#703 - Machinery Failure Analysis and Prevention

Course Objective

Upon completion of this course, participants will gain an understanding of structured, results-oriented, root cause failure analysis methods for all types of machine components and entire machinery systems. Participants will also learn how parts fail, why they fail in a given mode, and how to prevent failures. Participants will gain a thorough understanding of making the best possible use of available failure statistics and how these can be used in a conscientiously applied comprehensive program of specifying, purchasing, installing, commissioning and operating machinery.

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, chemical, mining, pharmaceutical, fertilizer, food processing, and utilities) will benefit.

Course Description

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, vibration 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 course relevant assembly drawings or such components as failed bearings, gears, mechanical seals, and similar machine elements for failure analysis discussion.

Course Outline

Day 1

Session 1: Failure Analysis and Troubleshooting

Causes of Machinery Failure
Contributing Factors Often Overlooked

Session 2: Metallurgical Failure Analysis Methodology

Failure Analysis of Bolted Joints
Shaft Failures and Their Origins
Ductile vs. Brittle Failures and Stress Raisers
Redesign Opportunities

Session 3: Machinery Component Analysis and Reliability Improvement

Wear Failures
Couplings, Bearings and Gear Failure Analysis

Session 4: Machinery Component Analysis and Reliability Improvement (Continued)

Mechanical Seals and O-Ring Failures – Selection Strategies

Day 2

Session 1: Machinery Component Analysis and Reliability Improvement (Continued)

Machinery Lubrication Management (Economics & Optimization)

Session 2: Vendor Selection and Reliability Review Methods

Why Reliability Reviews are Justified
Centrifugal Pump Selection Examples

Session 3: Vendor Selection and Reliability Review Methods (Continued)

Compressor Reliability Review Examples

Session 4: Machinery Troubleshooting

The Matrix Approach to Machinery Troubleshooting (For pumps, compressors, fans, turbines, and others)
Examples from Litigation Cases

Day 3

Session 1: Vibration Analysis - A Management Overview

Specific Machinery Problems
Monitoring and Analysis Methods
Future Outlook

Session 2: Structured Problem Solving Sequence

Situation Analysis
Cause Analysis
Action Generation
Decision Making

Session 3: Structured Problem Solving Sequence (Continued)

Root Cause Failure Analysis (RCFA) Principles I

Session 4: Structured Problem Solving Sequence (Continued)

Root Cause Failure Analysis (RCFA) Principles II

Course Texts

Practical Machinery Management for Process Plants, Volume 2, Machinery Failure Analysis and Troubleshooting; H.P. Bloch and F.K. Geitner