Improving Rotating Equipment Reliability and Machinery Health

Course Overview: According to industry reports more than 60% of maintenance costs are spent on equipment wear, tear and failure. This year the Witbank Institute of Technology will be providing training on Improving Rotating Equipment Reliability and Machinery Health to make sure all rotating Equipment functions at its best. Predictably, continuous improvement of reliability by optimizing predictive maintenance for rotating equipment is one of the most important challenges maintenance professionals face today. This three day session course explains The Causes of Rotating Machinery Failures, Precision Maintenance for Rotating Equipment and Machines, Condition Monitoring and Predictive Maintenance, Design of Rotating Equipment and Machines and Root Cause Failure Analysis Procedure.

Why Attend: • Identify the most common causes of shafts, bearings and seals fatigue and failures based with actual case studies. • Understand Precision Maintenance for Rotating Equipment and Machines. • Optimize reliability of rotating equipment through applying best practices. • Optimize Reliability – Fundamentals of Condition Monitoring and Predictive Maintenance. • Understand Rotating Equipment and Machinery Reliability Continuous Improvement. Tel: 011 929 3085 Fax to email: 086 547 4185 Web: www.wiot.co.za

Who Should Attend? Condition monitoring professionals • Electrical engineers • Equipment Engineers • Equipment support maintenance • Machinery engineer • Mechanical engineering Managers/superintendents/ supervisors • Machinist/ Machine Operator • Maintenance managers/ superintendents/ supervisors • Mechanical managers/ superintendents/ supervisors •Operations supervisors • Plant Maintenance Superintendent • Plant Operator/ Engineer • Predictive Maintenance Engineer • Production managers/ supervisors • Reliability Engineers Course Topics: DAY 1 Introduction to Rotating Equipment and Machinery Reliability: 1. THE CAUSES OF ROTATING MACHINERY FAILURES 1.1. True Cost of Failure • Financial impact of downtime • Understanding risk and consequence • Preventing defects and failure

1.2. Know the Process, Physical, Chemical Properties and Characteristics • Process condition disruptions and process effects on components • Corrosion, erosion and wear • Material and product internal build-up

Exercises & or Case Studies 1 (Equipment material of construction selection exercise) 1.3. Supporting Structure, Foundations, Strength, Rigidity • Attenuation of vibration • Dissipating operating loads and forces • Preventing equipment deformation

Exercises & or Case Studies (1 Removing soft-foot activity) 1.4. Fatigue and Failure Modes • Ways shafts fatigue and their causes • Ways bearings fail and their causes • Ways seals fail and their causes

1.5. Bearing Failures • Fluctuating loads and forces • Lubrication condition • Tell-tale bearing failure signs

Exercises & or Case Studies (1 Bearing failure case study)

2. PRECISION MAINTENANCE FOR ROTATING EQUIPMENT AND MACHINES 2.1. Reliability, Availability, Maintainability, Safety (RAMS) • Impact of special and common cause variation on RAMS • Precision maintenance for rotating equipment

Accuracy Controlled Procedures 2.2. Balanced Shafts, Balancing Standards • Causes of out-of-balance

• Engineering standards and limits for balancing

• Mechanical balancing

Exercises & or Case Studies (1 In-situ shaft balancing case study) 2.3. Shaft Alignment • Effects of shaft misalignment

• Standards and limits for alignment

• Methods of precision shaft alignment

Exercises & or Case Studies (1 Shaft alignment case study) 2.4. Rotating Equipment Vibration • Allowable vibration severity

• Bearing vibration causes

• Machinery vibration isolation

2.5. Lifting Maintenance Performance (To have additional focus) • Measuring maintenance outcomes and KPIs

• Maintenance Quality Systems for RAMS

• Using visual management to control performance

3. Optimizing Reliability – Fundamentals of Condition Monitoring and Predictive Maintenance: 3.1. Condition Monitoring Methods for Rotating Equipment • Tribology and lubrication analysis • Thermography • Rotating equipment non-destructive testing • Operating performance monitoring 3.2. Bearing Vibration Analysis • Vibratory condition based monitoring • Vibration signatures • Vibration analysis

Exercises & or Case Studies (1 Bearing vibration signature analysis case study ) 3.3. Tribology and Lubrication Overview • Wear particle analysis • Properties of lubricants • Sustaining lubricant health 3.4. Thermography • Temperature signature analysis • Mechanical equipment • Electrical equipment

3.5. Maintenance Strategy Mix (To have additional focus) • The PM - PdM - Breakdown mix • Total Productive Maintenance (TPM) and Operator driven reliability • Precision Maintenance

Exercises & or Case Studies (1 Select a maintenance strategy mix activity) DAY 2 Rotating Equipment and Machinery Reliability Continuous Improvement: 1. Design of Rotating Equipment and Machines 1.1. Strength of Materials for Shafts and Rotors • Metallurgy - stress and stress raisers • Metal fatigues • Bending and deflection of shafts 1.2. Horizontal Shaft Design, Vertical Shaft Design • Axial and radial loads • Shaft and equipment expansion considerations • Shaft manufacture, diameter and tolerances

Exercises & or Case Studies (1 Design a shaft)

