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ADVANCED MACHINERY FAILURE ANALYSIS, PREDICTIVE MAINTENANCE & PROBLEM SOLVING

Location
Kuala Lumpur, Malaysia
Date
From Date: 04-Aug-2025   
To Date: 08-Aug-2025
Duration
5 days
Language
ENGLISH
Discipline
MAINTENANCE & RELIABILITY ENGINEERING
Introduction

The course presents an understanding of equipment failure characteristics. To achieve an optimal maintenance program that meets specified safety, environmental, and economic goals. Participants will learn to preserve equipment functions by identifying appropriate predictive maintenance (Pd.M.) tasks, failure-finding tasks, and other actions that protect against failure or mitigate the consequences of failure

 

This course presents a systematic approach to fault diagnosis and failure prevention in a broad range of machinery used in many industries. The key routes to preventive maintenance are demonstrated through both overview and the study of examples in different failure analyses and a sequential approach to machinery troubleshooting and problem-solving

 

Failure analysis, Troubleshooting, and Predictive & Planned Maintenance techniques, including vibration analysis, oil analysis, and other techniques are discussed in the course to optimize the maintenance engineering effort while maximizing production

 

This course provides the fundamentals of Pd.M. and condition monitoring applicable to plants, facilities, and manufacturing lines. Predictive Maintenance & Condition Monitoring will provide Participants with a framework to make the right decisions on what equipment needs condition monitoring, what technologies to use to meet their needs, and how to measure the effectiveness of their decisions

Objective

Participants will learn how to collect, analyze and interpret failure statistics and will also gain an understanding of FMECA.
Participants will be instructed in condition monitoring methods and will be taught how vibration analysis can be used to detect, locate, severity assess and diagnose a range of common faults in machines

 

Upon the successful completion of this course, the participant shall be able to:

 

  • understand the principles of failure analysis in process plant
  • An understanding of Machine Failure Analysis and Troubleshooting techniques
  • learn about machinery troubleshooting in pumps, centrifugal compressors, gas turbines, and  electric motors
  • Describe the Benefits of a PdM & Condition Monitoring Program
  • Identify What Equipment to Monitor
  • Predict What Maintenance Needs to be Done and When
  • An understanding of a range of Planned & Predictive Maintenance Technologies
  • Knowledge of the potential contribution of each of these technologies to maintenance efficiency
  • Guidelines indicating how these technologies can interact with and support each other
Audience

This seminar is directed toward Supervisors, Team Leaders, and Managers in Maintenance, Engineering, and Production.  The seminar will also benefit anyone who wishes to update themselves on Predictive Maintenance Technologies and Failure Analysis techniques, as well as those who have to judge the suitability of these technologies for their needs and learn how to implement them for the benefit of their organizations

Content

DAY 1

 

Failure Analysis techniques

Equipment failure

Six patterns of the component failure rate over the life

Controlling introduced failure

Failure rate bathtub curve

Where to start: equipment criticality or risk

 

Failure analysis tools

Failure Mode & Effects Analysis

Reliability Centered Maintenance

Computer Maintenance Management Systems

Failure analysis - closing the loop

Root cause failure analysis (RCFA)

Building a system for equipment condition indicating

  1. Equipment data
  2. Failure data
  3. Maintenance data
  4. Data format

 

DAY 2

 

Failure and maintenance notations

Failure descriptors

Failure causes

Method of detection

Maintenance activity

Data requirements for various applications

Electrical motor

Gas turbines

Pumps

Compressors

 

DAY 3

 

The Basic Concept of Predictive Maintenance

The Top 6 Benefits of Predictive Maintenance

Establishing a Predictive Maintenance Program

Goals, objectives, and benefits

Functional requirements

Selling predictive maintenance programs

Selecting a predictive maintenance

System

Database development

Getting started

The optimum predictive maintenance Program

How to Choose the Right Pd.M. Technologies

Four Reasons Why Pd.M. Doesn’t Work

Are You Collecting The Right Data?

World-Class Maintenance

 

DAY 4

 

Predictive Maintenance – Pd.M.

Scheduled predictive

Predictive Technologies

Condition Monitoring Technologies

Vibration Analysis

General Analysis Method

IR Thermography

Ultrasonic Leak Detection

Oil and Wear Particle Analysis

Oil Analysis

Motor Circuit

Surface Flaw Detection

Liquid Penetration

Magnetic Particle

Sub-Surface Flaw Detection

Ultrasonic Thickness (Auto/Manual)

Eddy Current

Radiography

Endoscope (Borescope) inspection

 

 

DAY 5

 

Vibration analysis

Introduction

Data acquisition

Data interpretation

Vibration due to plane (journal) bearings

Vibration due to resonance

Turbomachinery problems

Vibration problems with specific machinery types

Gearbox vibration

 

Condition Monitoring

Condition Monitoring

The machine life cycle

Standards Organizations

List of BS/ ISO condition monitoring standard

BS ISO 17359

Computer application in machine condition monitoring

 

Note:

Pre & Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day Reviews & Assessments will be carried out.

 

 

……………………………………………………………….

 

Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences.  Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

  • 30% Lectures
  • 30% Workshops and work presentation
  • 20% Group Work& Practical Exercises
  • 20% Videos& General Discussions
Fees
• $6,000 per participant for Public Training including Course Materials/Handouts, Tea/Coffee, Refreshments & Lunch

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