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Reliability is the ability of a system to perform its required function under stated conditions for a specified period of time.
In real life however, actual plant reliability is almost always lower than it was designed for and built to achieve.
There are various reasons for not achieving this 'design reliability' which this course sets out to address.
It presents a typical reliability program; the implementation thereof and trains attendees in the key areas of
plant reliability with particular focus on the differences that can be achieved by focussing at shop floor level.
Who should attend?
Plant Engineers, Reliability Engineers, Consulting Engineers, Maintenance Managers, Instrumentation Technicians,
Pump Operators, Artisans, Mechanical Foremen, Process Engineers and Equipment Specialists.
Course outline:
1. Reliability Program Basics
- Introduction
- Program audit
- Program implementation
- Program metrics
2. Reliability Program Elements:
2.1 ASSET CARE
- Precision Maintenance (Procedures & Standards)
- Equipment installation
- Alignment
- Balancing
- Lubrication application
- Asses current lubrication process/practices
- Assess equipment criticality
- Develop measurable objectives
- Conduct lubricant requirement assessment
- Develop database with SOP's and schedules
- Evaluate results against objectives
- Contamination control
- Types of contaminants
- Establish component sensitivity to contaminants
- Develop cleanliness levels
- Identify contamination sources
- Set contamination control specifications
2.2 ASSET MONITORING
- Vibration
- Overall signal monitoring
- Fundamentals of vibration analysis
- Frequency spectra analysis
- Time waveform analysis
- Machine fault analysis
- Oil Analysis
- Analyse oil properties, contamination & wear
- Typical oil analysis tests/test classes/test slates
- Interpreting results
- Program implementations steps
- Select equipment, test slates & procedures
- Select sample location/sample frequency
- Ensure proper sampling & equipment information
- Evaluate results, action recommendations
- Infrared thermography
- IR fundamentals (devices, physics, benefits,limitations)
- IR inspections; qualitative vs quantitative
- Industrial applications
- General Plant Health Inspections
- Role of operators (24/7 @ machines)
- Inspection guideline
- Human senses (look, listen, feel, touch, smell)
- Operational parameters (temperature, pressure,flow)
- Product quality & performance monitoring
- Precision Machine Health Inspections
- Installation
- Couplings, belts, seals
2.3 Asset Improvement
- Root Cause Failure Analysis
3. Reliability Program Benefits
- 3.1 Reduced maintenance costs
- 3.2 Increased MTBF
- 3.3 Increased profits
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