School of Maintenance

Course Information

®

In Association With

A partnership in education

A member of the Set Point group

Maintenance and Lubrication Academy

School Of Maintenance

The vision of ABB School of Maintenance is to ensure that the topics taught in the various courses are professionally and effectively applied everywhere. Thisincorporates understanding the use of equipment and accessories to satisfactorily analyse faults and problem areas and how to capture meaningful data, what specific issues to be aware of and how to effectively interpret the data collected most effectively.

The mission of ABB School of Maintenance is to deliver highly professional training and to spread knowledge in the various fields taught effectively.

We at ABB School of Maintenance need to adjust support structures and training to fit local and overseas demands with regards to course offering, price, language, applications, culture and the specific needs of artisans and engineers at each plant and power station nationwide.

The School of Maintenance has full merSETA approval.

School of Maintenance is able to offer ASNTAccreditation on Condition Monitoring courses.

Get ICML Accreditation on MLA1 and MLT1 through School of Maintenance for Oil and Lubrication courses.

merSETA Certification

Courses Offered

Management Series

Condition Monitoring Series

Application-Specific Series

Engineers Series

Maintenance Planning and Scheduling 3 Days R5,100.00Maintenance Supervision Workshop 3 Days R5,215.00Effective Maintenance Review 3 Days R5,100.00Root Cause Failure Analysis 3 Days R5.100.00

Machinery & Lubrication Academy Level I (New Course) 3 Days R4,950.00Machinery & Lubrication Academy Level II (New Course) 2 Days R3,950.00Vibration Analysis Basic (New Upgrade) 3 Days R5,155.00Vibration Analysis Level I (New Upgrade) 3 Days R5,400.00Vibration Analysis Level II (New Upgrade) 4 Days R6,910.00Vibration Analysis Level III (New Upgrade) 4 Days R6,910.00Field Balancing 2 Days R3,985.00Thermal Applications for Predictive Maintenance Level I(Bringing your own camera is highly recommended) 5 Days R8,500.00Advanced Thermal Applications for Predictive Maintenance Level II(Bringing your own camera is highly recommended) 5 Days R12,000.00

Pump Maintenance 2 Days R3,855.00Statistical Failure Analysis (New Upgrade) 3 Days R5,440.00Airborne & Structure Borne Ultrasound 3 Days Inspection Certification (New Course) 3 Days R5,100.00Maintenance of Rotating Electrical Machines (New Course) 3 Days R6,690.00

Roller Element Bearing Maintenance for Engineers 2 Days R3,945.00Vibration Analysis for Engineers 4 Days R7,000.00Mechanical Applications using Infrared Thermography(New Course) 2 Days R5,100.00Electrical Applications using Infrared Thermography(New Course) 2 Days R5,100.00Vibration Analysis of Rotating Electrical Machines (New Course) 3 Days R5,400.00

Leadership

Principles of Leadership (New Course) 2 DaysLevels of Leadership (New Course) 1 Day

Additional Training Series

ASNT/ICML Certification Exams

On-Site Training Series

Statistical Analysis of Failure Time Data 3 Days R5,440.00Gearbox Maintenance 2 Days R3,855.00

ASNT Certifications Exams 4 Hours On the last day of each Vibration AnalysisTraining Course presented R1,800.00

ICML Certification Exams 3 Hours On the last day of each Oil Analysis &Machinery Lubrication Training Coursepresented R1,500.00

All training courses can be presented on-site at a 20% discount with a minimum of 10 delegates in attendance.

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Registration Information

General Info

Contact Us

Conditions of Entry

Payment

The ABB School of Maintenance, part of the Service Division of ABB South Africa (Pty) Ltd is based in Sunninghill, Johannesburg. The main objective is to increase the level of knowledge amongst maintenance practitioners across all disciplines of the field and on all skilsl levels. We promote generic principles and use recognised experts (affiliated to ABB or otherwise) in maintenance to transfer their knowledge to attendees.

All courses are presented at the ABB School of Maintenance, ABB Park, The Crescent, 3 Eglin Road, Sunninghill, Sandton. Should you require additional information, send an e-mail to abbsom@za.abb.com or telephone +27 11 236-7342.

Course material will only be made available to course attendees and no course material is for sale. Allcourse material is on display at the ABB School of Maintenance, ABB Park in Sunninghill for evaluation purposes.

Course fees do not include accommodation. Delegates are required to make their own arrangements regarding accommodation.

Course prices quoted are set as at 01 October 2004 (excl. vat) and are subject to change.

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Please phone +27 11 236 7342 for course dates and registration forms. A confirmation letter and proforma invoice will be faxed back to you on receipt of the registration form, including a list of accommodation and a map to the training venue.

� A purchase order is required.� Cancellations are accepted in writing and without penalty, up to 10 working days prior to the

commencement of the course.� Substitutes will be accepted.� Participants cancelling in writing less than 10 days prior to the commencement of the course will be

liable to pay a 30% cancellation fee.� If no prior written notification is received, participants will be liable to pay the full course fee.� In case of insufficient applications for a course, ABB School of Maintenance reserves the right to

cancel the course. Participants will be informed and all fees will be refunded immediately.

Cheques can be made out to ABB South Africa (Pty) Ltd., Process Industries DivisionDirect deposits can be made into ABB South Africa (Pty) Ltd bank account, i.e. Standard Bank, Sandton, Account no: 42 094 1606, Branch code: 01-92-05-90.

Get Certification

®

ICML CERTIFICATION

ASNT CERTIFICATION

This shows that you are a professional with the ability to successfully lubricate machines and utilise oil analysis. You will get worldwide industry recognition of your knowledge and proficiency in analysis/machinery lubrication techniques. It is a three hour closed book multiple choice examination.

Examination choice:

MLA @ R1500.00 per examination

MLT @ R1500.00 per examination

Technical Associates of Charlotte U.S.A. provides you with a certificate that states you have been trained and tested according to the SNT-TC-1A document, which is the standard that the American Society for Non-Destructive Testing (ASNT) has chosen to follow. It is a four hour closed-book multiple choice examination.

