Electrical Skills Series
Instrumentation Skills Series
Mechanical Skills Series
Regulatory Compliance Series
Basic Skills Series

Rotating Equipment Predictive Maintenance and Alignment

This comprehensive Activ® interactive multimedia training program consists of seven individual lessons that train participants to use predictive maintenance as a tool for prolonging equipment life and preventing major problems.

Audience: This program is excellent both for the training of maintenance personnel and equipment operators as well as for the multi-craft training needs of process and manufacturing facilities.

Principles and Practices of Predictive Maintenance


Prerequisites: This lesson is designed so that no prior knowledge is required.

Description: This lesson focuses on the general purpose of an effective predictive maintenance program by showing how methods such as vibration analysis, and lubricant and trend analysis can be used to determine equipment condition and predict equipment life.

Objectives:

  • Define predictive maintenance and differentiate it from other approaches such as run-to-failure and preventive maintenance
  • Describe the benefits of predictive maintenance
  • Describe how equipment vibration can provide an indication of equipment condition
  • Describe how impurities in equipment lubricant can provide an indication of the condition of the components being lubricated
  • Describe how trends reflected in equipment records can provide an indication of equipment condition
  • Describe some basic guidelines for a successful predictive maintenance program.

Vibration Analysis


Prerequisites: This lesson is designed for participants familiar with the basic principles and practices of predictive maintenance.

Description: This lesson teaches how to monitor vibration and perform a vibration analysis. The lesson also covers how to determine velocity and displacement as well as how to use a vibration analyzer and interpret various vibration patterns.

Objectives:

  • Identify two measures of vibration amplitude and the units of measurements used
  • Identify the points on a bearing where horizontal, vertical, and axial readings would be taken
  • Use a severity chart to get an indication of machine condition
  • Define amplitude and frequency
  • Identify the function of three filter settings on a vibration analyzer
  • Recognize the characteristics of vibration produced by conditions such as unbalance, misalignment, mechanical looseness, worn gears, and anti-friction bearings.

Lubricant and Trend Analysis


Prerequisites: This lesson is designed for participants familiar with the basic principles and practices of predictive maintenance.

Description: This lesson introduces the principles of lubricant and trend analysis. The lesson shows how to take oil samples and read an oil analysis report as well as how to identify and interpret trends.

Objectives:

  • Take an oil sample at a sampling valve and reservoir
  • Determine where to take a sample to check the condition of a particular component
  • Use operating data to establish trends in machine condition
  • Identify increasing, decreasing and flat trends
  • Compare trends using different data from the same machine.

Techniques for Extending Bearing Life


Prerequisites: This lesson is designed for participants familiar with the components and functions of bearings in relation to rotating equipment as well as with the procedures for installing bearings. A basic understanding of the principles and practices of predictive maintenance is also required.

Description: This lesson presents guidelines for maximizing the operational life of bearings for rotating equipment. The lesson emphasizes the proper handling, storage, installation, and maintenance of bearings.

Objectives:

  • Describe proper handling and storage procedures for bearings
  • Obtain readings on the outside diameter of the shaft and inside diameter of the housing
  • Determine proper fit
  • Describe two types of bearing lubrication
  • Identify three potential areas of lubrication contamination
  • Identify symptoms and possible causes of bearing problems

Principles of Reverse Double Dial Alignment


Prerequisites: This lesson is designed for participants familiar with precision measuring instruments, specifically dial indicators. A basic understanding of the principles and practices of predictive maintenance is also required.

Description: This lesson describes the principles of the reverse double dial alignment method used to measure and correct misalignment. The lesson also explains the data needed to determine offset and angularity misalignment values by using a graph. Formulas used to calculate misalignment corrections and factors which may affect alignment are also presented.

Objectives:

  • Identify three types of misalignment found in most rotating equipment
  • Distinguish vertical plane from horizontal plane
  • Identify the parts of the alignment rig and explain how they work
  • Convert sweep reading to offset values
  • Plot indicator offset values on a graph to find angular and offset misalignment values
  • Read specifications correctly
  • Perform calculations to determine how far and in which direction to move the machine.

Reverse Double Dial Alignment Procedure


Prerequisites: This lesson is designed for participants familiar with precision measuring instruments, specifically dial indicators, and the principles of reverse double dial alignment. A basic understanding of the principles and practices of predictive maintenance is also required.

Description: This lesson shows how to use the reverse double dial alignment procedure to determine and correct misalignment as well as how to take dial indicator readings. The lesson also teaches how to calculate the necessary vertical and horizontal adjustments and how to verify the results. Emphasis is on good record-keeping, the importance of accurately reading the dial indicators, and performing the calculations correctly to ensure that proper alignment is achieved.

Objectives:

  • Measure bracket sag and other dimensions necessary to calculate misalignment
  • Mount an alignment rig correctly on two shafts
  • Take a set of sweep readings
  • Determine if misalignment exists between two rotating shafts joined by coupling
  • Calculate the distance to move a machine to correct vertical misalignment
  • Shim a machine to correct vertical misalignment
  • Determine horizontal misalignment
  • Calculate the distance to move a machine to correct horizontal misalignment
  • Verify that equipment is aligned within specifications

Computerized and Laser Alignment


Prerequisites: This lesson is designed for participants familiar with the components and functions of bearings in relation to rotating equipment as well as with the procedures for installing bearings. A basic understanding of the principles and practices of predictive maintenance is also required.

Description: This lesson explains how to determine a computer's specifications and introduces proper steps to take in correcting misalignment with the use of a laser.

Objectives:

  • Take and then enter alignment measurements required by a computer
  • Use a computer to calculate offset and angular misalignment values in the horizontal and vertical planes to determine if a machine is within specification
  • Determine the amount and direction to move the machine to correct misalignment
  • Identify the components of a laser/detector system and properly set up the equipment
  • Take measurements necessary for the laser alignment system
  • Use the laser/detector system to calculate angular and offset misalignment in vertical and horizontal planes
  • Position the machine properly by using the laser