Course Details

Objective

By the end of this course, participants will be able to:

• Understand the principles and benefits of condition monitoring and inspection techniques.
• Learn about various diagnostic tools and methods for equipment monitoring, such as vibration analysis, thermography, oil analysis, and ultrasound.
• Gain knowledge of how to assess and interpret condition monitoring data to identify potential issues.
• Develop skills to create a condition monitoring program for machinery and equipment.
• Understand the importance of preventive and predictive maintenance in improving asset reliability.
• Learn how to apply inspection techniques to ensure the safety and performance of industrial systems.
• Explore the integration of condition monitoring into broader maintenance management systems.

Content

COURSE PROGRAM:

Day 1: Introduction to Condition Monitoring and Inspection

• Overview of condition monitoring and its role in predictive maintenance.
• The difference between reactive, preventive, and predictive maintenance.
• Benefits of implementing condition monitoring techniques: Cost reduction, improved equipment reliability, and reduced downtime.
• Key principles of inspection and diagnostics in industrial settings.
• Overview of different types of industrial equipment that require condition monitoring.

Day 2: Vibration Analysis

• Introduction to vibration analysis as a key condition monitoring tool.
• Understanding vibration patterns: Frequency, amplitude, and phase analysis.
• Common faults detected using vibration analysis (imbalance, misalignment, bearing wear).
• Vibration sensors: Types and applications in machinery.
• Data interpretation: Using vibration data to diagnose equipment issues.

Day 3: Thermography and Ultrasound Inspection

• Thermography: The use of infrared cameras to detect heat patterns and temperature anomalies in electrical and mechanical systems.
  • Common applications: Electrical panels, motors, transformers, and mechanical equipment.
  • Interpreting thermal images: Identifying faults such as overheating, electrical faults, and wear.
• Ultrasonic Testing: Using high-frequency sound waves to detect surface and subsurface flaws in materials and structures.
  • Applications in machinery and piping: Identifying corrosion, leaks, and material degradation.
  • Principles of ultrasonic waves and their interaction with materials.

Day 4: Oil Analysis and Other Inspection Methods

• Oil Analysis: The role of lubricant analysis in condition monitoring.
  • Types of oil analysis: Wear debris analysis, viscosity, and contamination levels.
  • How oil analysis helps in detecting wear, contamination, and potential failures in engines, turbines, and gearboxes.
• Other inspection techniques:
  • Magnetic particle testing: Detecting surface and near-surface defects in ferromagnetic materials.
  • Dye penetrant testing: Identifying surface cracks in non-ferromagnetic materials.
  • Radiographic testing (RT): Using X-rays to inspect welds and structural components for internal defects.
• The integration of multiple inspection methods for comprehensive asset monitoring.

Day 5: Implementing Condition Monitoring Programs and Data Interpretation

• Developing a condition monitoring program: Key components and steps.
  • Selecting appropriate monitoring techniques based on equipment and operating conditions.
  • Setting up measurement schedules and thresholds for alerts.
• Data analysis and decision-making: Interpreting condition monitoring data and identifying trends.
• Using condition monitoring data for decision-making: When to repair, replace, or overhaul equipment.
• Integration of condition monitoring with Computerized Maintenance Management Systems (CMMS).
• Review of key techniques and strategies, and open Q&A session.

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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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 own questions and to share in the development of the right answers using your own analysis and experiences.  Tests of multiple-choice type will be made available on daily basis 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