SKF Training Handbook

SKF Reliability Systems

2012 SKF Training Handbook

Proactive Reliability Maintenance

Condition Monitoring

Bearing Technology

Asset Management

Training Needs Analysis

Energy & Sustainability

A comprehensive reliability and maintenance skills training program from SKF

The Power of Knowledge Engineering

Welcome to the world of SKF Knowledge Engineering Our 2012 Training Handbook sets out a wide range of training courses to enable you to develop a successful knowledge base for your staff and meet the demands of today’s market. The wealth creation of all businesses depends on the skills of its personnel and how employers’ and industry support these personnel to fulfil their potential. Skills are key to economic transformation; the skills of workers increasingly determine an organisation’s ability to build sustainable competitiveness. Skills training not only improves people’s ability to do their job but also makes them feel valued and appreciated. At the same time, challenging them to learn more and be more involved in their careers. Unfortunately, many training initiatives are unsuccessful because they are launched without first identifying the areas where training is most necessary. There needs to be a structured approach to assess the training needs, prioritise the skills required and a plan to execute the knowledge transfer. Why SKF for reliability maintenance training? Our training courses are backed by over 100 years of experience and knowledge of rotating machine reliability that is unmatched in the world. Close working partnerships with our clients have given us a unique and intimate understanding of the processes and challenges specific to every major industry. SKF courses focus on enhancing the efficiency of plant machinery and equipment assets, which are the very heart of the production process. Our partnership with educational institutions within Australia & New Zealand will facilitate coordinated efforts in providing knowledge share with emerging technologies in the field of engineering and develop apprentice skills within rotating machines that will produce highly skilled technicians. Learn and gain knowledge from our experienced instructors who will lead you to enhance the efficiency of you plant machinery and equipment assets. SKF Reliability Systems operate with a quality management system and are accredited to ISO 9001. This ensures we strive for continuous improvement and client satisfaction. We look forward to further developing the knowledge and skills of your personnel in 2012. Hashim Poonawala

Business Manager – Training Solutions SKF Reliability Systems

2 | SKF Training Handbook

Energy & Sustainability Courses

Introduction to Training Solutions

SKF training courses at a glance Introduction to Training Solutions Energy and Sustainability Introduction to SKF Energy Efficiency Solutions within Maintenance Organisations Pump System Fundamentals and Energy Efficiency Compressed Air System Fundamentals and Energy Efficiency Introduction to Environmental Controls

Page 4 Course Code N/A N/A N/A N/A

Page 18 19 20 21 22

Basic E-learning web based training

Course Code

Page 24

Introduction to Asset Efficiency Optimisation Assessment Basics Proactive Reliability Maintenance Operator Driven Reliability Maintenance Strategy Review Introduction to Vibration Analysis Introduction to Thermography Introduction to Lubrication Analysis Spare Parts Management Bearing Basics Spherical Roller Bearings Angular Contact Ball Bearings CARB Toroidal Roller Bearings Taper Roller Bearings Deep Groove Ball Bearings Introduction to Lubrication Power Transmission Introduction to Shaft Alignment Balancing Basics Basics of Industrial Seals for Rotating Motion SKF Shaft Alignment Tool SKF Machine Condition Advisor

MS100 MS101 MS113 MS120 MS130 WI100 WI130 WI140 WC130 GRB001 GRB002 GRB003 GRB004 GRB005 GRB006 GRL001 GRPT01 WE140 WE150 WE170 PT02-TKSA20 PT01-MCA

