Condition Monitoring Engineer: Equipment Monitoring & Performance Analysis
The reliability of any engineering system depends heavily on the likelihood of failure occurrence. The
vendor dictates such reliability, and once the equipment is purchased, maintenance and operations are
confined to the limits of the purchased equipment. Proper maintenance, monitoring, and performance
analysis must be conducted to ensure the reliability of the equipment. Unfortunately, the way we
operate and maintain equipment impacts their reliability heavily.
- Define what is considered a fault and equipment failure modes
- Understand Criticality analysis and when to implement condition monitoring
- Gain an understanding of common fault types for Turbomachinery equipment
- Have an appreciation of different fault-finding strategies and the ability to select strategies
- Recognize the most important programs that are needed for efficient maintenance
- Ability to implement popular NDT such as: Thermography, oil analysis, acoustics, etc.
- Understand Vibration signatures-based diagnosis techniques
- Analyze faulty components to find root causes: Bearings and Seals as examples
- Implement condition-based maintenance, failure analysis, and AI-based predictive maintenance
- Analyze and interpret equipment performance trends and failure patterns
Instrumentation and control engineers, Maintenance engineers and technicians, Process engineers, Operations supervisors.
This interactive training course includes the following training methodologies as a percentage of total tuition hours :
- Lectures
- Workshops, work presentations ,
- Group Work in case study & Practical Exercises.
- Videos and general discussions
- Pre-Test and Post Test
Course Outline
Opening and Ice Breaking, Pre-assessment Test (Optional)
Introduction and Review
- Energy: An overview
- Fundamental principles of Materials: Stress-strain curve
- Fundamental principles of fluids: Properties of fluids, Basics of flow in pipes, Pressure, Pressure Drop, Head, Priming.
- Common Mechanical Failure Modes
- Exceeding Mechanical Limits
- Force: Tension, compression, and bending Torque: Torsion Stress and Strain Thermal expansion.
- Fatigue, Creep, Corrosion, and Erosion
- Surface finish degradation mechanisms
- Popular Mechanical Components operations, failure modes, and monitoring: Bearings, Shafts, Alignments, Gears, and Gearboxes
Condition Monitoring Fundamentals
- Overview of Equipment Reliability.
- Preventive Maintenance: Time-Based versus Condition-Based
- Failure Modes and Effects Analysis (FMEA)
- Needs and advantages for Condition Monitoring
- Equipment criticality assessment
- Condition Monitoring Maintenance Package Selection (RCM)
- Predictive Maintenance and AI
- Tools of analysis: Five Why and FEMA
- API and ASME Related Codes and Standards
- Applications: Centrifugal Pumps
Mechanical Vibrations
- Vibrations Overview
- Causes of vibrations: Mechanical, Dynamical, and Hydro-dynamical
- Effects of vibrations
- Control of vibration
- Vibration Monitoring
- Diagnosis using vibration signatures: SKF and Bently Nivida
- ISO Related Codes and Standards
- Applications: Rotating Equipment
Non-Destructive Testing for Failure Analysis
- Thermography: IR camera operation, friction, and heat patterns
- Electrical component monitoring and failure patterns
- Lubrication and Wear Particle Analysis: Oil sampling, Ferrography and particle counting, Contamination control strategies, and Surface degradation mechanisms.
- Acoustic emission for leak detection and greasing o Related Standards: ASME, ISO, and NFPA o Application
- Maintenance Strategies and Program Implementation
- Maintenance Strategies Overview
- Maintenance Proactive techniques
- Root Cause Failure Analysis: Cause Effect Mapping
- Condition Monitoring Program Implementation, Performance Measuring – KPI, Benchmarking, and Sustainability: continuous improvement processes
- Application: Analyzing faulty parts: Bearings, Mechanical seals, and Shafts