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Rotating Machinery: Troubleshooting Analysis

5 days MTM/RMTS
Level
Proficiency
Audience
  • Maintenance supervisors, engineers and all technical staff involved in rotating machinery maintenance, reliability and technical inspection.
Purpose
  • This course aims to enhance the maintenance staff skills through a clear understanding of online monitoring & failure analysis.
Learning Objectives
  • Upon completion of the course, participants will be able to:
  • facilitate troubleshooting investigation from failure analysis and monitoring,
  • prevent mechanical failure and reduce operating costs,
  • explain operating constraints,
  • propose improvements on machinery reliability.
Prerequisite
  • No prerequisites for this course.
Ways and means
  • Case studies based on industrial & actual feedback.
  • Teamwork: mini projects dedicated to industrial cases.

TROUBLESHOOTING ANALYSIS 2.5 days
  • Drop of the machine performance analysis: loss of flowrate, loss of process fluid pressure, increase of process fluid temperature.
  • Monitoring results analysis: high vibrations levels, lubrication and seal circuit parameters, abnormal values, oil quality.
  • Component failures: seal leakages, bearing damages, rotor sags, impeller cracks, misalignment.
  • Hydraulic phenomena: cavitation, unpriming, volute effect, surge.
  • Reliability improvements to increase time between failures.
  • Applications & exercises: troubleshooting analysis of pumps, compressors and turbines.
MACHINE MONITORING DEVICES 1 day
  • Process operating parameters: monitoring and analysis of the machine process data & logs.
  • Monitoring tools dedicated to the machine type: vibration monitoring, PV card indicator, rod drop, bearings temperature.
FAILURE ANALYSIS & INSPECTION TOOLS 1.5 days
  • Material analysis: Non Destructive Tests (liquid penetration inspection, radiography, magnetic particle inspection, ultrasonic inspection). Destructive tests after rupture: hardness, welding sample test, tensile test. Analysis of the specific failure surface morphology.
  • Performance analysis: vibration analysis reports, thermographic analysis report, efficiency follow-up reports, noise analysis reports, oil analysis reports. Appreciation of standard failures.
  • Solutions to avoid failure: design parameters, stress limitations, operating parameter conditions, online monitoring.
  • Case studies: rupture and wear examinations of typical machine components (bearings, mechanical seals, rotors, crankshaft). Analysis of most common failures on centrifugal pumps, reciprocating compressors, centrifugal compressors and gear box.
  • Understanding a vibrations & oil analysis report.