25 26 26 26 26 27 27 27 27 28 28 28 28 29 29 30 30 30 30 31 31 31

Self learning PC based training

Course Code

Page 33

Vibration Analysis I Vibration Analysis II Vibration Analysis of Industrial Fans Diagnostics of Cement Plant Machinery Dynamic Balancing I Basics of Rolling Element Bearings Mounting of Rolling Element Bearings Dismounting of Rolling Element Bearings and Failure Analysis Vibration Analysis of Rolling Element Bearings Vibration Analysis of Plain Bearings Vibration Analysis of Electrical Machines Operation and Maintenance of Pumps Operation and Trouble shooting of Material Handling Systems Analysis of Resonance Related Problems Dynamic Analysis for Equipment and Structural Analysis Alignment - Theory and Practice Diagnostics of Sugar Plant Machinery Diagnostics of Thermal Power Plant Machinery Diagnostics of Paper Plant Machinery Onsite Short Courses Tradesman, Fitter and Apprentice Course on Bearing Technology Fitting Spherical Roller, Self-Aligning Ball and CARB Bearings Introduction to Bearing Housings and Seals Bearing Handling and Storage Bearings for Electric Motors Bearing Failure Analysis Bearing Lubrication Practical Handling of High Precision Bearings Introduction to Oil Seals Introduction to Epoxy and Sealant Applications V Belts and Pulleys Introduction to Condition Based Maintenance Introduction to Airborne Ultrasound Introduction to Asset Management 4 | SKF Training Handbook

SLT1 SLT2 SLT3 SLT4 SLT5 SLT6 SLT7 SLT8 SLT9 SLT10 SLT11 SLT12 SLT13 SLT14 SLT15 SLT16 SLT17 SLT18 SLT19 Course Code N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

33 33 34 34 34 35 35 36 36 37 37 38 38 39 39 40 40 41 41 Page 42 42 42 42 42 43 43 43 43 44 44 44 44 45 45

SKF Training Handbook | 5

How can I increase profitability through Skill Management?

SKF recommends 5 Key Steps to Successful Training Results Step 1 Step 2

Select the right Work Category

(Highest return on investment to an organisation)

Training Needs Analysis

(Highest skills improvement opportunity for staff)

Drawing on years of SKF productivity experience, we can help you identify improvement opportunities that will yield positive bottom-line results, then suggest a strategy for implementing a program to achieve them. Our goal at SKF is to help you achieve maximum return on your reliability investment. The SKF Client Needs Analysis is a performance benchmarking process with proven success in many industries. The SKF Client Needs Analysis enables this understanding, combining our experience in reliabilityfocused maintenance with your knowledge of plant conditions. The goal is to provide useful, actionable information to help you focus on credible performance improvement opportunities.

Introduction to Training Solutions Energy & Sustainability Courses

Step 1: Select the right Work Category

Level 1 Courses

OUR AVI BEH

Level 2 Courses

ARD REW

Level 3 Courses

ting figh Fire

Product Training

E MM GRA TIC PRO TERIS C A R CE CHA NAN Y NTE RIT MAI MATU VER DRI

Industry Application Courses

ING IMIZ OPT


Step 2: Training Needs Analysis


Step 4: Monitor Performance Improvement Through structured Documented Savings process

Spend minutes. Save thousands. With SKF Documented Solutions. Using a powerful new software program, an SKF representative can show you how to track thousands or even hundreds of thousands of dollars of savings when knowledge gained from SKF training is implemented. Solutions range from unique SKF training, products that reduce maintenance costs, to reliability services that solve recurring machine problems and virtually eliminate unplanned downtime. How can you have confidence in the forecasted savings? Because you’ll plug in your own numbers – for materials, labour, downtime, energy costs, inventory, lubrication, replacement costs and more. You’ll see actual, bottom-line results of similar solutions implemented by others in your industry, and learn what others with similar problems are doing in different industries.


Key to success… • A corporate culture willing to embrace the need for change

Process

Level 3 Courses

• Willingness to support processes for implementing cultural and technology changes

Product Training

Technology

Level 2 Courses

• Commitment to implementing new technologies with requisite financial, training and personnel resources

SUCCESS

Culture

Level 1 Courses

SKF recommends customers to re-assess the improvements made in different work categories after a period of 12-24 months. It also allows customers to identify new improvement opportunities, thereby closing the reassessment loop and making this part of a continuous improvement process.


Basic Courses


Continuous improvement and re-activation of skills cycle


Step 5: Work Category Re-assessment


Can’t spare time out for training? Looking for a convenient solution?