Examination choice:

Vibration Level One Certification @ R1800.00 per examination

Vibration Level Two Certification @ R1800.00 per examination

Vibration Level Three Certification @ R1800.00 per examination

Please note: All prices quoted are exclusive of Vat and subject to the Rand/Dollar exchange rate.

Leadership

How important is your company’s ability to develop leaders in achieving competitive advantage?

The Learned Leader.

· Has seen leadership modelled most of life

· Has learned leadership through training.

· Has self-discipline to be a great leader

All three qualities are acquired.

PRINCIPLES OF LEADERSHIP

�What can you learn from the top business people� The essentials of Leadership� Application and Development of the

essentials

Course duration: 2 days

Who should attend?

Anyone aspiring to achieve better Leadership qualities

LEVELS OF LEADERSHIP

� Understanding the Levels of Leadership you have reached� Increasing influence - pre-requisite for

others to follow� Attract new followers

Course duration: 1 day

Who should attend?

Anyone aspiring to achieve better Leadership qualities

It is recommended that students attend the Principles of Leadership course before enrolling on this course

Maintenance Planning and Scheduling

MAINTENANCE PLANNING ANDSCHEDULING

What is the role of the Planner?

The organisation should avoid a situation where the Maintenance Planner is merely issuing work orders, without any consideration for the amount of work being given to any particular workshop. The amount of outstanding work will just grow.The workshop will be totally demoralised, and there will be no improvement in their productivity,or achievement in terms of reducing breakdowns.

However, there is potential conflict between the Maintenance Planner and the Supervisor, as the Supervisor is responsible for allocating work to his team (not the Planner).

How can conflict be avoided?

It is therefore important for the roles of the Maintenance Planner and the Supervisor to be clearly defined and understood.The Planner cannot work in isolation from the workshops that he services. He needs to be aware of artisans on leave or absent and to adjust his scheduling accordingly.

Eradicate the paper giant!

High frequency schedules have to be handled sensibly to avoid an accumulation of paper-work, which has no significant contribution to the information system. Yet these very schedules are the backbone of the maintenance system and have to be controlled.

The Plant Inventory is essential for identifying what needs to be maintained, and the accompanying code should be an indicator of both the machine and its location in the plant. This identifying code is indispensible for correct, short-form identification in the maintenance computer system. The hierarchical approach to numbering is discussed.

Maintenance schedules need to be effective

The Maintenance Planner should be the co-ord inator when put t ing together the maintenance schedules. Although the Supervisor (or even one of the artisans) may be

the best person to write up the potential failures of a particular machine, they normally do not have the time to draw up an effective schedule. Also, the Planner, as co-ordinator, is able to maintain a common format, and logical approach to the document.

Reliability Centred Maintenance (RCM) forms the basis of the potential failure analysis. Apractical exercise is given to reinforce the technique.

Proper Planning Prevents Poor Performance

Shutdown planning is about completing the shutdown on time and within budget to the set quality standards.Network Analysis is the ideal tool for this. By knowing the basics of this technique, the planner will have a better understanding of any computerised programme that may be used and will be able to optimise the time/resources conundrum that is so crucial for shutdownplanning.

A Review of Maintenance PlanningMaintenance Organisation and ResponsibilityManpower PlanningDocumentation and ProceduresPlanning and Controlling Maintenance SchedulesPlant InventoryDeveloping a Maintenance ScheduleIntroduction to Network AnalysisShutdown Management

Maintenance PlannersMaintenance SupervisorsWorkshop ManagersRCM FacilitatorsProduction Supervisors

COURSE CONTENT:

WHO SHOULD ATTEND?

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Maintenance Supervision Workshop

MAINTENANCE SUPERVISION WORKSHOP

What the Maintenance Supervisorreally needs to know

All too often, a Maintenance Supervisor is promoted to that position because of his proven technical abilities. This is interpreted as good reason for promotion which is true, as we require these technical skills, knowledge of the plant and the industry to train his subordinates for problem solving.

But …

Have we given him the skills that he really requires to perform effectively as a supervisor? What does he understand about budgets and more importantly, about controlling costs, or does the new supervisor just assume that 'if it breaks, it must be fixed', and the cost is out of his hands? Or is his attitude one that leads to preventing breakdowns, thus reducing maintenance costs?

The newly appointed Supervisor may have the technical skills and knowledge of the plant, but is he able to solve problems systematically particularly with his subordinates? Has he been given training in this key skill?

Overcome the skills shortage through effective use of your resources.

Is there a perception that the maintenance personnel are “always walking around?” (and we defend this by saying that it is part of their job as they have to move between assigned tasks). But, are they properly managed and utilised? What has the organisation done to prepare the inexperienced Supervisor to allocate work effectively to his subordinates who were, very possibly, his recent work-mates?

One of the dilemmas facing most organisations today, is the spiraling cost of maintenance. Yetthe Maintenance Store is filled with spares that are seldom use! Yes, there is a need for machine specific “essential spares”. However,there are many more non-essential items that tie up capital. How does the supervisor make a decision on what spares should be held in stock?“Just-in-case” is not a spares strategy!

LEADERSHIP

COURSE CONTENT:

WHO SHOULD ATTEND?

A decisive element in organisational success is the ability to achieve results through employee performance.

This is the greatest challenge facing the newly appointed supervisor. How does he communicate with colleagues and how does he motivate his subordinates without alienating them? With no support from them, the supervisor will not have an effective workshop under his control and will not achieve the desired results.

This is recognised as a significant requirement for a technical supervisor and thus Leadership forms an extensive portion of this workshop.

The Supervisor will learn as much about himself as he will learn about conversing with others, and this is a valuable insight into the art of communication.

