Logo

Machinery Failure Analysis and Troubleshooting

Introduction

Machinery Failure Analysis and Troubleshooting

Course Objectives

Upon completion of the Machinery Failure Analysis and Troubleshooting course, the participants will be able to:

• Strengthen and update understanding of the Terminology used in measuring and analysis
• Offer methods to improve equipment through the prediction and the avoidance of Equipment Failure
• Understanding and considering the critical necessities and priorities associated in maintaining machinery
• Key procedure for the implementation and application of risk-based failure analysis
• Become familiar with condition-based maintenance rather than corrective maintenance
• Implement and apply real improvements in machinery reliability and plant performance
• Work on case studies based on both technical and non-technical situations
• Know how to reduce the overall life cycle cost of owning a piece of equipment
• Maximize and increase component life by avoiding the cause of failure
• Manage critical equipment and functional failure

Who Should Attend?

This course is designed for:

• Design Engineers responsible for equipment reliability and performance
• Operation Engineers managing day-to-day machinery operations
• Supervisors overseeing maintenance and production activities
• Maintenance Engineers involved in equipment repair and upkeep
• Planning Engineers developing maintenance strategies and schedules
• Mechanical Engineers working in refineries, petrochemical plants and power stations
• Production Engineers focused on operational efficiency
• Senior Technicians involved in equipment troubleshooting and diagnostics

Course Outline

Module 1: Concept of Failure

• Pre – Test
• Introduction to Failure Analysis and Troubleshooting Systems
• Causes of Machinery Failure
• Machinery Design Properties
• Equipment Failure
• Types of Failure Causes
• Effect of Failure
• Failure Cascading
• Failure Modes
• Chronic vs. Sporadic Failures
• Failure Reporting
• Failure Reduction Programs

Module 2: Root Cause Failure Analysis Process

• What is RCFA?
• Why it is done?
• Types of Root Causes
• SEVEN Generic Steps in an RCFA
• Challenges in Setting up RCFA
• Sustaining an RCFA Process
• Application on RCFA (Exercises)

Module 3: Failure Analysis & Investigation Tools

• Brainstorming
• Flow Charts
• Histograms
• Fishbone Diagrams
• Pareto Charts
• Fault Tree Analysis
• Failure Mode and Effect Analysis (FMEA)
• Applications (Exercises)

 Module 4: Failure Mode and Effect Analysis (FMEA)

• Failure Analysis Methods
• Common Failure Analysis Techniques
• Implementing FMEA
• FMEA Procedure
• Application of FMEA (Exercises)

Module 5: Machinery Troubleshooting

• Condition Monitoring
• Machine Failure Modes
• Equipment Performance
• Methods of Detection
• Applications (Machine Failure)

Module 6: Structured Problem-Solving Techniques

• Win – Win Problem Solving
• Development of Problem-Solving Skills
• Alternative Solution Training
• Formulate Alternative Strategies
• Guidelines for Decision Making
• Priority ‐ Setting

Module 7: Machine Reliability

• Reliability, availability, maintainability
• Risk Assessment and Management
• Life Cycle Management
• Reliability & Maintainability
• Techniques & Analysis of Reliability
• Human and System Reliability
• Human Performance Approach
• Reliability Centered Maintenance
• Centrifugal Pump-Reliability Improvement
• Machinery Reliability Audits and Reviews

Module 8: Case Studies

• Failure causes in Journal and Tilting Pad Thrust Bearings
• Mechanical Seal Failure Modes
• Lubricant of Pumps and Motor Problems
• Causes of Shaft Failure
• Causes of Coupling Failure
• Causes of Gear Failure
• Post Test