Proposed Training Modules for Online course on Condition Monitoring

Module-1: Understanding maintenance philosophies

1. Breakdown or run-to-failure maintenance: When is it economically justifiable?
2. Scheduled or calendar-based maintenance: Is there a significant flaw in this method?
• Do machines fail when you expect them to fail?
• MTBF and MTBR
• The P-F curve
3. Predictive or condition-based maintenance
• The benefits
• Planned maintenance versus unplanned
• Is your plant ready for it?
4. Precision or reliability centred maintenance
• The philosophical difference
• The benefits
• Understanding OEE
5. Understanding risk
• Minimising risk
• Reliability, condition monitoring and insurance
6. Improving the bottom line: Cut maintenance costs or improve OEE?

Modue-2: Improving reliability

1. Taking care of the simple things
2. Bearing and seal installation
• A quick review of the importance of correct installation and operation of bearings and seals
3. Precision shaft and belt alignment
• The importance of precision alignment
• What is misalignment?
• How can you tell if a machine is not aligned
• An overview of shaft and belt alignment techniques
• Using dial indicators
• Using laser-based systems
• Correcting soft foot
• Dealing with thermal growth
4. Precision balancing
• The importance of balancing
• What is unbalance?
• How can you tell if a machine is not balanced
• An overview of the balancing process
• Single-plane balancing
• Two-plane balancing
• In-situ versus shop balancing
• Balance grades (ISO standards)
5. Resonance control
• What is resonance?
• How common is resonance?
• An overview to detecting resonance
• An overview to correcting resonance
6. Improving lubrication
• Understanding lubrication
• The importance of lubrication
• Contamination control
 7. Acceptance testing, FMECA and Root cause failure analysis
• Create a good plan with FMECA, and close the loop with RCA
Modue-3: Condition monitoring overview
1. Overview of condition monitoring
2. Is condition monitoring still necessary if you improve reliability?
3. Vibration analysis
• A quick review of the fundamentals
• The time waveform, spectrum analysis, overall level measurements
• How to collect vibration readings
4. A quick introduction to diagnosing unbalance, misalignment, resonance, looseness, rolling
element and journal bearing faults
• Implementing a simple program to get started
• Using portable analysers, on-line monitoring systems, and protection systems
5. Oil analysis
• What information can be revealed?
• What do the different tests mean?
• Contamination, oil cleanliness, particle counting, elemental analysis, and more
6. Wear particle analysis
• Why is it needed?
• Relating particle size, shape, and color to machinery components
7. Infrared analysis or thermography
• Understanding thermography
• Spot temperature and the flawed measurement techniques
• Infrared image analysis
• Being aware of emissivity and environment conditions
• Understanding resolution and focal length
• Applying thermography to mechanical and electrical systems
8. Ultrasound or acoustic emission
• How does it work?
• Applying ultrasound to mechanical and electrical systems
9. Electric motor testing
• A quick introduction to how vibration analysis and motor current analysis can detect faults
in electric motors
• Rolling element bearing testing
• A quick introduction to how ultrasound testing, vibration analysis, and oil analysis can be
used to detect bearing faults
10. Performance monitoring
• Integrating performance monitoring into the condition monitoring program
• Incorporating plant inspections into the condition monitoring program
11. Condition monitoring technologies and ISO and ASNT standards
• Training and certification
• The importance of plant-wide training
12. An overview to running a successful program
• Selecting the appropriate technologies
• Why programs succeed
• Why programs fail
Module-4: Case studies that demonstrate
• the financial benefits of predictive maintenance and reliability,
• how each technology can be implemented in order to detect fault conditions and diagnose
the severity and nature of the fault condition.