The intensive 3-day outcomes-based workshop will cover the following topics:

IntroductionEffective Maintenance, Effective ReturnsMaintenance in PerspectiveDaily Work PlanningOrganising Spares and MaterialsBudget ControlCommunication and FeedbackTime ManagementProblem SolvingLeadership

Maintenance PlannersMaintenance SupervisorsProduction ManagersMaintenance Operations Managers

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Effective Maintenance Review

EFFECTIVE MAINTENANCE REVIEW

Reliability Centered Maintenance (RCM) and Total Productive Maintenance (TPM), are just two of the recognised maintenance strategies that have proven track records in achieving remarkable results in many industries. If this is true (and it is) then why can these strategies not be universally applied to each and every Organisation? One of the main reasons for this lack of sustainability in many companies, is that an immense amount of “backroom” organisation is required to maintain and control the necessary infrastructure to keep the momentum going. Arigorous RCM analysis of your plant will be time-consuming and tedious. In essence, it is a potential failure analysis, that is, a discussion of all the things that could go wrong, but never will. While this detailed analysis is entirely suitable to some industries such as the airline industry,space, nuclear, petro-chemical and other high cost industries, it is an over-kill for industries where the cost and consequences of a failure are significantly less – but still need to be managed. The application of the RCM principles is beneficial in any industry to improve the throughput of the plant. Thus a less meticulous analysis, based on the knowledge and experience of the personnel, (both operational and maintenance), and of the facilitator, can be most helpful in reducing the downtime and the number of stoppages in the plant.

And this is the objective of maintenance!

This Outcomes-based module will be a practical workshop to assist delegates in understandingthe principles of an Effective Maintenance Review and to practice these, so that he or she may apply the newly learned skills in the workplace. The programme will be interactive. Yes, the delegates are expected to share their experiences and knowledge with each other.There will be many discussions and group exercises.

THE OUTCOMES

COURSE CONTENT:

WHO SHOULD ATTEND?

Through the workshop, the delegates will:

Gain an understanding of the benefits of an effective maintenance programmeHave insight into the effectiveness of differenttypes of maintenance strategiesPractice failure analysis techniques to develop an effective strategy for themselvesDevelop an Action Plan to improve maintenance at work

1. Effective Maintenance, Effective Returns2. The Types of Maintenance Strategies3. Effective Maintenance Review

Potential failuresCauses of failureConsequences of failure and riskEffective maintenance task selectionWho should do the task?How often should the task be done?

4. Set an Action Plan

Your superior will be notified that you have an action plan, so that he or she may follow up on the progress and thus gain a benefit from the programme.

Maintenance PlannersMaintenance SupervisorsProduction ManagersMaintenance Operations Managers

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Root Cause Failure Analysis

ROOT CAUSE FAILURE ANALYSIS

COURSE FORMAT:

COURSE CONTENT:

There is an alarming trend in industry to discount the potential contribution of the maintenance function to productivity improvement, product quality and gains in market share. Principles taught in this course will help you to understandthe true nature and different techniques of problem solving in the technical environment.

Participants will have access to the latest research in maintenance management, which forms the basis of the program. On completion the student will posses the skills to initiate a RCFA program in their own organisation. Theyare encouraged to bring at least one specific problem to the course for group analysis and hypotheses formulation.

Finding (and fixing!) the root cause of a problem, means that the same problem will not re-occur ever again. Consistent application of RCFA will set you on the road to the achievement of WorldClass performance standards.

The course has been structured to accomodate the needs of both beginners and more advanced students. The emphasis is on high levels of participation, practical implementation of principles and affordable solution sets. Advanced mathematical algorithms are avoided. Case studies and a “hands-on” approach are used throughout the program, so that the student can easily relate to his/her own situation. Thecourse material is structured such, that it can be used as a reference afterwards.

IntroductionA framework to accommodate a RCFAprogrammeKey success factors for RCFA ImplementationStandard problem solving techniquesPsychology of problem solving and decision makingIntegrating techniques in the problem solving processCase studies

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WHO SHOULD ATTEND?

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Maintenance practitioners from supervisor level to engineering managerIndustrial engineersProduction Managers with a focus on integration of the maintenance processCost accountants

Machinery & Lubrication Academy Level One

LEVEL ONE

Introducing Machinery Lubrication Academy.This is the result of an expanded association between ABB School of Maintenance and Wearcheck Africa. The training courses are aimed specifically at the South African market. These courses will change the way you think about lubrication of equipment foreverand will help you to develop world class lubrication practices in your workplace.

“There is always money available to repair a component when it fails, but there is never money to prevent it from happening” Mostcompanies find themselves in a comfort zone when condition monitoring techniques, like oil analysis, vibration analysis, thermographic analysis and other non destructive techniques are utilised; but how effective are they?

Oil analysis can have a massive return on investment if the thinking process is right. Most companies use condition monitoring in a reactive manner - critical wear indicates an imminent failure so stop the machine before it catastrophically fails. When employing pro-active thinking principles, the root cause always has to be addressed.

These courses have been developed takinglocal conditions into account and the wealth of information gathered doing oil analysis over the last 30 years. These courses will help companies to identify problem areas, identify root causes and implement solutions. This will result in massive savings as a result of component availability, lower lubricant usage and overall improved maintenance practices. Some of the key areas addressed include specification and consolidation, storage and handling of lubricants, oil sampling techniques, lubricant analysis, contamination control and general lubrication and re-lubrication principles.

COURSE CONTENT:

WHO SHOULD ATTEND?

� Basics of lubrication�Oil sampling principles� Fluid property analysis� Pro-active maintenance and contamination

control�Machine wear and analysing wear modes� Classification of oils�Grease and its analysis

� All Maintenance Professionals� Craftsmen & Millwrights� Vibration Instrumentation Technicians� Predictive Maintenance Technicians� Equipment Operators�Maintenance Supervisors� Reliability Engineers�Maintenance Managers�Manufacturing and Industrial Engineers� Lubrication Engineers�Operations Managers

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Clay Rock Dust Rust

Spheres Soot Wear DebrisA member of the Set Point group

Machinery & Lubrication Academy Level Two

LEVEL TWO

COURSE CONTENT:

Machine oil usually carries advanced notice of upcoming disasters, but very often these catastrophes go undetected until it is too late. Utilising the information to be found in oil, requires more than just the correct tests, precise sampl ing locat ions, correct sampl ing frequencies and appropriate sampling techniques - i t also requires careful management. For this reason, ABB School of Maintenance, in conjunction with WearcheckAfrica, bring you this course, which deals with the subjects mentioned below and will help you to maximise the potential cost savings in oil analysis. It aims to give professionals a firm understanding of the concept and theory of oil analysis without spending unnecessary time on finer details.

