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Machinery Failure Analysis & Repair Methods

Machinery Failure Analysis & Repair Methods

5 days
MTM/RUPT-E
Sessions
This course is not scheduled.
Who should attend?

Audience

    • Maintenance supervisors, engineers and technical staff involved in rotating machinery maintenance and technical inspection.

Level

  • Advanced
  • This course enhances the maintenance staff skills through a clear understanding of machinery failure analysis.
Learning Objectives
  • Upon completion of the course, participants will be able to:
  • prevent mechanical failures and reduce operating costs,
  • apply a methodology to identify the type and the failure root cause,
  • propose improvements on machinery reliability.
Course Content

FAILURE ANALYSIS

3 days

  • Rupture phenomena:
  • Ruptures study: material characteristics, influences of metallurgy and surface treatment, design parameters, consequences due to the modification of material behavior.
  • Characteristics of the main kind of ruptures: tensile and compressive stress with necking appearance, influence of the resilience and the transition temperature with regards to the service temperature, mechanical fatigue.
  • Rupture face analysis: mechanisms of rupture, surface morphology.
  • Solutions to avoid rupture: design parameters, limiting stresses, operating conditions & limitations.
  • Wear phenomena:
  • Wear study: friction principle with friction factor and wear rate, tribology.
  • Characteristics of the main kind of wear: adhesive wear depending on the lubrication mode, abrasive wear through particle presence, erosive wear due to flow, mechanical surface fatigue on gears and bearings.
  • Morphology of a worn surface: temperature colors, scratching, scoring, seizure.
  • Solutions to avoid wear: design parameters, limiting friction, operating conditions.
  • Case studies: rupture and wear examinations of machinery parts (bearings, mechanical seals, rotors), analysis of some failures on process centrifugal pumps, reciprocating & centrifugal compressors and gearbox.

REPAIR & RENOVATION WORK

2 days

  • Repair philosophy: integrating all the criteria to choose the best solution: repair or replacement.
  • Different modes of repair: welding, surface treatment, metal striching, deposits (HVOF application).
  • Costs: repair costs, delivery time, on site capabilities.
  • Case studies: description of different approaches used to repair some machines and components.
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Ways & Means
  • Case studies based on industrial & actual feedback.