Turbo-machinery and rotating machinery equipment play a significant role in numerous industrial plants. In many cases, when these machines experience premature and chronic bearing failures, they are often replaced without undergoing a thorough investigation using root cause analysis (RCA). However, what is truly disheartening is that these machine breakdowns could have been prevented, as they often exhibit early symptoms (such as vibration signatures) before experiencing complete or partial failure. The purpose of conducting a basic root cause failure analysis for the bearings is to equip facility personnel with the necessary skills and knowledge to identify and address the problems and chronic failures they encounter in their daily work, ultimately aiming to eliminate such issues.

Course Objectives:

To familiarize participants with problem definition, generating solutions, enforce solution implementation and evaluate situations
To familiarize and illustrate the theory of root cause failure analysis and its usage for solving chronic problems with bearings
To illustrate how to analyze failed bearings (noisy, heat, vibration, etc.) and their components
To learn about bearing support of loads and mounting
To know the causes of bearing failures and ways to prevent them
To highlight the need for lubrication and its role in bearing failures
To gain more knowledge about bearings predictive maintenance techniques
To illustrate bearings vibration measurement and analysis to health monitor machine conditions using the vibration signatures
To improve the ability of the participants to maintenance and troubleshoot of bearings via industrial case studies

Who Should Attend?

This course will benefit mechanical, rotating equipment and reliability engineers, maintenance, machine repair, technicians and managers responsible for dealing with rolling bearings performance and reliability. Applications of this root cause failure analysis for bearings are widely open, including a diversity of machines such as pumps, compressors, fans, blowers, engines, steam turbines, gas turbines, and electric motors, etc.

The course is of interest to those working on power plants, pumping stations, gas boosting stations, desalination plants, oil rigs, chemical industry, petrochemical industry, off-shore structures and all other industries using the previous machines.

Course Outlines:

The theory and function of a bearing while supporting loads
Bearings technology and types
Mounting damages
Operating environment and its effects on the bearing components
Maintenance practices and their effect on the bearing (improper installations)
Lubrication: marginal and excessive
Bearings reactions to contamination, moisture, abrasive, etc.
Vibration/impact damages (sources, identification, and solutions)
Causes of bearing failures
Troubleshooting and problem-solving skills and generation of solutions
Root cause failure analysis technique illustrated
Failure classifications
Bearings collected data organization and analysis: sequence diagrams, why-why, how-how, fishbone and fault tree analysis
How to analyze a failed bearing
Applications: pumps, gearboxes, motors, fans, extruders, compressors etc... See and inspect sample photos of bearings that have failed - identify, and interpret actual bearing failures
Vibration signatures analysis for pining bearings failures
Case studies: compressor journal bearing failure (participant will practice a complete drill on bearings root cause failure analysis)

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