Did you know SKF Reliability9 t6v4 tt36a3(3026 p)6(r)-4(m )]TJ16sP5nitn Na6Ft5 vf3o73(n)14(i)134(l)15(k)-4(n Advantages Diverse Range of Courses • Access to a full range of public programs as well as programs tailored to meet your industry-specific needs

Convenience • We arrange timing and delivery of courses to suit your schedule • No travel time for delegates, thus providing time and cost savings – we come to you!

Experienced Presenters • Industry experts who are able to provide course participants with the full spectrum of maintenance and reliability based training

Cost Effective • Cost effective method for training groups of employees from your organisation

Team Environment • Training all employees at the same time promotes a team environment and provides immediate learning impact

Is Onsite training an option for you? • You have 7 or more people from your organisation who need training • You want to choose a date and location that suits you • You want a trainer that understands your industry • You want to save time and money, while getting the best training

For more information on what Onsite training can do for you: Tel: (Australia) +61 3 9269 0763 Fax: (Australia) +61 3 9269 0886 Email [email protected] Visit www.skf.com.au/training

(New Zealand) 0800 753 872 (New Zealand) 0800 753 329


Instructors Trevor Huf Trevor completed his engineering courses in the Royal Australr3e30 v\2350-4(D6)s it025 t\02uvR



Geoff Stevens Geoff Stevens is a Reliability Engineer with SKF Reliability Systems. He has


Energy and Sustainability ‘‘Sustainability is a long-term commitment for SKF and I am very proud that we have been recognised for our efforts, particularly in the areas of promoting sustainable products. SKF is committed to sustainability not only as a responsibility, but also as a way of developing our business. We see this as one of our competitive advantages in working with our business partners and in attracting, retaining and developing our employees.” Tom Johnstone, President and CEO, AB SKF


This course provides students the knowledge to conduct an extensive plant-wide assessment that identifies high-energy consumption areas within an operation. The course also examines chemical treatments, lubrication use and other operating processes that could be improved to reduce environmental impact.

Course Content

Who Should Attend

Energy-assessment solutions

• Plant representatives and those with primary responsibility within high energy intensive industry

• Vibration analysis • AC electric motor monitoring • Belt/shaft alignment • Precision balancing

• Operations Managers, Maintenance Managers, Environmental and Compliance Officers, Planning Manager and Reliability Engineer

• Performance monitoring: pumps, turbines, fans, compressors

Course Information

• Steam trap monitoring

Time

• Heat exchanger efficiency

Days

• Low-friction and hybrid-magnetic bearings

Course Fee

$1,750 AUD + GST $1,750 NZD + GST

• Pneumatic to electric actuation conversions

2 days †

Exam Fee

N/A

Anatomy of hidden energy savings

Course Type

Onsite & Public

Using a variety of inspection technologies such as thermography and vibration analysis, SKF energy specialists help companies discover energy reduction opportunities in every corner of the plant. The example shown here involves “found energy” within a typical electric motor pump.

Certification

N/A

Advanced diagnostics and monitoring can reduce energy use 2. Precision alignment

† Course fee is per person and Public courses. Contact SKF for Onsite course fees. Refer to Enrolment Form on page 119.

1

Level 2 Courses

1. Electric motor analysis


8.30am – 4.30pm

Level 1 Courses

• Thermography analysis


Course Overview

Basic Courses

Introduction to SKF Energy Efficiency Solutions within Maintenance Organisations

2 4

3 5

Properly aligned machinery consumes less energy 3. Lubrication and sealing Optimum lubrication and sealing methods can cut energy use

Vibration analysis allows hydraulic improvements that can cut energy 5. Precision balancing

Product Training

4. Hydraulics

Proper balancing can reduce energy consumption SKF Training Handbook | 19


Product Training

Level 3 Courses

Level 2 Courses

Level 1 Courses


Basic Courses

Energy and Sustainability Courses


Basic Courses Basic understanding of the subject with


E-Learning web based training Assessment basics

Operator Driven Reliability

MS101

MS 120

Course Overview

Course Overview

Excellence in asset management is no more or less complex than being able to ask and answer structured questions routinely and accurately. This course provides a general introduction to the subject of assessing maintenance performance. Tuition includes guidance on the selection and implementation of the correct assessment approach. The nature of organisational change is also discussed and suggestions made regarding management of the change process.

