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Assembly and Installation – Course 4

Date: Aug. 14, 2017–Aug. 18, 2017

Time: 8:00 am–5:00 pm

Location: Estabrook Hall Room 13

What can you expect to learn in Assembly and Installation?

Preface:

Upon completion of this course students will understand the procedures needed for effective installation and operation of rotating equipment. Topics include; correction of common assembly errors, typical machinery case and associated pipe strain distortion problems, steps to obtain precise, documented and known “cold” machinery alignment, balance retention and how to improve asset balance quality, and review a “performance” report that states as found and as left conditions with the use of dynamic measurement tools to extend asset reliability. Attendees will have a better appreciation of how bearing and lubrication failures degrade machine life. Participants  gain the knowledge of how correct procedures and processes must be in place to reach reliable manufacturing goals. Attendees will use these procedures and processes as part of an ASD/RCA processes for developing equipment care strategies and determining true failure root causes. Students will return to the plant with the ability to review current practices and suggest improvements for the use of precision tools, machine assembly / installation procedures and practices.

Objectives:

We start by introducing attendees to the various maintenance philosophies and where each is correct. Next, is an understanding of how technicians can use overall and bearing specific vibration instrumentation to discover and prove machinery improvements. Attention is paid to coupling assemblies and their purpose, rolling element bearing types and their applications, belt drives, and precise alignment principles. Torque requirements and procedures, common assembly errors and the difference between reliability and run-ability are also discussed. A special section on measuring tools, lubrication techniques and doing the job right the first time are provided. Technicians use hands-on, live and dynamic demonstrators with exercises to reinforce correct principles and practice new techniques. Attendees will find the seminar informative, loaded with practical tips, and finish with a renewed sense of readiness and a fresh approach to maintenance activities. This crucial foundation course assists technicians to develop correct assessment, measurement, troubleshooting and precise reliability improvement habits. This initial module develops techniques and corrections for “facility common” errors that may constitute as much as 70% of facility failures.

Subjects (included but not limited to):

Introduction 

  • Report out  of previous class assignments

Vibration as a Tool 

  • Term familiarity

  • Understanding alarm & precise levels

  • Determining what parts are failing

Fitting Housing and Shaft

  • Determine proper shaft and bearing fit.

  • Problems with Housings and Shafts

  • Error Prevention

  • Precision Measurement Tools

​Assembly Errors

  • Proper fitting of keys

  • Coupling types and common problems

  • Set screw techniques, nicks and burrs

  • Correct torquing & heating practices

Practical Lubrication 

  • Greasing Techniques and tools to measure

  • Correct re-lube amounts & intervals

 Precision Belt Alignment Aligning 

  • Four Faces

  • Axial position

  • Adjustable Sheaves

  • Understanding Sheave Eccentricity

  • Achieving Correct Tension

Understanding Precision Shaft Alignment 

  • Pre-alignment Checklist

  • Alignment Tips, Precautions & Tolerances

  • Plotting the relative shaft position

  • Practical removal of “soft foot”.

  • Knowing the “best” move each time.

  • Introduction to Thermal Growth

Understanding Bearings

  • Don’t destroy the evidence

  • Brinnelling, Apex Zone, Fretting, Spalling, Fatigue, L10 Life, Radial Internal Clearance.

  • Bearing Failure Sources and Failure Stages

  • Introduction to: Conrad, Max Capacity, Self Aligning, Angular Contact, Spherical, Cylindrical, Needle, Pillow block and Journal Bearings

  • Seals, shields & using bearing heaters Tracking of misalignment in bearings

Unbalance 

  • What is it? … Static/Couple/Dynamic

  • Tolerances & retention depends on you!

Common Machinery Errors 

  • Motors, Fans, Pumps, Gearboxes and others

Target Participants:

ERMS  has been carefully designed for anyone who has a role in reliability including Production and Maintenance leaders, supervisors, engineers, and lead hands. Reliability leaders, managers and engineers.

Prerequisite: 

ERMS Bootcamp and Course 2


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