PM/ECCM Course Description and Outline

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1 PM/ECCM Course Description and Outline Preventive Maintenance/Essential Care and Condition Monitoring is one of the cornerstones in a world-class reliability process. Condition monitoring will provide early warning of failures and feed into the planning and scheduling process for corrective action. Preventive maintenance is actions that prevent failures from happening and/or extends life of components IDCON s PM/ECCM training will give your group the ability to understand how to set up and improve a whole PM/ECCM system cost effectively. The understanding will be based on basic reliability concepts such as failure developing, equipment life, inspection frequencies, and selection of maintenance methods together with IDCON s unique documentation methods. The class will practice PM/ECCM documentation techniques for equipment during the class. The class will also introduce inspection tools and inspection techniques for operations and maintenance. In the customized version there are field exercises and field tours together with the instructor. Please note that for onsite training we will focus on the areas within your PM program that we find have the most opportunity to impact your organization. The Topics with Green Headings are covered in IDCON s standard training, which is delivered both onsite and as public trainings. Course Objectives How to cost effectively optimize your preventive maintenance program Understand available techniques for preventing failures Available condition monitoring options Practically practice documenting full preventive maintenance tasks for equipment Discover how to financially prove results from preventive maintenance The reliability basics such as equipment life, failure developing, and different maintenance methods Find out about the different implementation steps for improving preventive maintenance in your plant Who Should Attend Maintenance Supervisors Maintenance Planners Craftspeople Operators Operations Supervisors/Superintendent Reliability Engineers Maintenance Managers Overview Definition of Maintenance Do the right thing or do things right are you focusing on the right things? 1

2 Mission of PM/ECCM improvement Goal of PM/ECCM improvement Example of plant goal and mission statements statement Definition of Failure Definition of Breakdown Definition of Failure Source Definition of PM/ECCM Exercise develop PM/ECCM definition Overall Process for PM Development Scope out and Prepare o Defining o Equipment List o Criticality Assessment and Priority o Collecting Information o Assembling the Team o Developing the Project Plan Process To Select Maintenance Method and Task Selection o Document: Function and Components o Failure Modes o Method and Essential Care Task Creating the Program and Implementing Trial Implementation and Test Practicality Develop Checklists, Routes and Standard Job Plans Final Implementation and Training Ongoing Feedback and Continuous Improvements Detailed Cleaning of Equipment Detailed Cleaning Impact on Reliability Motor life Inspectability Mindset for detailed cleaning/what is clean Lubrication/ Hydraulics Lubrication basics and purpose of lubricants Types of Lubricants Defining the measurements of oil cleanliness A micrometer measurement for filtration How dirt enters systems How dirt affects component life Filter ratings Water in Oil Oil/grease inspection methods Oil/grease inspection tools Implementation of better lubrication practices 2

3 Alignment for operation Why align Alignment basics Understand how to detect misalignment Misalignment effect on bearing life Operating Procedures How operating Procedures effect equipment reliability Examples: Parallel Systems Thermal Growth Water Hammer Bearings, Vibration and SPM Speed Increase and bearing life Load increase and bearing life Exercise calculate bearing life reductions while changing load and speed Lubrication, dirt, alignment problems combined Shock Pulse Measurement Vibration Pen Vibration Analysis Other inspection tools Couplings & stroboscopes Coupling types Inspection of couplings Stroboscope basics Exercise - Inspection of gear coupling Chain, Belt & Guards Belt Basics Chain inspection Belt inspection Tensiometer Ultrasonic inspection Sheave guides Motor shelf Material crack detection Dye Penetrant Ultrasonic Eddy Current Magnetic powder Corrosion & Heat exchanger Corrosion Galvanic Corrosion Heat exchange inspections 3

4 Exercise Heat exchanger inspection Temperature Inspections Stickers Infrared gun Crayons Infrared Camera Examples of applications for infrared cameras Exercise: IR Gun ration calculation Pumps and Mechanical Seals Pump Basics Cavitation Seal types: Mechanical, packing, dynamic seal Seal inspections Exercise: Set up a PM program for a centrifugal pump. Motor Control Center How it works Inspection Techniques Instrumentation Loop Leaks Cost of water leaks Cost of steam leaks Cost of air leaks Leak inspection Utrasound tools Leak detection Smoke Leak detection Soap water Implementation of a better PM/ECCM process Financial results Cut cost and/or increase reliability Charter/Mission/Goal How to benchmark current performance How does PM/ECCM affect RCFA/ Planning/Scheduling/Database/Stores What is the biggest opportunity in your plant Assessment of your plant Reliability Basics Essential Care Maintenance methods Operate to Break Down Maintenance method Fixed Time Maintenance Maintenance Method Condition Monitoring Expected life of components Failure Developing period Selection of most cost effective maintenance method Consequence of failure analysis 4

5 Example Financial Calculation comparing Maintenance Method Costs Document PM/ECCM What is a route What are shutdown PM s Decide PM/ECCM activities for sample equipment Who should inspect equipment Decide inspection tools to use Software/ Hardware requirements Organize PM/ECCM in comprehensive format for users Reporting of PM/ECCM performance Exercise: Do financial calculation and decide what maintenance method to use Exercise: Document PM/ECCM for selected equipment 5

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