This interactive course provides an introduction to the concept of Operator Driven Reliability (ODR). Its origins and terminology are explained, and the relationships between ODR and other maintenance methodologies is discussed. Factors that are key to successful implementation are also described.

Course Information Duration

6 month subscription

Course Fee

$100 AUD + GST $120 NZD + GST

Course Type

Online

Category

Maintenance Strategy



Course Fee


Course Type

Online

Category


Maintenance Strategy Review MS 130

Proactive Reliability Maintenance MS113 Course Overview This course provides an introduction to proactive maintenance. It starts by exploring what is meant by the term “proactive maintenance” and goes on to discuss five of the primary tools that are typically used in its implementation. An introduction to the use of key performance indicators to monitor program effectiveness is included, along with suggestions for a disciplined approach to operational review. Course Information


Course Overview The course starts with an explanation of what a good maintenance strategy is meant to achieve. It then goes on to introduce “Reliability Centred Maintenance” (RCM) as a means of devising an effective strategy. Some variations on the classic RCM methodology are described, including SRCM and Risk Based maintenance. A cost-based approach to RCM is also outlined. The course goes on to suggest how a maintenance strategy review project might be organised, and concludes by discussing the challenges that must be faced when implementing the results of such a project. Course Information

Duration


Duration


Course Fee


Course Fee


Course Type

Online

Course Type

Online

Category


Category



E-Learning web based training Bearing Basics

Angular Contact Ball Bearings

GRB001

GRB003

Course Overview

Course Overview

On completion of this course the learner will be able to: Describe the three primary functions of a bearing. Correctly identify the component parts of a standard bearing. Explain eight factors that will affect the choice of bearing for a particular application. List the most common bearing types. Describe, with the aid of notes, the main characteristics of each of the common types of bearing. Identify, with the aid of notes, the bearing type described by use of a basic designation. Identify, with the aid of notes, variants of a standard bearing design from information given in prefixes and suffixes applied to standard designations.

Before taking the Angular Contact Ball Bearings course, it is recommended that you have passed the Bearings Basic course (GRB001), or have some prior knowledge about bearings. Lessons focus on features and benefits of single row and double row angular contact ball bearings. Arrangement of universally matchable angular contact ball bearings is also discussed. Four-point contact ball bearings are also considered. SKF Angular Contact Ball Bearings are used in many pump and compressor applications. Three examples of demanding applications are presented. Course Information



Course Fee


Course Type

Online

Category

Work Execution

Spherical Roller Bearings GRB002 Course Overview This course consists of a number of lessons: • • • • •

Introduction Executive summary Features and benefits Product range and designations Applications

Before taking the Spherical Roller Bearings course, it is recommended that you have passed the Bearings Basic course (GRB001), or have some prior knowledge about bearings. Course Information Duration


Course Fee


Course Type

Online

Category

Work Execution

Duration


Course Fee

$100\05031(5ECN.S27)4tion)]TJ02/GSt19.8031(5ECN70S62)4tion)]TJ)j460.73scn/GSg-91d(C)1(ourse F)J031 0 B02/GStT*15 025y(7-40\grN)- svIt8(S16)407-2nf3tvI)-31740K2P


E-Learning web based training Introduction to Lubrication

Introduction to Shaft Alignment

GRL001

WE140

Course Overview

Course Overview

Before taking the SKF Lubrication course, it is recommended that you have passed the Bearings Basic course (GRB001), or have some prior knowledge about bearings. In this course you will learn about the physics of lubricants and the function of a lubricant within a bearing. The features and benefits of SKF standard bearing greases will be outlined, and you will be shown how to select grease for a specific application. The presentation also discusses the features and benefits of SKF automatic lubricator systems; SYSTEM 24 and SYSTEM Multipoint.

