Predictive Maintenance Power: Unlock Your Machinery Potential

Course overview

The stakes in today’s oil, gas, and process plants are extremely high and they are quite complicated. These plants are made up of pipelines and other rotating and stationary equipment. These devices must not abruptly malfunction while in use. A corporation may not be prepared to bring production back online in the event of a sudden breakdown failure, in addition to the obvious safety, health, and financial consequences that result.

Modern inspection and maintenance methods support Predictive Maintenance, which uses vibration analysis and condition monitoring to give adequate warning about the deteriorating states of equipment/machines in advance.

For big rotating machines without standbys in the plant, such as turbo-compressors and turbo-generators, online vibration analysis is essential. Vibration analysis and condition monitoring are crucial for all machinery and equipment to plan maintenance without surprises.

Simple portable vibration data collectors to sophisticated built-in online Vibration Monitoring and Diagnostics Systems are all used in vibration monitoring. Tools for online condition monitoring include temperature sensors and profilers, acoustical emissions techniques, bearing analyzers, machinery stethoscope, ultrasonic integrity testing, and more.

Participants in this Training Bee training session will leave with a thorough understanding of “Predictive Maintenance, Vibration Analysis, and Condition Monitoring of Machines.”

Introduction

A specific training program called Predictive Maintenance, Vibration Analysis, and Condition Monitoring of Machines was created to give professionals and technicians the information and abilities needed to guarantee the dependability, safety, and effectiveness of machinery in a variety of industries. With an emphasis on vibration analysis and condition monitoring techniques, this training covers important facets of predictive maintenance.

A crucial training course for professionals in sectors where machine dependability and operational effectiveness are top priorities is called Predictive Maintenance, Vibration Analysis, and Condition Monitoring of Machines. Participants are given the knowledge and abilities necessary to preventatively manage and maintain machinery, which ultimately boosts output and decreases downtime.

We are The Training Bee, a global training and education firm providing services in many countries. We are specialized in capacity building and talent development solutions for individuals and organizations, with our highly customized programs and training sessions.

Learning Objectives

Upon completing Predictive Maintenance, Vibration Analysis and Condition Monitoring of Machines, participants will be able to:

• Recognize the fundamental ideas behind vibration analysis, predictive maintenance, and equipment condition monitoring.
• Discover the basics and benefits of predictive maintenance.
• Learn about the hardware, such as probes and data processing tools, as well as the analysis software that goes along with vibration monitoring.
• Understand different types of condition monitoring, including ferrography, temperature rise, pressure fluctuation, rotating machine bearing checks, condition trending using internal process parameters, and analysis of the fluid composition at the output of processes, equipment, and machines.
• Understand the significance of, and planning centered on, condition monitoring, vibration analysis, and predictive maintenance in oil, gas, and process plants.

Our Unique Training Methodology

This interactive course comprises the following training methods:

• Journaling – This consists of setting a timer and letting your thoughts flow, unedited and unscripted recording events, ideas, and thoughts over a while, related to the topic.
• Social learning – Information and expertise exchanged amongst peers via computer-based technologies and interactive conversations including Blogging, instant messaging, and forums for debate in groups.
• Project-based learning
• Mind mapping and brainstorming – A session will be carried out between participants to uncover unique ideas, thoughts, and opinions having a quality discussion.
• Interactive sessions – The course will use informative lectures to introduce key concepts and theories related to the topic.
• Presentations – Participants will be presented with multimedia tools such as videos and graphics to enhance learning. These will be delivered engagingly and interactively.

Training Medium

This Predictive Maintenance, Vibration Analysis and Condition Monitoring of Machines training is designed in a way that it can be delivered face-to-face and virtually.

Course Duration

This training is versatile in its delivery. The training can be delivered as a full-fledged 40-hour training program or a 15- hours crash course covering 5 hours of content each day over 3 days

Pre-course Assessment

Before you enroll in this course all we wanted to know is your exact mindset and your way of thinking.
For that, we have designed this questionnaire attached below.

• What is your present position or field of expertise, and how does it relate to preventive maintenance, vibration analysis, or machine condition monitoring in your company or sector?
• Have you had any official instruction or certification in condition monitoring, vibration analysis, or a comparable field? If so, kindly give further information.
• Could you give a brief overview of your experience maintaining machinery, including any participation with condition monitoring, vibration analysis, or predictive maintenance methods in your present or former roles?
• Describe how you think about preventative maintenance and its importance to machine dependability and cost savings.
• Describe your familiarity with vibration analysis, including your understanding of its fundamental concepts and its use in identifying mechanical issues.

