Alignment Methods and Application of Rotating Machinery and Trouble Shooting

Introduction

This course is designed to explain the effective method of component condition monitoring for use as both a predictive maintenance and root cause analysis tool. It also details the major failure causes, the world-class proven root cause analysis procedure with exercises and case histories, installation, pre-commissioning planning, functional testing and commissioning, preventive maintenance strategies and more.

This Couplings & Shaft Alignment training course will provide an overview of coupling designs and applications for transferring the torque and rotation from the driver shaft to the rotating machine: pump, compressor or turbine. The training course will indicate the importance of good installation, maintenance and failure analysis of couplings. The topics are specially designed for engineers and technicians that have had limited exposure to couplings and need to upgrade their technical knowledge about coupling characteristics and various operating loads. The focus in the course will be on problem detection, root cause analysis, and failure prevention.

Shaft alignment is a technical skill that is categorized as a specialty. It requires measurement instruments and relies on technician’s skill and experience if good results are to be expected on pumps, compressors or turbines. This training course will provide integral training knowledge and experience of shaft alignment to solve misalignment problems in rotating machinery. Emphasis will be on the ways to analyze, identify and correct the root causes of misalignment, unbalancing and vibration in order to achieve smooth operation, and improved machine performance.

Objectives

At the end of this training course, you will learn:

• Guidelines for good coupling installation
• Solving common coupling problems and failure prevention
• Vibration monitoring related to coupling health and machinery performance
• Methods and practices for efficient alignment of rotating machine
• Use of classical reverse dial methodology and modern laser optic technique
• Develop an in-depth understanding of rotating equipment reliability optimization & continuous improvement and recognize the concept of organizing for world class operations particularly the characteristics and steps used toward pacesetter performance
• Review equipment failure patterns and maintenance effect on reliability and discern how maintenance influences equipment performance.
• Heighten awareness and understanding of root cause failure analysis (RCFA) by relating to its step by step process.
• Know the principle of predictive maintenance and be able to employ the various predictive maintenance & component condition monitoring techniques and apply its importance in rotating equipment reliability optimization and continuous improvement.
• Understand the concept of optimizing reliability particularly condition monitoring and predictive maintenance and be able to identify its components and importance 

Training Methodology

Maintenance Auditing and Continuous Improvement is a highly interactive training course with opportunities to advance your opinions and ideas. Participation is encouraged in a supportive environment. To ensure the concepts introduced during the program are understood, they will be reinforced through a mix of learning methods, including lecture-style presentation, open discussion, case studies, simulations and group work.

Who Should Attend?

• Professionals dealing with the operation and maintenance of rotating equipment
• New technicians who wish to improve knowledge and skills
• Those who are involved in condition monitoring and vibration analysis
• Maintenance technicians who are in charge of correcting the machinery problems.
• Engineers and maintenance planners involved in the machine’s condition monitoring

Course Outline

Day 1: Couplings - Types, Application & Operation

• Classification & Application of Couplings

• Characteristics of Rigid Couplings

• Characteristics of Flexible Couplings

• Selection of Parameters of Couplings for Pumps & Compressors and Turbines

• Advantages & Disadvantages of Different Types

 Day 2: Couplings - Installation, Maintenance & Troubleshooting

• Installation Best Practices & Safety Issues

• Coupling Inspection in Operation

• Vibration Monitoring and Analysis

• Preventive Maintenance & Condition Monitoring

• Failure Prevention & Troubleshooting

 Day 3: Shaft Alignment Basics

• Need for shaft alignment

• Effects of shaft misalignment

• Types of misalignment: offset and angularity

• Measuring techniques

• Rim and face alignment method: TIR determination

 Day 4: Alignment Measurement Methods

• Reverse dial methodology

• Correcting misalignment: foundation and soft foot

• Thermal growth determination

• Laser optic technique

• Misalignment detected by vibration monitoring

Day 5: Effect of Misalignment on Bearings & Seals

• Effect of misalignment of bearings

• Vibration monitoring results as indication of misalignment

• Effect of misalignment on seals of pumps and compressors

• Leakage control & prevention