�Maintenance philosophies� Designing a total fluid management

programme that includes oil analysis�Why oil analysis sometimes does not work� Six most expensive oil analysis tests�Ways to make oil analysis work� Alarms and limits�Getting the most from your oil analysis

reports� Integrating oil analysis with other CM

techniques� Savings calculations� Case studies� Data interpretation

WHO SHOULD ATTEND?

The course is developed for delegates from all levels of expertise within maintenance o p e r a t i o n s , e n g i n e e r i n g a n d o t h e r administration functions, such as production and purchasing. The course will help anyone in pulp and paper, steel milling, water, transport, chemical and petrochemical, power generation and many other industries, who are working with the following machinery, to apply best practices to overcome the problems of contamination and inadequate maintenance:

GearboxesHydraulic systemsBearingsDiesel enginesPaper machinesProcess pumpsTurbinesBlowers/fans

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A member of the Set Point group

Vibration Analysis Basic & Level One

VIBRATION ANALYSIS BASIC

Little or no previous experience is required to do this course. However, no vibration analyst can truly be effective without some basic skills and previous experience in maintenance of machines that will be included in the maintenance programme. General familiarity with using a calculator along with some good math skills in arithmetic and simple algebra is helpful.

COURSE CONTENT:

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PREDICTIVE MAINTENANCE ANDMACHINE VIBRATION

Introduction to Maintenance SystemsPredictive Maintenance Programme (PMP)Steps to Condition Monitoring for successful PMP

MACHINE VIBRATION BASIC THEORYPART ONE

Basics of VibrationDisplaying Vibratory Motion

MACHINE VIBRATION BASIC THEORYPART TWO

AmplitudeRoot Mean Square, Peak, Peak-To-Peak, ConversionsPeriod of VibrationAnalysing Frequency Peaks & Amplitude LevelsPhase Relationships

PREPARING FOR DATA COLLECTIONTransducers, Choosing a TransducerTransducers, Mounting Locations & TechniquesSelection CriteriaFFT Data CollectorsReal-Time Spectrum Analysers

DATA COLLECTIONSetting Up a DatabaseDownloading a RouteSelecting Necessary EquipmentSafety PrecautionsCollecting DataUploading the RouteReport PrintoutsPlot Formats

DATA ANALYSISDefinitions of TerminologyDiagnosing Vibration Problems

VIBRATION ANALYSIS ONE

COURSE CONTENT:

Aspiring vibration analysts with little (less than one year) vibration experience will benefit from this course. Candidates should have basic skills and previous experience in maintenance of machines that will be included in their predictive maintenance programme. General familiarity with using a calculator along with basic math skills are required.

INTRODUCTION TO THE BASICS OFVIBRATIONPHASE MEASUREMENT AND ANALYSISOVERVIEW AND SELECTION OF TRANSDUCERSOVERVIEW OF VIBRATIONINSTRUMENTATIONROLE OF SPIKE ENERGY, SHOCK PULSE AND HFDVIBRATION SIGNATURE ANALYSIS TODIAGNOSE:

Mass unbalanceOverhung rotor imbalanceEccentric motorsBent shaftsMisalignmentMechanical loosenessAnalysis of rolling element bearingsIntroduction of resonance problemsElectrical problems with induction motorsAnalysis of gears and gear drivesBelt drive problemsAerodynamic / hydraulic forces

SPECIFYING SPECTRAL BAND ALARMLEVELS AND FREQUENCYCOMMON PITFALLS IN EVERYDAYVIBRATION MEASUREMENTSIMPLEMENTING AN EFFECTIVEPREDICTIVE MAINTENANCE PROGRAMMEREAL-WORLD CASE HISTORIES

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Vibration Analysis Level Two & Three

VIBRATION ANALYSIS TWO

COURSE CONTENT:

At least one to two years vibration spectrum analysis experience is recommended for potential candidates. General familiarity with using a calculator and computer is required. Good math skills and simple algebra, primarily solving for one unknown, is a must. Some fundamental trigonometry background will also prove helpful. If certification is desired at Level Two, a student must have attended the Level One course and passed the Level One Certification exam, or have an equivalent Level One Certification.

Brief review of “Analysis One”Principles of Digital Data Acquisition and FFTProcessing for Reliable Spectral AnalysisIntroduction to Natural Frequency TestMethodsEnhanced Vibration Diagnostics Using Phase AnalysisConcentrated Vibration Signature AnalysisResonance ProblemsTracking of Rolling Element Bearing ConditionsPlain Bearing ProblemsRotor RubFlow-induced Vibration ProblemsGear ProblemsElectrical Problems with Induction MotorsHow to refine both Overall and Spectral Band Alarms using Proven Statistical TechniquesIntroduction to Narrowband Envelope AlarmsIntroduction to High Frequency Demodulated and Enveloped SpectraIntroduction to Vibration Isolation MechanismsIntroduction to Vibration Damping TreatmentsReal-world Case Studies

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VIBRATION ANALYSIS THREE

COURSE CONTENT:

Students should have approximately two to four years spectrum analysis experience. General familiarity with using a calculator and computer is required. Good math skills, including algebra and fundamental trigonometry, are mandatory.It is recommended that students attend both Analysis One and Two before enrolling on this course. Students wanting Level Threecertification are required to have passed both the Level One and Two Certification exams.

