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Assessing and Improving Reliability of Rotating Equipment
Calgary, AB
(Oct 28 - 29, 2010)
Course Code: 01-0912-2119
After participating in this course, you will be able to:
• Discover how to monitor the condition of rotating machinery and how to diagnose problems using state-of-the-art
technology including thermal, lubricant and vibration-based fault detection and diagnostic techniques
• Gain a working knowledge of the techniques of reliability engineering and the ability to apply them effectively in
improving the maintenance, maintainability, and reliability of rotating machinery
• Develop the principles and practice of reliability-centered maintenance and of condition monitoring, how to interpret
the measurements and symptoms, and how to diagnose associated faults
• Add to your ability to evaluate the economic impact of reliability improvement activities and to achieve cost-effective
maintenance of your plant equipment
• Broaden your technical knowledge base leading to increased contributions in plant reliability, integrity and reduced
downtime as well as enhance your career advancement potential
Description
Reliable operation of the rotating equipment in any plant is its life blood. Engineers must have an integrated viewpoint focusing on it through design, operation and maintenance. This seminar comprehensively presents from such an integrated viewpoint state-of-the-art techniques and methodologies for improving reliability of rotating equipment.
Topics include reliability basics; maintenance philosophies and strategies, their relationships to each other, and their effective application; machinery condition monitoring; machinery condition assessment and asset management; effective fault diagnosis techniques; failure mode and causal analysis; life-cycle strategies to promote increased reliability; reliability improvement program development and implementation including structure and personnel considerations; and business ramifications of reliability improvement.
The course will comprise lectures and workshop to maximize your benefits. Additionally, an optional “Question and Answer” period is included to provide you with opportunity to get expert answers on your specific questions.
Objective
To provide a comprehensive understanding of the fundamentals and techniques underlying the assessment of rotating machinery reliability, detection and diagnosis of faults, and best practices for cost-effective reliability improvement.
Who Should Attend
Design, maintenance, machinery and plant engineers, supervisors and technicians as well as operations personnel involved in operation, condition assessment, troubleshooting and maintenance of rotating equipment in the manufacturing, chemical processing, pharmaceutical, petrochemical, power, mining, pulp and paper, food, and other process industries. Recent graduates will benefit within the short period of two days from years of experience of the instructor.
Program Outline
Instructor: Faculty: Nabil Al-Khirdaji, Kappa Associates International
Day I
8:00 Registration and Coffee
8:20 Welcome, Introduction, Workshop Preview, Learning Outcomes and the Assessment Method
8:30 Reliability Engineering
• Reliability basics
• Elements of world-class reliability
• Reliability prediction models
• Traditional approach to reliability prediction
• Failure mode and effect analysis
• Machinery reliability assessment
• Ascertaining the functionality and remaining life of rotating equipment
9:30 Maintenance Methods and Strategies
• Breakdown, preventive, predictive and proactive maintenance
• Reliability-centered maintenance (RCM)
• Precision maintenance
• Computerized maintenance management systems (CMMS)
10:30 Refreshments and Networking
10:45 Reliability Improvement Program Development and Implementation
• Program definition and development: structure, objectives, impact on business
• Reliability action teams: structure, training, mandate, and resources
• Identify and rank reliability deficiencies and associated lost production costs
• Critical poor performers (bad actors) identification and tracking
11:30 Reliability Analysis Software Review
12:00 Lunch
1:00 Economics of Machinery Failures and Reliability
• Improvement
• Cost impact of machinery failure
• Justification and economic evaluation of reliability improvement projects
• Financial concepts: capital assets, time value of money, life cycle costs and risk
• Life cycle costs methodology
1:30 Effectiveness of Reliability Deficiency Corrections
• Reliability performance indicators
• MTBF, MTTR
• Lost production cost
• Direct failure information
• Reporting
2:00 Vibration in Rotating Machinery
• Vibration fundamentals
• Vibration in condition monitoring
• Vibration monitoring and analysis methods – benefits and limitations
• RMS broad-band vibration meters
• Shock-pulse technology
• Diagnostic screening technology
• Narrow band vibration analysis
• Cepstrum analysis
• Automated diagnostic system for vibration analysis
• Intelligent (smart) machines
• Data interpretation
3:00 Refreshments and Networking
3:20 Industrial Lubrication
• Lubrication theory and practice
• Plant lubrication systems and programs
• Wear particle analysis technology; Ferrography techniques and instruments
• Bearing failures – Detection, diagnosis and prevention guidelines and tips
4:20 Stretch Break/Adjournment
4:30 Question and Answer Session with Instructor
This one hour optional session will provide an opportunity to get expert answers to your specific questions on course or related topics.
The adjournment will be at 5:30 pm but participants may leave when they feel the instructor has answered all their questions.