1.3. Bearing Design and Selection, Radial and Axial Bearings • Roller bearings and plain bearings – uses and limitations of each • Bearing lubrication and selection • Bearing housings and construction Exercises & or Case Studies (1 Select a bearing for the shaft exercise) 1.4. Lubrication Selection • Properties of lubricants • Lubricant operating environment • Lubricant life-extension additives 1.5. Shaft Seals – Methods, Types, Designs, Process Effects • Seal design overview • Seal failure modes • Seal selection

1.6. Vibration Prevention and Isolation (To have additional focus) • Basics of spring/damper systems • Natural frequency • Machinery vibration isolation

Exercises & or Case Studies (1 Perform a simple vibration isolation calculation) 2. Root Cause Failure Analysis Procedure 1.7. Root Cause Failure Analyses (RCFA) • RCFA fundamentals • The RCFA process • Developing and implementing solutions 1.8. Finding the Evidence and Proof • What specifically will be covered? • Operating and maintenance records and analysis • Creative disassembly • Importance of keeping accurate records and history 1.9. Applying RCFA in the Workplace • What specifically will be covered? • Cross-functional teams • The 5 Whys method • Operator and maintainer buy-in for improvement Exercises & or Case Studies (1 RCFA exercise)

DAY 3 3. Design Screening (Component Function) Examples 1.10. Design, Operation and Cost Total Optimisation Review • What specifically will be covered? • Life cycle operating cost • Cost impact calculations • Design review and optimisation 1.11. Risk Reduction Strategies in Design • Understanding and measuring risk • Chance vs. consequence risk reduction methods • Applying risk reduction during design 1.12. Lifting Lifetime Reliability (to have additional focus) • Equipment reliability overview • Measuring reliability: for components – Weibull; for systems - Crow/AMSAA • RCM/FMEA fundamentals 4. Management of Rotating Equipment and Machines 1.13. Reliability of Systems • What specifically will be covered? • Series and Parallel systems • Implications for series systems • Implications for parallel systems 1.14. Instigating Rotating Equipment Operational Excellence • Necessary Asset Management systems • Documentation requirements • Training and up-skilling of personnel 1.15. Rotating Equipment Integrity Management • Statutory, Safety, Operating and Maintenance Standards • Documentation and Record Keeping requirements • Auditing and Analysis of operating management systems 1.16. Rotating Equipment Reliability Improvement Strategy

• Setting Equipment Performance Specifications • Selecting best practice methods to achieve the performance objectives • Developing and managing workplace best practice processes

The Witbank Institute of Technology Pty Ltd (WIOT) is a world classes IT and business skills development Company based in Johannesburg, South Africa. It was established in 2009. We are accredited with MICT SETA. (Accreditation number: ACC/2010/07/059) Our aim is to deliver superior quality training solutions that produce tangible results. We want to build confidence in our learners so that they can utilize their newly acquired skills to improve their performance on the job and provide their company with a meaningful return on investment (ROI). We offer a wide range of internationally recognized qualifications and skills programmers across South Africa and the continent.

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Tel: 011 929 3085 Fax to email: 086 547 4185 www.wiot.co.za

TERMS & CONDITIONS PAYMENTS: 1.1 Payment shall be made in full prior to delegate(s) attendance of event. 1.2 Payments should be made within 7 working days after receipt of invoice, failure to which, attendance will not be permitted unless agreed otherwise with WIOT preceding the confirmation of the booking. CANCELLATION & RESHEDULING: 1.1 WIOT reserves the right to reschedule, change the speaker, change the venue or cancel the event, and will use reasonable efforts to notify delegates 7 working days before event runs. 1.2 The client needs to inform WIOT of all cancellations in writing. 1.3 Delegates will not be charged if WIOT cancels or reschedules any event. Provided that invoice was paid, delegate(s) will be issued credit vouchers to attend any other WIOT event, this voucher will be valid for up to 12 months from date of issue. 1.4 Cancellations received after the booking form has been signed and received by WIOT, client will be charged a service fee of 5% of invoiced amount. 1.5 Cancellation received by WIOT 21 working days before event commences will be liable for a cancellation fee of 70% of the total amount invoiced. 1.6 Cancellations received 14 working days before commencement of event will be liable for 100% cancellation fees. 1.7 In the event of a delegate not showing up at the event OR does not complete the course, he/she will forfeit entire amounts paid to WIOT 1.8 Delegate substitutions can be made by client at no charge to client provided client puts it in writing. RECOVERY: In the event of any action for the recovery of monies, or any action by WIOT in terms of these terms and conditions, the client hereby acknowledges that they will be liable for all legal costs. LIABILITY: WIOT shall not be held liable for any losses or damages nor assume liability whatsoever as a result of an act of God, unforeseen occurrence or any other event that renders performance of the event impracticable or impossible. For purpose of this clause, a fortuitous event shall include but not restricted to: war, fire, labour strike, extreme weather or other emergencies. DAMAGES: In the event that delegates are working with computers or any other WIOT equipment’s, they shall be held liable for any damages suffered by WIOT to the equipment through any negligent act by delegate

Price: R9,999 Per Delegate Excl. VAT

1. Bank Transfer : Witbank Institute of Technology Bank: Nedbank Account Number: 1913435113 Branch Code: 198765, Cresta Swift Code: nedszajj