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Module For Condition Based Maintenance

The proposed training modules cover topics related to condition monitoring and predictive maintenance. Module 1 discusses different maintenance philosophies and improving reliability. Module 2 focuses on specific reliability best practices like bearing installation, alignment, balancing, and lubrication. Module 3 provides an overview of various condition monitoring technologies like vibration analysis, oil analysis, infrared thermography, and ultrasound. It also discusses implementing a basic program. Module 4 presents case studies demonstrating the financial benefits of predictive maintenance and how each technology can detect and diagnose fault conditions.

Uploaded by

Sachidananda Swar
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
40 views

Module For Condition Based Maintenance

The proposed training modules cover topics related to condition monitoring and predictive maintenance. Module 1 discusses different maintenance philosophies and improving reliability. Module 2 focuses on specific reliability best practices like bearing installation, alignment, balancing, and lubrication. Module 3 provides an overview of various condition monitoring technologies like vibration analysis, oil analysis, infrared thermography, and ultrasound. It also discusses implementing a basic program. Module 4 presents case studies demonstrating the financial benefits of predictive maintenance and how each technology can detect and diagnose fault conditions.

Uploaded by

Sachidananda Swar
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Proposed Training Modules for Online course on Condition Monitoring

Module-1: Understanding maintenance philosophies


1. Breakdown or run-to-failure maintenance: When is it economically justifiable?
2. Scheduled or calendar-based maintenance: Is there a significant flaw in this method?
• Do machines fail when you expect them to fail?
• MTBF and MTBR
• The P-F curve
3. Predictive or condition-based maintenance
• The benefits
• Planned maintenance versus unplanned
• Is your plant ready for it?
4. Precision or reliability centred maintenance
• The philosophical difference
• The benefits
• Understanding OEE
5. Understanding risk
• Minimising risk
• Reliability, condition monitoring and insurance
6. Improving the bottom line: Cut maintenance costs or improve OEE?

Modue-2: Improving reliability


1. Taking care of the simple things
2. Bearing and seal installation
• A quick review of the importance of correct installation and operation of bearings and seals
3. Precision shaft and belt alignment
• The importance of precision alignment
• What is misalignment?
• How can you tell if a machine is not aligned
• An overview of shaft and belt alignment techniques
• Using dial indicators
• Using laser-based systems
• Correcting soft foot
• Dealing with thermal growth
4. Precision balancing
• The importance of balancing
• What is unbalance?
• How can you tell if a machine is not balanced
• An overview of the balancing process
• Single-plane balancing
• Two-plane balancing
• In-situ versus shop balancing
• Balance grades (ISO standards)
5. Resonance control
• What is resonance?
• How common is resonance?
• An overview to detecting resonance
• An overview to correcting resonance
6. Improving lubrication
• Understanding lubrication
• The importance of lubrication
• Contamination control
7. Acceptance testing, FMECA and Root cause failure analysis
• Create a good plan with FMECA, and close the loop with RCA
Modue-3: Condition monitoring overview
1. Overview of condition monitoring
2. Is condition monitoring still necessary if you improve reliability?
3. Vibration analysis
• A quick review of the fundamentals
• The time waveform, spectrum analysis, overall level measurements
• How to collect vibration readings
4. A quick introduction to diagnosing unbalance, misalignment, resonance, looseness, rolling
element and journal bearing faults
• Implementing a simple program to get started
• Using portable analysers, on-line monitoring systems, and protection systems
5. Oil analysis
• What information can be revealed?
• What do the different tests mean?
• Contamination, oil cleanliness, particle counting, elemental analysis, and more
6. Wear particle analysis
• Why is it needed?
• Relating particle size, shape, and color to machinery components
7. Infrared analysis or thermography
• Understanding thermography
• Spot temperature and the flawed measurement techniques
• Infrared image analysis
• Being aware of emissivity and environment conditions
• Understanding resolution and focal length
• Applying thermography to mechanical and electrical systems
8. Ultrasound or acoustic emission
• How does it work?
• Applying ultrasound to mechanical and electrical systems
9. Electric motor testing
• A quick introduction to how vibration analysis and motor current analysis can detect faults
in electric motors
• Rolling element bearing testing
• A quick introduction to how ultrasound testing, vibration analysis, and oil analysis can be
used to detect bearing faults
10. Performance monitoring
• Integrating performance monitoring into the condition monitoring program
• Incorporating plant inspections into the condition monitoring program
11. Condition monitoring technologies and ISO and ASNT standards
• Training and certification
• The importance of plant-wide training
12. An overview to running a successful program
• Selecting the appropriate technologies
• Why programs succeed
• Why programs fail
Module-4: Case studies that demonstrate
• the financial benefits of predictive maintenance and reliability,
• how each technology can be implemented in order to detect fault conditions and diagnose
the severity and nature of the fault condition.

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