Review of “Analysis Two” seminar topicsHow to and How Not to Create Meaningful Narrowband Spectral Alarm EnvelopesProper use of High Frequency Demodulated and Enveloped SpectraHow to Analyse Low-speed Machines (especially 10-300 rpm)How to Analyse High-speed Machines Generating Frequencies of 10-60kHzHow to Analyse Variable-speed machinesHow to Best Communicate the Achievementsof Your Plant's Condition Monitoring Programme on a Continuous BasisReporting at the Individual Plant Level Versusat Corporate Levels.Introduction to Motor Current SpectralAnalysisHow to Detect Problems with DC Motors and their ControlsIntroduction to Time Waveform AnalysisOperational Deflection Shape (ODS) Analysisusing Animated Computer SoftwarePresentation of a Tabulated Chart TrackingAdvancement Through the Vibration Analysisand Rotor Dynamics fields

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Field Balancing

FIELD BALANCING

REQUIREMENTS

Unbalance is one of the most common problems in industry and to address the problem properly,a thorough knowledge of balancing techniques is required. The ABB School of Maintenance (in conjunction with Technical Associates of Charlotte U.S.A.) is presenting a world-class course on this subject at your doorstep.

This course has 5 primary objectives:

Teaching the student how to properly balance a variety of machinery, using both graphical and programmable methodsExplaining single-plane and dual-plane field balancing techniques using various datacollector systemsTeaching special balancing techniques required on overhung rotorsInstructing how to confirm unbalance as root cause of vibration, using straightforwardspectral and phase analysis techniquesProviding and explaining present balancing tolerances

Previous field balancing experience is helpful, but is not required prior to taking the class. General familiarity with using today’s datacollectors or portable balancing instruments is also beneficial (a variety of such instruments will be demonstrated during interactive class exercises). Basic math skills and the ability to use and interpret graphs and tabular information will be beneficial in order to maximise understanding.

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COURSE CONTENT:

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Definition of unbalanceTypes of unbalanceHow to ensure the dominant problem is unbalanceCauses of unbalanceDynamic field balancing techniquesRigid versus flexible rotorsRecommended balancing speed and number of planesBalancing machines - soft versus hard bearingRecommended vibration and balance tolerancesDemonstrations

Craftsmen and Millwrights Vibration Instrument Specialists Predictive Maintenance Technicians Equipment Operators Maintenance Supervisors

Thermal Applications for Predictive Maintenance

THERMAL APPLICATIONS FORPREDICTIVE MAINTENANCE

SUPPORT

LEVEL ONECOURSE CONTENT:

Innovative teaching methods

Snell Infrared training classes use innovative training techniques that will give you an understanding of theory along with applied, hands-on learning. All infrared cameras are welcome in our courses. Student/teacher ratios are low to ensure you receive plenty of individual attention. A comprehensive manual - for use in class and later as a reference tool - is included in both Level I and Level II classes.

After your course, Snell Infrared is there for you with on-going support including:

Toll-free telephone supportCritique of program documents, report forms and proceduresReview of reports and applications problemsSubscription to the Snell Infrared newsletter,Think Thermally®Connection to our network of thousands of graduates and professional associates

Our job does not end when the training is over.We will continue to support you, to help you achieve your goals.

A basic course including theory, applications and hands on training.

Learning to Think Thermally®.Basic theory of thermography and itsapplication.Hands-on use of thermal imaging equipment.Concepts of infrared imaging that apply to predictive maintenance applications.The elements of proper image acquisition and documentation.Documenting findings and writing effectivereports.

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LEVEL TWO - ADVANCEDCOURSE CONTENT:

WHO SHOULD ATTEND?

A professional course for experienced thermographers who want to expand their knowledge and skills.

Understanding quantitative thermography.Developing skills for advanced temperature measurement.Refining inspection techniques.Developing new applications.

Maintenance PersonnelEngineering PersonnelOperations PersonnelFacilities PersonnelConsulting Thermographers

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Pump Maintenance

PUMP MAINTENANCE

COURSE CONTENT:

Pumps are often such an imperative element in production processes, that pump downtime is simply unacceptable. One of the most importantsteps in achieving high pump availability, is performing quality maintenance on pumps. For this reason, the ABB School of Maintenance (in conjunction with Sulzer Pumps), brings you an intensive course on pump maintenance.

This 2-day course focuses primarily on centrifugal pumps, although other types of pumps are also briefly discussed. Pump fundamentals are reviewed in detail because a fundamental understanding of the working of pumps is required to make educated decisions regarding the maintenance of pumps. Guidelines for appropriate pump selection are considered in this course as a first step in minimisation maintenance activities on pumps. External influences on pump maintenance, such as installation and operation practices.

Centrifugal pump fundamentalsPump specification and selectionDesign and installation flaws affecting pump maintenanceBest pump maintenance practicesOperator errors resulting in unnecessary maintenanceCondition monitoring of pumpsCase studies

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WHO SHOULD ATTEND?

POSSIBLE BENEFITS OF ATTENDINGTHIS COURSE:

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Rotating Equipment Specialists� Reliability Improvement Engineers�Maintenance Supervisors� Pump Technicians

Increased pump availability� Reduction in pump maintenance costs� Higher return on pump investments� Fewer unexpected production losses

Air and Structure Borne Ultrasound Inspection

COURSE CONTENT

WHO SHOULD ATTEND:

The ABB School of Maintenance brings you this world-famous course on Ultrasound Inspection in conjunction with SDT North America. Thiscourse will change the way you think about predictive maintenance and ultrasound inspection forever. Proper training is the foundation of an effective ultrasound inspection program at your company.