This e-learning module provides a basic introduction to the subject of shaft alignment. The terminology associated with precision alignment practices is explained, and the benefits to be accrued from their implementation are discussed. The module includes an introduction to straight-edge / feeler gauge alignment, RimFace Method, and Reverse Indicator method. An introduction to the use of laser technology is also included.



Course Fee


Course Type

Online

Category

Work Execution



Course Fee


Course Type

Online

Category

Work Execution

Balancing Basics Power Transmission GRPT01

Course Overview This course provides a basic introduction to field balancing from first principles.

Course Overview This course presents the basics of the unique SKF power transmission product range, which consists of six main product categories which are belts, pulleys, chains, sprockets, couplings, as well as bushings and hubs. Course Information


WE150

Duration


Course Fee


Course Type

Online

Category

Work Execution

Unbalance is one of the most common causes of machinery vibration. Nowadays vibration monitoring and analysis instruments typically include a dynamic balancing facility. These balancing programs can usually be relied upon for good results. Occasionally, however, things do not appear to go as they should, and it is useful in such circumstances to have an understanding of the fundamentals of balancing in order to speedily arrive at a solution. Course Information Duration


Course Fee


Course Type

Online

Category

Work Execution



E-Learning Enrolment form Please complete and fax to (Australia) +61 3 9269 0886 (New Zealand) 0800 753 329, or scan and email this form to [email protected] to submit your order. Tel: (Australia) +61 3 9269 0763

(New Zealand) 0800 753 872

Description Product code AEX101 Full site Includes unlimited access to all articles, RMI Online, and interactive services. AEX301-AM Asset Management focus area Includes access to all articles, interactive tutorials and interactive services related to Asset Management. AEX301-RE Reliability Engineering focus area Includes access all articles, interactive tutorials and interactive services related to Reliability Engineering. AEX301-MM Mechanical Maintenance focus area Includes access all articles, interactive tutorials and interactive services related to Mechanical Maintenance. AEX201-R All training modules (RMI Online) Includes access to all training modules Specific E-Learning Web Based and Self learning PC based training Course Name (Please write your options below)

Price AUD $1575

Price NZD $1890

$625

$750

$625

$750

$625

$750

$625

$750

Price AUD

Price NZD

Order Total

$

$

Add GST

$

$

Qty.

Qty.

Customer Information First name

Last name

Work phone number

E-mail

Company name Street address Suburb

Postcode

Country

I give SKF approval to contact me - for further assistance regarding my inquiries on the web.

Yes

No

METHOD OF PAYMENT Cheque: Made payable to SKF Australia Pty Ltd Mailing address - SKF Reliability Systems, PO Box 301, Oakleigh VIC 3166 Company Order No Credit Card No.

VISA

MasterCard

AMEX Security Code

Card Holder’s Name Signature 32 | SKF Training Handbook

Exp Date

/

AMEX

SKF Tr.3972cm/5-6.401-63972.4011-1-1341-1-03

Self learning PC based training Module: SLT5 Dynamic Balancing Unbalance has been identified as one of the PI



Self learning PC based training Module: SLT8

Module: SLT9

Dismounting of Rolling Element Bearings and Failure Analysis

Vibration Analysis of Rolling Element Bearings

When shafts and bearings are damaged during the dismounting of bearings, there is always a cost associated with it, in terms of both time and material. In addition, the use of the wrong tools and techniques for dismounting can be hazardous to the operator. Course Overview This SLT basically gives information about how dismounting of bearings can cause damage to both the bearings and associated components. This demonstrates how to avoid using incorrect tools and techniques. List of Topics • Basic Principles • Cold Dismounting • Hot Dismounting • Dismounting Tools • Bearing Damages and Failures High Points This SLT gives an in-depth overview of: • Methods of dismounting bearings using the correct tools • Ways to increase the life of the bearing with minimal wear and tear Add-Ons Practical Tips, Exhaustive Case Studies and Stimulating Exercises Course Information


