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Reliability Solutions, Essential Craft Skills 1: Precision Maintenance, Assembly & Installation

Date: Jun. 5, 2017–Jun. 9, 2017

Time: All Day

Location: Estabrook Hall Room 13

Members: $1,800

Non-Members:  $1,950

 

 

Course Description:

Machinery Assembly and Installation … Although all craft technicians have a set of basic skills, all too often we have found that they have forgotten, never used, or were not taught correct “precision” principles and techniques. In the assembly, installation, repair and day to day care of facility assets we have not always understood or applied correct reliability principles. Maintenance has typically been viewed from a “remove and replace” or “get it going” perspective and rarely includes; long term, lowest cost, highest manufacturing, and reliability/profitability perspectives. This seminar is a set of essential reminders and refreshers with new information that is meant for immediate field use.

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 runability are also discussed. A special section on measuring tools, lubrication techniques and doing the job right the first time are introduced. 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.

The seminar is aimed towards participants with a mechanical craft background but production operators and engineers will find the seminar valuable and first line supervision is encouraged to attend to demonstrate advocacy and understanding for renewed essentials. The seminar is five days in duration. (Alignment techniques are demonstrated using the “Reverse Dial” alignment method to enhance session visual impact; all principles can and should be applied to laser technology alignments as well.)

Subjects … Included but not limited to:

Introduction to Precision

  • Maintenance Philosophies
  • Cost per HP per Year
  • Machinery Failure Pie
  • Changing Craft Responsibility

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
Click Here for more information on the R&M Engineering Implementation Certificate Program.

 

 


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