� All predictive maintenance personnel� Reliability professionals� Energy auditors� Maintenance planners and trainers� Millwrights� Lubrication technicians� Engineers� Vibration analysts� TPM and RCM operators� Electrical supervisors� Infrared technicians

YOU WILL LEARN

Principles of Ultrasound� Properties of Leaks� How to find leaks in any environment� Acoustic Lubrication Techniques� Electrical Systems Inspection� Steam Trap Fault Detection�Mechanical Condition Monitoring� All Applied to a PdM Program

Power Generation Petrochemical Pulp and Paper Process Manufacturing Automotive Transportation Facilities Steel Aviation and Aerospace Marine Materials and Composites Food processing Waste Water Treatment Rubber & Tire Gas distribution Textiles

INDUSTRIES THAT WILL BENEFIT FROM THIS COURSE:

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Course Curriculum - Ultrasound Inspection

DAY 1

Course Objectives

Course Introduction� Principles of Sound� Hearing� Types of Ultrasound� Ultrasound Equipment� Testing Methods

Leak Detection� Properties of Leaks� Leak Detection Techniques� Practical Learning� Testing and Documentation

Electrical Inspections� Safety Considerations� Electrical Discharge and Effects� Practical Learning� Electrical Inspection Techniques� Documentation

Review and Questions

DAY 3:

� Review and Questions from Day 1 & 2�Written Examination� Practical Examination

DAY 2:

Review and Questions

Mechanical Testing� Structure Borne Testing� Stages of Mechanical Failure� Building Trends and Alarms� Data Collection� Practical Learning� AVM - Acoustic Vibration Monitoring� Acoustic Bearing Lubrication� Procedures and Methods

Valves and Steam Traps� Operating Principles� Effects of Defective Components� Inspection Methods� Practical Learning

Review and Questions

COURSE CONTENT:

Roller Element Bearing Maintenance

ROLLER ELEMENT BEARINGMAINTENANCE FOR ENGINEERS

This 2-day course has been specifically designed for engineers and plant managers. It aims to give these professionals a game plan to implement throughout their plants. It delivers the skills and necessary information to implement an effective programme to reduce failures and increase bearing life. The course is presented in a manner designed to facilitate practical implementation of the key elements delivered in the course.

Learn How Your Organisation Can Prevent Over 70% of Roller Element Bearing

Failures.

POOR LUBRICATION, 36%Although 'sealed-for-life' bearings can be fitted and forgotten, some 36% of premature bearing failures are caused by incorrect specification and inadequate application of the lubricant. Inevitably, any bearing deprived of proper lubrication, will fail long before its normal service lifespan. Because bearings are usually the least accessible components of machinery, neglected lubrication frequently compounds the problem. Lubricant selection, lubricant requirements and implementing an effective Lubrication programme for Lubricators are all discussed for extended service life.

FATIGUE, 34%Whenever machines are overloaded, incorrectly serviced or neglected, bearings suffer from the consequences, resulting in 34% of all premature bearing failures. Sudden or unexpected failure can be avoided, since neglected or overstressedbearings emit "early warning" signals, which can be detected and interpreted using condition monitoring equipment. The range of instrumentsdiscussed includes hand-held instruments, hard-wired systems and data management software for periodic or continuous monitoring of key operating parameters.

POOR FITTING, 16%Around 16% of all premature bearing failures are caused by poor fitting (usually brute force...). Individual installations may require mechanical, hydraulic or heat application methods for correct and efficient mounting or dismounting. Thecourse reviews the tools, equipment and

methods to make these tasks easier, quicker and more cost effective. The course also presentsalignment standards and tolerances typically accepted in industry. Artisan training requirements for world-class maintenance are also presented.

CONTAMINATION, 14%A bearing is a precision component that will not operate efficiently unless both the bearing and its lubricants are isolated from contamination.And, since sealed-for-life bearings in ready-greased variants account for only a small proportion of all bearings in use, at least 14% of all premature bearing failures are attributed to contamination problems. The course deals extensive ly wi th methods to reduce contamination and extend bearing life.

� Best practices of bearing maintenance� Condition monitoring technologies� Root cause failure analysis and prevention

All Maintenance ProfessionalsMaintenance ManagersPlant ManagersPlant Engineers

Can you identify these failure modes?What steps would you take to prevent these

failures from recurring?

COURSE CONTENT:

WHO SHOULD ATTEND?

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Vibration Analysis for Engineers

VIBRATION ANALYSIS FOR ENGINEERS

This 4-day course has been designed by engineers for engineers. It aims to give these professionals a firm understanding of the concepts and theory of vibration analysis. It teaches how to diagnose virtually every type of machine used in general industry. The course delivers three courses (Vibration Analysis Level I, II & III) at a pace that engineers are accustomed to. The course was compiled by Technical Associates of Charlotte’s U.S.A. notes and combines the material from all three courses. This course serves as one of the most authoritative texts on Vibration Analysis in the world.

Learn what every engineer should know about vibration analysis:

The Techniques…The Analysis of…The Application…

Your credibility may be on the line!

Engineers and plant managers are ultimately responsible for maintenance costs and plant availability. These two performance indicators are often of such magnitude and importance that Engineers are expected to make decisions with the highest degree of confidence. Vibrationanalysis has become one of the most important tools in assisting engineers to make those decisions, and although many companies employ skilled vibration analysis technicians to provide this information, it is absolutely essential that engineers have at least a firm understandingand insight into the subject. After all, it is the engineer that will ultimately be accountable for the plant and not the analyst.

A refresher course for senior vibration analysts !

The course also serves as an excellent refresher course for senior vibration analysts.

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COURSE CONTENT:

WHO SHOULD ATTEND?