5:30 Adjournment
Day II
8:30 Machinery Component Failure and Analysis
• Common causes of component failures: bearings, seals, shafts, couplings, controls
• Design, application, materials, and installation factors
• Operating practices
• Maintenance practices and quality
• Wear failure models
• Troubleshooting guidelines
• Metallurgical failure analysis methodology
• Reliability of standby equipment
• Periodic exercising program
• Best industry practices, guidelines and tips.
• Impact of equipment standby practices on reliability and maintenance costs
10:00 Refreshments and Networking
10:15 Fault Causes, Detection, and Diagnosis
• Failure evolution process
• Bases for the detection of faults in rotating machinery
• Principles of rotor dynamics and balancing
• Mass unbalance
• Bent shafts – thermal distortion, large unbalance force
• Cracked shafts – vibration caused by fatigue-induced cracks
• Shaft misalignment
• Bearing lubrication, misalignment, and rubbing
• Excessive forces and moments by connected piping
• Equipment base plate grouting
11:30 Machinery Condition Monitoring
• On-line condition monitoring strategies
• Protection systems vs. diagnostic systems
• Parameters measured and measurement locations
• Typical field data collection processes and systems
• Remote monitoring and diagnostics
• Expert systems – smart machines
• Enhancements to CBM technologies
• Interpretation of measurements, trend analysis and diagnostics
12:30 Lunch
1:30 Machinery Failure Analysis and Prevention
• Troubleshooting rotating machinery
• Failure mode and effect analysis
• Failure investigation process
• Root cause failure analysis methods
• Corrective action: continue, repair, redesign, replace
2:30 Refreshments and Networking
2:50 Workshop
Work on machinery failure case studies and your own examples under the guidance of the instructor.
4:10 Questions and Answers and Feedback to Participants on Achievement of Learning Outcomes
4:30 Concluding Remarks and Final Adjournment
1.2 CEU / 12 PDH
Faculty
Nabil Al-Khirdaji
Nabil Al-Khirdaji, M. Eng., P. Eng. is president of Kappa Associates International, which provides engineering and project services to the petroleum, process, energy, and related industries. Nabil has taught many professional development courses, and he specializes in the areas of plant integrity and petroleum refinery and process plant equipment design and operation. Mr. Al-Khirdaji holds B.Eng. (Mechanical) degree from the American University of Beirut and M. Eng. degree from the University of Toronto. He is a registered professional engineer with the Association of Professional Engineers of Ontario, Canada.
Nabil has over 35 years of professional experience mainly in the petroleum, petrochemical and related industries, both in Canada and the Middle East, including 24 years with Shell Canada Limited. He assumed a number of project, engineering specialist, and engineering management positions with responsibilities covering design & construction; pressure equipment & piping; combustion & heat transfer equipment; mechanical equipment & drives; materials, corrosion & inspection; utilities & energy systems; and engineered safety. He also assumed the position of mechanical program director with EPIC, a primary provider of professional development training in Canada, and a senior project management position with an oil and gas engineering company in Milan, Italy. Mr. Al-Khirdaji served for several years on the API Committee on Refinery Equipment which oversees the development of engineering practices for the design, fabrication, installation, inspection, and use of materials and equipment in refineries and related processing facilities.
Nabil has developed and delivered well over a hundred technical professional development courses covering design, operation and maintenance of process plant equipment and piping systems. He has taught in Canada, USA, Saudi Arabia, Kuwait, Sudan, Yemen, Oman, Abu Dhabi, Dubai and Malaysia, on topics including API 579 Fitness-For-Service, Mechanical integrity in refineries and petrochemical plants, and Layout design of equipment and piping systems.
The fee for this course is $1,295 + GST. If you register after September 24, 2010 the fee increases to $1,465 + GST.
Venue Information
TBA
On-Site Program
EPIC programs can also be delivered on-site at your premises. For more information on our on-site program, please contact Tim Chugh at 1-888-374-2338 ext. 242 or by email at tchugh@epic-edu.com.
Group Discounts, Cancellations And Withdrawals
Registration covers all program materials, refreshments during breaks and lunch but excludes accommodation. For organizations sending more than one participant, the following discounts to the course fee apply: 10% discount to the second, 15% to the third, 20% to the fourth and 25% to the fifth and subsequent registrations.
To withdraw from a course, you must send your request in writing with the official receipt to our office:
• Fifteen or more business days in advance: full refund less $50.00 administration charge.
• Five to fourteen business days in advance: non-refundable credit of equal value for any future EPIC seminar within one year.
Credits are transferable within your organization.
In case of an unexpected event occurring after this time, you may send someone else to take your place without any additional cost. If a speaker is not available due to unforeseen circumstances, another speaker of equal ability will be substituted. EPIC reserves the right to cancel or change the date or location of its events. EPIC's responsibility will, under no circumstances, exceed the amount of the fee collected. EPIC is not responsible for the purchase of non-refundable travel arrangements or accommodation or any associated cancellation/ change fees. To avoid any fees or charges, please call to confirm that the course is running before confirming travel arrangements and accommodations.
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