Machinery Failure Analysis and Repair Methods

Introduction

This course presents a systematic approach to fault analysis and failure inhibition in numerous machinery used in the petrochemical and other process industries. The key methods of preventive maintenance are demonstrated through the study of examples in metallurgical failure analysis, vibration analysis and a progressive approach to machinery troubleshooting and problem-solving.

The course goes through a systematic methodology to effective failure analysis and troubleshooting, including goal achievement, checklists use and constituting a failure analysis team. Referring to specific case studies, for example centrifugal pumps, it will be shown that such a systematic schedule of actions can lead to significant failure decreases in many types of machinery. Through pumps and compressors examples, the vendor selection procedure is highlighted as well as methods for reliability review.

Objectives

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

• Employ systematic techniques on machinery failure analysis, vibration, and predictive maintenance.
• Identify machinery failure patterns covering the nature of failure, the types of equipment failures and their categorizations
• Apply machinery diagnostic testing, metallurgical failure analysis methodology, and machinery component analysis and reliability improvement.
• Carryout machinery troubleshooting and root cause failure analysis (RCFA).
• Analyze the vibration signals for different faults and machinery.
• Differentiate between the factors of human reliability through the classification of human error and human reliability analysis, familiarize the different reliability tools using life cycle cost analysis and life data analysis and discuss the key elements of reliability engineering and how to manage assets in projects.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations.

Who Should Attend?

This course covers systematic techniques in maintenance and reliability management to assist maintenance management team in delivering maximum reliability and availability of equipment at the lowest possible cost. The course will present techniques designed to improve the effectiveness of maintenance management activities, to ensure that physical assets perform their required functions, operate reliably, and support corporate goals. It is essential for all maintenance and reliability management staff.

Course Outline

Machinery Failure Patterns

• Understand the Nature of Failures – Types of Equipment Failures
• Failure Classifications & Failure Patterns – Why Equipment Fails
• Failure analysis & Root Cause – Reasons for Equipment Failure

Machinery Diagnostics

• Diagnostic Objectives – Mechanical Inspection – Test Plan Development
• Data Acquisition and Processing – Data Interpretation
• Conclusions and Recommendations – Corrective Action Plan

Atomic Absorption Spectroscopy

• Principle of operation
• Spectrophotometer Architecture
• Sources, Filters and Detectors
• Flame AAS
• Nebulizer/Burner systems
• Graphite Furnace AAS

Metallurgical Failure Analysis Methodology

• Failure Analysis of Bolted Joints – Shaft Failures and their Origins
• Ductile vs. Brittle Failures of Shafts – Stress Raisers in Shafts

Machinery Component Analysis and Reliability Enhancement

• Redesign Opportunities – Analyzing Wear Failures
• Bearings in Distress – Rolling Element Bearing (AFB) & Bearing Failure Analysis
• Journal and Tilt-Thrust Bearings – Gear Failure Analysis
• Coupling Failure Avoidance
• Determining the Cause of Mechanical Seal Distress
• Mechanical Seal Selection Strategies
• O-Ring Failures and their Causes

Machinery Troubleshooting

• Machinery Troubleshooting through matrices
• Pumps – Centrifugal Compressors – Blowers and Fans
• Reciprocating Compressors – Engines – Gas Turbines and Others

Machinery Root Cause Failure Analysis (RCFA)

• Structured Problem Solving and RCFA – Cause Analysis
• Two-Track Approach – Failure Types – The Three Levels of Cause
• Collecting Failure Data – Parts and Position – The Analysis Process
• Describing the Process – Data Analysis I – Data Analysis II – Data Analysis III
• Human Root Causes – Solutions – Stewardship of RCFA Results

Vibration Analysis – A Management Outline

• Specific Machinery Problems
• Monitoring and Analysis Methods
• Future Outlook

Machinery Vibrations

• Equipment and Processes Typically Monitored by Vibration Analysis –
• Typical Vibration Problems and their Approximate Percentage of Occurrence
• Rotary Mechanical Vibrations – Other Mechanical Vibrations –
• Non-Mechanical Vibration Problems – Spring-Mass-Damper Model of Vibration
• Simplest Form of Vibrating System – Real-world System
• Peak vs RMS vs Peak to Peak-to-Peak.
• Frequency – Phase Measurement – Phase Relationship
• Measurement Relationships – Vibration Measurement
• Vibration Data Type and Formats – Frequency Domain vs Time Domain
• Low, Medium and High-Frequency Ranges – Excitation Frequencies
• Natural Frequencies and Mode Shapes

Vibration Signal Analysis for Different Failures

• Gear Boxes – Electric Motors – Flow-related Problems Pumps, Fans and Compressors
• Vibration Frequencies Related to Machinery Faults

Formal Failure Reporting for training

• Actual Cases Cited and Explained in Detail
• High-Speed Pump Failure & Bearing Failures

Examination of Failed Components

• Bearings – Gears
• Mechanical Seals & Others

Process/Mechanical/Technical Interaction

• How PMT Teams Work – Turnaround Management
• Preventive vs. Predictive Maintenance Concepts
• Integrated vs. Separate Maintenance
• Centrifugal Pump Failure Reduction Programs

Machine Condition Estimation

• Vibration Severity Limits – Shaft Vibration – Bearing Vibration
• Casing Vibration – Standards – ISO 2372 Chart – ISO 10816 Chart
• The IRD General Machinery Vibration Severity Chart

Predictive Maintenance & CBM

• Types of Condition Based Monitoring – Vibration Monitoring
• Pump Monitoring Frequency – Infrared Thermography
• Physical Effects Monitoring
• Lube Oil Analysis – Modern Monitoring
• Effective Monitoring
• Following Monitoring schedules

Continuous Reliability Improvement

• Optimized Lubrication for Pumps and Electric Motors
• Economics of Dry Sump Oil Mist Lubrication
• Lubrication Considerations for Pump and Electric Motors
• Major Machinery Lubrication Management.