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Introduction To The Basics Of VibrationPresentation of 6 Bearing Failure ScenariosDisplacement, Velocity & Acceleration?When Should Bearings be Replaced?Selecting Frequency Span & Resolution LinesPlain Bearing ProblemsPhase Measurement & AnalysisRotor Rub, Partial Rub & Full Annular RubTransducers & Vibration InstrumentationFlow-Induced Vibration ProblemsSpike Energy, Shock Pulse & HFDGear Problems: Gear Tooth Wear & LoadingGear Eccentricity and/or BacklashGear Tooth MisalignmentCracked or Broken Gear TeethHunting Tooth ProblemsRMS vs Peak vs Peak-to-Peak MeasurementsSpectral Band Alarm Levels & FrequenciesCommon Pitfalls In Vibration MeasurementsMeasurement Locations & Point IdentificationImplementing An Effective ProgrammeFractional Gear Mesh FrequenciesNatural Frequency, Resonance and Critical SpeedPolar & Bode Plot Acquisition & InterpretationElectrical Problems With Induction MotorsMass UnbalanceNarrowband Envelope AlarmsEccentric RotorsHigh Frequency Demodulated & EnvelopedSpectraBent ShaftsVibration Isolation MechanismsMisalignmentVibration Damping TreatmentsMechanical Looseness (3 Types)Motor Current Spectral AnalysisBelt-Drive Problems Motor Current vs VibrationSpectral AnalysisBeat Vibration Problems, Problems With DCMotors and Their Controls

All Maintenance Professionals�Maintenance Managers�Maintenance Supervisors� Production Executives� Vibration Engineers

Mechanical Applications

MECHANICAL APPLICATIONS

COURSE CONTENT:

The ABB School of Maintenance brings you this specialised course in conjunction with Snell Infrared. This course addresses the needs in a timely and cost efficient manner, by providing the latest information on applications that are relevant to your job and personal development interests.

Level One or extensive thermographic experience is a recommended pre-requisite for this course.

This advanced course will focus on mechanical applications relevant to typical in-plant predictive maintenance and troubleshooting needs. Theparticipants, upon completion of the training, will be able to better utilise the imaging equipment to perform mechanical surveys at the site and will be able to more fully incorporate thermographic inspect ions in ex is t ing maintenance programmes. This will reduce unscheduled downtime, improve system performance and reduce maintenance costs.

Like all Snell Infrared courses, the emphasis is on practical real-world skill building, with incorporation of the theory relevant to these skills. In this course, theory will be limited to basic concepts of energy and work, heat as a process by-product, friction and pressure-temperature-volume relationships.

Rotating equipment (bearings, couplings, belts, gears and brakes)Prime movers (electrical motors, generators, gas engines and turbines)Gas systems and components including pneumatic and vacuum systemsLiquid systems (hydraulic systems, tank and silo levels and sludge detection)Energy and steam systems (heat exchangers, steam traps, condensers, heaters and boilers)Refractory and insulation, including kilns, process vessels and tank carsOther systems including vehicles, robots, conveyors, crushers and storage piles.

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WHO SHOULD ATTEND?

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Maintenance PersonnelEngineering PersonnelOperations PersonnelFacilities PersonnelConsulting Thermographers

Electrical Applications

ELECTRICAL APPLICATIONS

COURSE CONTENT:

The ABB School of Maintenance brings you this specialised course in conjunction with Snell Infrared. This course addresses the needs in a timely and cost efficient manner, by providing the latest information on applications that are relevant to your job and personal development interests.

Level One or extensive thermographic experience is a recommended pre-requisite for this course.

This advanced course will focus on electrical applications relevant to typical in-plant, utility and distribution systems. The participants, upon completion of the training, will be able to better utilise the imaging equipment to perform electrical surveys and will be able to more fully incorporate thermographic inspections in existing maintenance programmes. This will reduce unscheduled downtime, improve system performance and reduce maintenance costs.

Like all Snell Infrared courses, the emphasis is on practical real-world skill building, with incorporation of the theory relevant to these skills. In this course, theory will incorporate concepts of electrical resistance, power, heat and internal vs. external temperatures.

Motor control centres, panels and componentsExterior substations and componentsDistribution and transmission systemsTransformers, circuit breakers and busworkMotors, generators, batteries and power suppliesDC systems and circuitsInspection parameters, procedures and electrical safetyReporting, severity assessment and prioritisationInfrared inspection windowsUsing ultrasonicsAdding high emissivity targets

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WHO SHOULD ATTEND?

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Maintenance PersonnelEngineering PersonnelOperations PersonnelFacilities PersonnelConsulting Thermographers

Maintenance of Rotating Electrical Machines

MAINTENANCE OF ROTATINGELECTRICAL MACHINES

COURSE FORMAT:

COURSE CONTENT:

The cost of maintaining electrical motors is oftensuch a major item on the maintenance budget of production industries, that the ABB School of Maintenance has decided to bring you a first in maintenance training in South Africa. A training course series on Electrical Motor Maintenance to help you drive down motor maintenance cost. This course will help you understand electrical motors working, wear mechanisms and failure modes and will provide you with insight into maintaining electrical motors once you understand the underlying principles.

The emphasis lies on practicality and detail for this course. It has a “hands on” approach with many examples and case studies. It starts at the basic working principles of electrical motors and goes through to the latest condition monitoring techniques and equipment. Material is presented in such a manner that the student can easily relate to his/her own situation. It aims at a conceptual understanding of electrical motors and electrical motor maintenance at a paceengineers are accustomed to. Attention is given to the management of motor maintenance as well as the latest trends in the industry.

Theory of Rotating Electrical MachinesDesign of Rotating Electrical Machines Manufacture of Rotating Electrical MachinesApplication of Rotating Electrical MachinesInsulation Systems and WindingsVariable Speed DrivesFailure MechanismsMotor management: Maintenance, monitoring and protection basicsCondition monitoring

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WHO SHOULD ATTEND?

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All maintenance professionalsReliability EngineersMaintenance ManagersMaintenance SupervisorsMaintenance PlannersMillwrightsProduction ExecutivesOperations ManagersCondition Monitoring ManagersCondition Monitoring TechniciansElectrical Motor ManufacturersIndustrial Engineers

Vibration Analysis of Rotating Electrical Machines

VIBRATION ANALYSIS OF ROTATINGELECTRICAL MACHINES

COURSE CONTENT:

Numerous courses exist which cover the field of rotating machine vibration, but these courses tend to lack detail in the specific field of rotatingelectrical machines. This course focuses on vibration of rotating electrical machines, but still covers sufficient fundamental vibration material to benefit those who have had no previous formal vibration training. However, those who have covered basic and even advanced vibration courses will still benefit from the course if they are specifically interested in rotatingelectrical machines.

