#709 - Fault Diagnosis and Failure Prevention

Course Objective

Upon completion of this course, participants will gain an understanding of structured, results-oriented root cause failure analysis methods for machine components and machinery systems. Participants will also learn how parts fail, why they fail in a given mode, and how to prevent failures. Participants will gain a thorough understanding of making the best possible use of available failure statistics and how these can be used in machinery/machinery systems specifying, purchasing, installing, commissioning, and operating machinery. Participants will also grasp the following learning outcomes:

Who Should Attend

Maintenance and machinery engineers, supervisors, and technicians involved in machinery operation and troubleshooting. Personnel from all process industries (refining, petrochemical, chemical, mining, pharmaceutical, fertilizer, food, and utilities) will benefit.

This course is for all engineers, technologists, and other operational personnel who currently or may in the future be involved with the technology or business of running a process plant, a refinery, a power plant, and/or an oil and gas facility. Personnel can be involved in:

While this course is of major benefit to newer people in the field, it is also valuable as a revision and technology update for more experienced personnel.

Course Description

This course presents a systematic approach to fault diagnosis and failure prevention in machinery used in process, manufacturing, power generation, and mining industries. Preventive maintenance is taught through theory and examples in metallurgical failure analysis, vibration analysis, machinery troubleshooting, and problem solving.

Since equipment failure cases will be reviewed, participants are encouraged to bring to the course relevant assembly drawings or such components as failed bearings, gears, mechanical seals, and similar machine elements for failure analysis discussion.

Successful failure analysis and troubleshooting requires the determination of goals, use of checklists, and setting up a failure analysis team. The case studies show that a systematic program can lead to significant failure reductions in machinery. Through examples, vendor selection protocol and reliability review is demonstrated.

A matrix approach to machinery troubleshooting uses illustrative examples in pumps, centrifugal compressors, blowers and fans, reciprocating compressors, engines, and gas turbines. Next, a systematic approach to machinery problem-solving is followed with: situation analysis, cause analysis, action generation, decision-making, and planning change(s). Finally, a highly effective Root Cause Failure Analysis (RCFA) method is explained in detail.

Course Outline

Day 1

Day 2

Day 3

Day 4

Course Text

“Machinery Failure Analysis and Troubleshooting,” Gulf Publishing, by F.K. Geitner and H.P. Bloch (included in the course fee)

Course Duration - 4 days