Maintenance Management training

Course content: Theory and exercises

Troubleshooting vs failure analysis – failure patterns – influence of age, degradation, wear on components/equipment – RCFA techniques: cause & effects diagram, fault tree analysis & sequence of events analysis – choosing appropriate RCFA techniques – RCFA methodology: data collection, design review, procedure review, interviewing people, brainstorming, arriving at the root cause – eliminating the root cause – implementing & monitoring the failure prevention strategy

Course outcome

At the end of the Program, the participants will be able to:

• Define failure, failure modes
• Differentiate between troubleshooting and failure analysis
• Define Root Cause Failure Analysis
• List and use RCFA techniques such as Fault Tree Analysis, Cause & Effect Analysis and Sequence of Events Analysis
• Select the equipment for performing RCFA
• Gather and analyse the failure data and document
• Analyse the root causes of common failures in typical equipment of process plants
• Analyse the given problem and identify the root cause

Special requirements

Drawings, Details & Failure data of client’s equipment which fails frequently

Course content: Theory and exercises

Why RCM – Failure patterns – SAE RCM Standard – The seven steps of RCM Process – Functional criticality analysis – FMEA methodology – Hidden & Evident failures – Maintenance task selection – PF interval – Frequency for random failures

Course outcome

At the end of the Program, the participants will be able to:

• Calculate Criticality Score, Priority Score and Criticality Index for plant equipment
• Rank equipment according to criticality as most-critical, critical and less-critical
• Select critical equipment for RCM based on criticality index
• Identify the functions and functional failures of an equipment
• List dominant failure modes and their effects
• Classify functional failure consequences into one of the following categories

  • Hidden or evident
  • Safety or environmental
  • Operational or non-operational
• Define proactive task, reactive task, on-condition task, scheduled restoration task and failure-finding task
• Perform analysis using RCM-Decision Logic and chose the maintenance tasks
• Determine the appropriate maintenance required at the right intervals.

Special requirements

Drawings, Details & Failure data of client’s equipment which fails frequently

Course content: Theory and exercises

Vibration analysis terms - instrument selection – probe location – vibration parameters – measurement – analysis of measured data – interpretation of readings – diagnosis

Course outcome

At the end of the Program, the participants will be able to:

• Define vibration analysis terms – displacement, velocity, acceleration, frequency, spectrum and phase
• Select appropriate vibration analyser for a particular task
• Identify and locate the vibration pickup precisely with respect to position and orientation for achieving best results
• Measure and record data using the vibration analyzer
• Analyse the vibration data to pinpoint problems relating to

  • Unbalance, Misalignment, Mechanical looseness
  • Differentiate between bearing defects like Axial play, Adaptor sleeve looseness, Axial thrust, Increased clearance, Ovality in bearing housing, Fit between bearing and shaft, Bearing skewness (improper seating of bearing in housing)
  • Gear meshing, Belt inaccuracies
• Differentiate between bent shaft and misalignment
• Identify resonance problems
• Electrical defects such as air gap variation, electrical unbalance, magnetic centre deviation
• Identify allowable limits of vibration
• Classify the machinery on the basis of vibration readings
• Define the procedure for in-situ balancing
• Achieve Clarity on applying ISO 10816 Standards for rotating and non-rotating parts

Special requirements

Access to rotating machinery in your site for hands-on practice. The vibration analyzer will be brought by HIMER.

Course content:

Asset management for total productivity – functional and equipment criticality analysis – maintenance methodology for different equipment – reliability, availability & maintainability – maintenance organization – maintenance planning & scheduling – work control – computerized maintenance management systems – key performance indicators & benchmarking

Course outcome

At the end of the Program, the participants will be able to:

• Identify critical equipment based on maintenance and production factors
• Choose appropriate maintenance methodology
• Calculate true MTBF, MTTR & reliability
• List planning steps
• List scheduling parameters
• Adopt maintenance work control
• Implement / fine tune CMMS to meet organisational goals
• Select key performance indicators for measurement and improvement

Special requirements

None