High Precision Maintenance - Reducing common assembly errors in equipment to exponentially extend MTBF
Learn How to Easily Double or Triple Rotating Equipment Life by making vibration much lower through the elimination of common assembly errors and adherence to rigid precision installation, rebuild, and maintenance standards which we will show you how to achieve with little or no extra downtime.
Programme
Participants will dis-assemble, re-assemble, correct defects, perform precision alignment for both in-line coupled & v-belt driven machines, and measure the noticeable improvements as common field & shop assembly errors are eliminated from our running and static simulators.
Day 1
- Overview of the week - Why are we here, why are we being asked to change, what’s the week’s objectives? What’s happening in industry? Why Precision Maintenance and what can it do for our equipment life
- Machine failure patterns, failure history in another typical plant / company
- Layman’s understanding of vibration, balance standards, and how it all relates to reliability
- Most common assembly errors, fits & tolerances, soft-foot and how to avoid and/or or correct
- Precision measurement, new and used Parts
- Hands On - Run simulators for initial as found vibration, amp, temp – Record all
- Hands On - Rough align – Run for results
- Hands On - Measuring tools
Day 2
- Measurement continued from day 1, bearings, shafts, housings, fitment guidelines
- Fits and tolerances
- Torque, fasteners, and torqueing, keys and keyways
- Bearings, bearing failure sources, heaters, wear patterns, correct and incorrect lubrication
- Pre-alignment requirements, checklist for rough-in, assembly errors found and eliminated
- Hands On - Find and eliminate all common assembly errors most have never seen
- Hands On - Run simulators for results, Hands On – Bearing tolerances simulator
Day 3
- Intro to precision alignment, tolerances, measurements, thermal growth
- Plotting to learn what the laser and indicators are trying to tell us to do. Optimum moves
- Hands On - Precision alignment of simulators
- Hands On - Alignment complete and final “as left” readings compared
- Hands On - Pipe strain - How a little goes a long way to disrupt your precision alignment
Day 4
- Thermal Growth, Field Measurements, Plotting Corrections
- Energy cost and benefit
- Balance, Unbalance
- V-Belts, tensioning, sheaves, alignment exercises
- Hands On - Balance Exercises
- Hands On - Thermal Growth
- How to implement Precision - Tools needed – processes
- Summary – End of Training discussion
Learning objectives
- Understand what Precision Maintenance is & how to achieve
- without extra downtime
- How to identify and avoid common assembly errors
- Understand and correct common fit & tolerance problems
- Learn basic bearing installation problems and corrections
- Learn what is good, fair, and bad vibration & how it affects equipment life
- How to lower vibration & exponentially improve bearing life (MTBF)
- How to significantly improve and retain balance
- How to improve upon "status-quo" alignment standards & achieve precision alignment
- How to create smooth running belt drives
- How to reduce energy consumption 5%, 10%, or more on most equipment
- Learn common lubrication errors & how to avoid
Method
Participants can immediately apply the theory from the lesson to the running and static simulators.
Recommended audience
Maintenance and construction craftsmen, planners, engineers, and supervisors.
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10 Steps to reliabile precision maintenace - This customised workshop provides an overview of these basic steps and shares tangible results in implementing Precision Maintenance for Reliability.
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