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Machinery Failure Analysis & Repair Methods

5 jours MTM/RUPT-E
Niveau
Expertise
Public
  • Maintenance supervisors, engineers and technical staff involved in rotating machinery maintenance and technical inspection.
Finalité
  • This course enhances the maintenance staff skills through a clear understanding of machinery failure analysis.
Objectifs
  • To prevent mechanical failures and reduce operating costs.
  • To apply a methodology to identify the type and the failure root cause.
  • To propose improvements on machinery reliability.
Les + pédagogiques
  • Case studies based on industrial & actual feedback.

FAILURE ANALYSIS 3 jours
  • Rupture phenomena
  • Ruptures study: material characteristics, influences of metallurgy and surface treatment, design parameters, consequences due to the modification of material behavior.
  • Characteristics of the main kind of ruptures: tensile and compressive stress with necking appearance, influence of the resilience and the transition temperature with regards to the service temperature, mechanical fatigue.
  • Rupture face analysis: mechanisms of rupture, surface morphology.
  • Solutions to avoid rupture: design parameters, limiting stresses, operating conditions & limitations.
  • Wear phenomena
  • Wear study: friction principle with friction factor and wear rate, tribology.
  • Characteristics of the main kind of wear: adhesive wear depending on the lubrication mode, abrasive wear through particle presence, erosive wear due to flow, mechanical surface fatigue on gears and bearings.
  • Morphology of a worn surface: temperature colors, scratching, scoring, seizure.
  • Solutions to avoid wear: design parameters, limiting friction, operating conditions.
  • Case studies: rupture and wear examinations of machinery parts (bearings, mechanical seals, rotors), analysis of some failures on process centrifugal pumps, reciprocating & centrifugal compressors and gearbox.
REPAIR AND RENOVATION WORK 2 jours
  • Repair philosophy: integrating all the criteria to choose the best solution: repair or replacement.
  • Different modes of repair: welding, surface treatment, metal striching, deposits (HVOF application).
  • Costs: repair costs, delivery time, on site capabilities.
  • Case studies: description of different approaches used to repair some machines and components.