Course Modules

This Predictive Maintenance, Vibration Analysis and Condition Monitoring of Machines cover the following topics for understanding the essentials of the Agile Workplace:

Module 1 – CONCEPTS

• Equipment/Machines in the Plants
• Maintenance Planning
• Analysis of Vibration
• Monitoring Situation

Module 2 – BREAKDOWN MAINTENANCE VS. PREDICTIVE

• Cost benefits and business repercussions
• Industry trends worldwide
• Environmental, health, and safety benefits
• Procedures based on risk

Module 3 – QUAKES (SESSION-1)

• Cause of Vibration and the Physics at Work
• Rotational and stationary equipment vibration: comparative analysis
• Vibration detection Probes: Acceleration, Velocity, and Displacement
• Vibration threshold limits and acceptance standards
• Both permanent and portable tools as well as advanced instrumentation
• Gathering, analyzing, and monitoring data

Module 4 – QUAKES (SESSION-2)

• Analyses of vibration cases
• Vibrations could develop if maintenance is not done on time.
• Machine industry advancements: balancing spinning components
• Vendors who sell equipment and tools
• Service providers for data collecting, issue diagnosis, and problem resolution

Module 5 – Monitoring of conditions (Session-1)

• What circumstances can cause machines or equipment to degrade?
• Variations in the state of the machinery and equipment in the active plant
• Variations in condition as a sign of a deteriorating trend
• Tools for capturing variations

Module 6 – Monitoring of conditions (Session-2)

• Initial situation
• Online status
• Condition based on risk
• Risk-based surveillance

Module 7 – WORLDWIDE INDUSTRIAL TRENDS

• Machine monitoring is more prevalent than human health is monitored by medical professionals.
• The comparison between business and condition monitoring in medicine
• Predictive maintenance is a lifeline and a widely used tactic today.
• The field of condition monitoring and diagnosis is well-regarded.

Module 8 – SECTIONS OF VENDORS

• Types and ranges of tools for data collection and diagnosis available Local vs. foreign suppliers with brand-name products and services
• Instruments for vibration and condition monitoring need to be calibrated and validated.
• Examining, maintaining, manipulating, and storing these devices properly

Module 9 – EXACTLY HOW DO I CHOOSE SERVICE PROVIDERS?

• What details should I give them?
• Data logging assists professionals in trend analysis, diagnosis, and solution development.
• Professional remote/virtual diagnosis of a complex issue
• Trusted international service providers

Post-course Assessment

Participants need to complete an assessment post-course completion so our mentors will get to know their understanding of the course. A mentor will also have interrogative conversations with participants and provide valuable feedback.

• Give an explanation of the foundational ideas of preventative maintenance that you have learnt in this course.
• How might preventative maintenance help to increase equipment dependability and save downtime?
• Discuss your expertise in vibration analysis, including your capacity for reading vibration data and locating mechanical issues.
• Describe your knowledge of different condition monitoring techniques, including oil analysis, thermography, and ultrasound, and how they can be used to evaluate the health of machinery.
• As mentioned in the course, emphasize the value of safety when undertaking tasks such as condition monitoring, vibration analysis, and predictive maintenance.
• Describe the protocols and safety measures that must be taken.
• Think about how well you could use the information and abilities you learned in this course in the workplace.

Lessons Learned

The Importance of Predictive Maintenance: Participants ought to have developed a profound understanding of the significance of predictive maintenance in the management of contemporary machinery. Predictive methods allow for the early discovery of faults and aid in averting expensive failures.

Vibration Analysis as a Diagnostic Tool: Participants should have left the program with the knowledge and abilities necessary to effectively utilize vibration analysis as a diagnostic tool. They should be able to recognize machine flaws including imbalance, misalignment, and bearing wear by interpreting vibration data.

Diverse Condition Monitoring Methods: Participants should be aware of the importance of various condition monitoring methods, such as oil analysis, thermography, and ultrasound. They ought to be aware of how these techniques work best when combined to evaluate the condition of machines.

Safety First: The training ought to have stressed the significance of safety in operations involving condition monitoring, vibration analysis, and predictive maintenance. In order to safeguard themselves and their fellow participants, participants should put safety procedures first.

Practical Application: Students should be able to use the knowledge and abilities they’ve learned in class to solve problems in their employment. They must to have faith in their potential to improve machine dependability and cut downtime.