Classical Vibration FundamentalsVibration TerminologyApplication of Vibration to Rotating Electrical MachinesHow electrical machines differ in terms of vibrationStructured Methodology for vibration analysis on electric machines

The following aspects are covered:

Rotating Electrical machine componentsImportant electromagnetic theoryThree-phase fundamentals

Why three phases?Generation of three-phase voltagesRotating field due to three-phase supply

DC machines Synchronous machines

Salient-pole rotorCylindrical rotor

Induction machinesSquirrel-cage rotorsWound rotors

Torque, work, power, inertia and acceleration (equations of motion)Air-gap torque and shaft torqueTorque, power and inertia relationships across gearboxes and belt drivesVariable speed drivesMain failure typesStator failure mechanismsRotor failure mechanismsBearing failure mechanisms

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Rotor stresses Stator stresses Bearing stressesVibration spectrum analysis (and magnitudes)Current spectrum analysis Unbalanced magnetic pullMotor-induced versus supply-induced effectsRotor eccentricityTransient torques in induction machinesTransient torques in synchronous machinesSupply-induced transient torquesFault-related electromagnetic influencesThe importance of slip frequencyInterbar currents and their associated forcesElectromagnetic vibration = Current variation (CSA)How this leads to Current Spectrum AnalysisStructured vibration analysis methodology

All maintenance professionalsReliability EngineersMaintenance ManagersMaintenance SupervisorsMaintenance PlannersMillwrightsProduction ExecutivesOperations ManagersCondition Monitoring ManagersCondition Monitoring TechniciansElectrical Motor ManufacturersIndustrial Engineers

WHO SHOULD ATTEND?

Statistical Analysis of Failure Time Data

STATISTICAL ANALYSIS OF FAILURE TIME DATA

The availability of failure time data is literally growing day-by-day with the popularity of Computerised Maintenance Management Systems. It is now easier than ever before to obtain failure histories of plant equipment to help you optimise preventative maintenance strategies. The problem is, however, how should the data be analysed and the results be interpreted? This course on statistical analysis of failure time data is brought to you by the ABBSchool of Maintenance to solve the problem.

Objectives of the course:

The course aims to enable the student to analyse failure time data, totally self-reliant without being an expert in statistics. The course shies away from the fundamental underlying s ta t i s t i cs and concen t ra tes on the implementation and interpretation of the theory with one primary goal to maximise plant availability while minimising cost

Course Format:

Every learner must bring his/her own laptop computer with Microsoft Excel or Lotus 123 installed on it. (In the case of Microsoft Excel, make absolutely certain that the Solver Add-Onis installed). The theory of statistical failure analysis will then be explained with regular practical exercises in between, where the learner will have the opportunity to implement concepts on his/her own computer. Thisapproach enables the learner to take knowledge capital back to his/her organisation that can have an immediate positive effect on plant availability

This course may give you the competitive edge!

By applying the techniques learned from this course in your situation, your company may attain the competitive edge through an optimised preventative maintenance strategy.

COURSE CONTENT:

WHO SHOULD ATTEND?

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Statistical Failure Analysis In ContextMathematical and Statistical PreliminariesPreparing DataRenewal TheoryOptimisation Models Suitable for Renewal TheoryCase Studies / Practical Examples of Renewal TheoryShortcomings of Probabilistic Modelling and the Need for Repairable Systems TheoryElementary Point Process TheoryRepairable Systems TheoryOptimisation Models for Repairable SystemsCase Studies/Practical Examples on Repairable Systems Theory

The nature of the subject is such that, an above average mathematical or statistical background is required. Second year math or statistics on a University level is a must, to benefit from this course. Advanced computer literacy, especially on Microsoft Excel will be required. Typicallearners are:

University Graduates in EngineeringMaintenance Decision-MakersReliability EngineersEngineering ManagersProduction Executives

Gearbox Maintenance

GEARBOX MAINTENANCE

OBJECTIVES

Gearboxes are integral links between rotatingmachinery and end-applications in virtually every production line. Failures of gearboxes can result in costly production interruptions and secondary damage to equipment. For these and other reasons, the ABB School of Maintenance is presenting a course on the fundamentals of Gearbox Maintenance. The course aims to provide the maintenance fraternity with the know-how to minimize operational costs on gearboxes while maximizing availability through efficient and effective maintenance principles and practices.

Why must I know more about Gearbox maintenance?

Do you operate and maintain industrial gearboxes?Are you experiencing unexpected gearbox failures?Are your gearbox maintenance costs growing?Is unscheduled production down time due to gearbox failures unacceptable to you?

If you answered YES on any one of the questions above, this course is for you!

An industrial gearbox is the fundamental link between the prime mover and the driven equipment. Maintenance is therefore an essential part to ensure continuity in the process cycle. This course aims to provide students with a fundamental understanding on industrial gearboxes and the components that make it either function efficiently or fail. It further describes the tools and processes that are required to define a maintenance policy for various gearboxes. Finally, it also describes the philosophy of conducting a successful overhaul of a failed gearbox after an appropriate failure analysis has been conducted, to determine the root cause. In essence, it would provide the student with the ability to improve the standard of maintenance on his/her organisation ’sgearboxes.

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COURSE CONTENT:

WHO SHOULD ATTEND?

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FundamentalsMaterials and surface engineeringBearingsShaftsSealsGearbox applicationsExternal attachments lubricationMaintenance principlesHealth determinationCouplingsOverhaul principlesFailure analysis

Maintenance supervisorsMaintenance plannersCraftsmenMillwrightsCondition monitoring techniciansGearbox manufacturers

ABB South Africa (Pty) LtdSchool of Maintenance

ABB ParkThe Cresent3 Eglin RoadSunninghillSandton

Private Bag X37Sunninghill2157

Tel +27 11 236 7342Fax +27 11 236 7053abbsom@za.abb.com