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Predictive Maintenance, Vibration Analysis and Condition Monitoring of Machines

Introduction

Predictive Maintenance, Vibration Analysis and Condition Monitoring of Machines

Course Objectives

• Understand the basic concepts of predictive maintenance, vibration analysis, and condition monitoring of machines and 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, or maintenance
• Understand non-destructive testing techniques aiding in condition monitoring and predictive maintenance

Who Should Attend?

• Engineering, fire & safety, maintenance, operation, and inspection personnel at all levels, including trainees and interns
• Insurance, regulatory, and lending agencies
• Middle-level and top management personnel seeking an introduction to predictive maintenance
• Contractors and service providers in predictive maintenance, vibration analysis, and condition monitoring

Course Outline

MODULE 1: CONCEPTS

• Machines/Equipment in the Plants
• Predictive Maintenance
• Vibration Analysis
• Condition Monitoring

MODULE 2: PREDICTIVE VS BREAKDOWN MAINTENANCE

• Cost advantages and business implications
• Global Industry trends
• Safety, health, and environmental advantages
• Risk-based practices

MODULE 3: VIBRATION (SESSION-1)

• 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

MODULE 4: VIBRATION (SESSION-2)

• 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

MODULE 5: CONDITION MONITORING (SESSION-1)

• 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

MODULE 6: CONDITION MONITORING (SESSION-2)

• Baseline condition
• Online condition
• Risk-based condition
• Risk-based monitoring

MODULE 7: 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

MODULE 8: VENDORS SEGMENTS

• Types and ranges of data gathering, and diagnostics instruments available
• Local vs international vendors with brand quality of equipment and service
• Calibration/validation of vibration and condition monitoring instruments
• Inspection, maintenance, proper handling, and appropriate storage of these instruments

MODULE 9: HOW TO SELECT SERVICE PROVIDERS?

• What information to share with them?
• Datalogging helps the experts to study the trend, diagnose and provide a solution
• Remote/virtual diagnosis of a complex problem by experts
• Reputed global service providers

MODULE 10: CASE STUDIES AND ATTENDEES’ PARTICIPATION

• 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