Equipment Failure Analysis and Prevention

Equipment Failure Analysis and Prevention

Course Overview:

This course presents a systematic approach to fault diagnosis and failure prevention in a broad range of machinery used in the process, manufacturing, power generation and mining industries. The key routes to preventive maintenance are demonstrated through both overview and the study of examples in metallurgical failure analysis and a sequential approach to machinery troubleshooting and problem solving.

Equipment failure events will be reviewed and participants are encouraged to bring to the seminar relevant assembly drawings or such components as failed bearings, gears, mechanical seals and other machine elements for failure analysis discussion.

The course explores a systematic approach to successful failure analysis and troubleshooting programs, including the determination of goals, use of checklists and evaluating failing populations of components. By reference to specific case studies, dealing with gas turbines and other machinery, it will be shown that such a systematic program can lead to significant failure reductions in many types of machinery.

A matrix approach to machinery troubleshooting uses illustrative examples in pumps, centrifugal compressors, blowers and fans, reciprocating compressors, engines and gas turbines. Next, a systematic approach to generalized machinery problem-solving is described in terms of situation analysis, cause analysis, action generation, decision making and planning for change. Finally, a highly effective root cause analysis method is explained in detail.

After a thorough definition of reliability terms, generating and using equipment availability indices will be investigated and discussed. It will be shown how various reliability indices allow reliability performance tracking but are of little use when it comes to the identification of reliability improvement strategies. Here is where statistical techniques based on Reliability Engineering (RE) principles for analyzing equipment failure data will help.  By using practical, real world examples it will be demonstrated that the application of these techniques will provide a basis for improved equipment management and reduced maintenance costs. Participants are encouraged to bring their failure statistics (motors, pumps, machinery components etc.) for manual (plotting) or computerized analysis.  Similarly, equipment replacement decisions based on RE principles will be examined together with practical operating and maintenance strategies leading to the improvement of plant reliability.

The course continues by exploring reliability assessment techniques such as Failure Mode and Effect Analysis (FMEA) and Fault Tree Analysis (FTA) of equipment presently installed in the participants' plants. It will be shown how the results of these analyses can provide input into maintenance strategies and operating procedures and thus increase overall equipment availability.

Who Should Attend?

This is a highly practical course for maintenance and machinery engineers, supervisors and technicians involved in machinery operation and troubleshooting. Personnel from all process industries (refining, petrochemical, power generation, chemical, mining, pharmaceutical, fertilizer, and food processing) will benefit.

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