILITY AND MAINTENANCE STRATEGY MIX The Six Purposes of Maintenance Equipment Availability as a Function of Maintenance Costs  Asset Management & Business Performance Reliability and Maintenance Best Practice Assessment Plant and Equipment Life Cycle When Operating Costs are Committed Component & System Reliability Modelling Reliability of Parts and Components Reliability of Systems of Parts and Components (i.e. Machines) Equipment Reliability Strategies Failure Mode and Effects Analysis (FMEA) Equipment Criticality  Rotating Machinery Health Management and Rotating Equipment Maintenance and Reliability Training Course Content 4-Day Rotating Machinery Excellence Introductory and Advanced Course Content Get the latest version at www.lifetime-reliability.com   –   the maintenance and reliability growth experts    Rotating_Machinery_Management_Course_Content .docx 22 April 2009 Page 4 of 7 Course Content Continued Rotating Equipment Maintenance Strategy PM - PdM - Replace - Breakdown Mix Operator Driven Reliability  A Strategy for Equipment Reliability Maintenance KPIs and Outcomes Maintenance Quality Improvement Use Visual Management for Feed Forward Control of Performance  Activity 4  –  RE Life-Cycle Reliability Strategy Day 3 - Machinery Health and Reliability Excellence - Advanced LUBRICATION SELECTION Physics of Lubrication Properties Of Lubricants and Additives Purpose Of Grease Additives Use Grease or Oil? Dry Lubricant Lubricant Operating Environment for Oils and Greases Wear Debris Analysis Lubricant Life-extension with Lubrication Management PROCESS CONTAINMENT SEALS Methods, Types, Designs, Process Effects Process Containment Seal Design Overview Sliding Lip Seals Seal Failure Modes Long-life Seal Conditions Seal Selection Issues TRANSMITTED VIBRATION PREVENTION AND ISOLATION Basics of spring/damper systems Forced Frequency and Natural Frequency Passive Machinery Vibration Isolation  Activity 1  –  Vibration Isolation Calculation STRENGTH OF MATERIALS FOR SHAFTS AND ROTORS Metallurgy - Stress and Stress Raisers Stress Concentration Effect Metal Fatigue Metal Fatigue Control Bending and Deflection of Shafts Horizontal and Vertical Shaft Design Combined Axial, Radial and Torsional Loads Controlling Axial, Radial, Torsional Loads Shaft & Equipment Assembly Considerations Shaft Manufacture, Diameter and Tolerance  Activity 2  –  Life Considerations for a Shaft and Bearing Assembly BEARING DESIGN AND SELECTION - RADIAL AND AXIAL Roller Bearing Loads  –  Max and Min
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