Condition monitoring of Rolling Element Bearings using Vibration Analysis can prevent a majority of problems and failures. Course Overview This SLT is designed to teach you more about the Basics of Rolling Element Bearings. It covers vibration theory and bearing vibration in detail. List of Topics • Basics of Vibration • Bearing Vibration, Variable Compliance Vibration • Geometrical, perfections and SEE (Spectral Emitted Energy) • Random Ultrasonic frequencies, Natural Frequencies of Bearing Components • Spike Energy Measurements, Rotational Defect frequencies • Bearing damages and failure High Points This SLT gives an in-depth overview of: • Vibration Analysis of Rolling Element Bearings to diagnose problems in bearings during operation • Methods of reducing the stoppage of machinery • Methods of increasing the life of machine/ bearing Add-Ons Practical Tips, Exhaustive Case Studies and Stimulating Exercises

Duration

N/A

Course Information

Course Fee

$1,345 AUD + GST $1,615 NZD + GST

Duration

N/A

Course Fee

$1,345 AUD + GST $1,615 NZD + GST

Course Type

Onsite

Category

Work Identification

Course Type

Onsite

Category

Work Execution


Module: SLT13 Operation and Trouble shooting of Material Handling Systems Material Handing Systems is very important to


Self learning PC based training Module: SLT16

Module: SLT17

Alignment – Theory and Practice

Diagnostics of Sugar Plant Machinery

Misalignment is responsible for up to 50% of breakdowns in rotating machinery. Those breakdowns cause increased machine downtime that translates directly into higher costs.

In the sugar industry, a high level of diagnostic accuracy is expected from vibration analysis because of the non-availability of standby equipments. There is also the need for continuous and trouble-free operation of all the critical equipments.

Implementing the latest alignment methods like laser alignment discussed in this SLT can improve the reliability of the equipments. Course Overview In this SLT, we have covered the various types of misalignments, causes and harmful effects of misalignment and diagnostics of misalignment. We have also covered in detail about alignment methods like dial indicator method and laser alignment. List of Topics • Types of misalignment • Causes and harmful effects of misalignment • Pre-alignment check and diagnostics of misalignment • Alignment methods and procedures High points This SLT gives a never before in-depth overview of diagnostics of misalignment using dial indicator and laser alignment methods. Add-ons Practical tips and Exercises are the highlights of this SLT. Course Information


Duration

N/A

Course Fee

$1,345 AUD + GST $1,615 NZD + GST

Course Type

Onsite

Category

Work Identification

Course Overview In this SLT, we are covering the major machinery problems common for all Sugar Plant equipment and also the spectrum and phase characteristics of each problem and how to detect them using vibration analysis. List of Topics • Sugar Plant - main process and equipment details • Vibration characteristics • Vibration analysis and problem diagnostics of sugar plant machineries High points This SLT gives an in-depth overview of problem diagnostic procedures with spectrum and phase characteristics using vibration analysis. Add-ons Practical tips, case studies and exercises are the highlights of this SLT. Course Information Duration

N/A

Course Fee

$1,345 AUD + GST $1,615 NZD + GST

Course Type

Onsite

Category

Work Identification


Onsite Short Courses Tradesman, Fitter and Apprentice Course on Bearing Technology

Introduction to Bearing Housings and Seals

Participants will learn to install and maintain rolling element bearings in rotating machinery.

Course Outline • Bearing Housing Design • Seal Types and Applications • How a Bearing Housing can affect Bearing Life • Identification • Quality • Standardisation and Rationalisation

Course Outline • Bearing Applications • Principles of Mounting and Dismounting (Hands-on Workstations) • Bearing Lubrication and Cleanliness • Fits and Tolerances • Bearing Storage and Handling • Failure Analysis Who Should Attend Tradesmen, Fitters, Maintenance and Mechanical / Electrical Apprentices

Who Should Attend Any personnel involved with selecting, requesting, identifying and issuing housings (i.e. Engineers, Draftsmen, Purchasing, Stores, Tradesmen, Fitters, Maintenance and Mechanical / Electrical Apprentices) This course covers the application and fitting of Plummer Block housings. Typical applications for these housings include conveyors and fans. Course Information Duration

1/2 Day

Course Fee

$3,600 AUD + GST $3,600 NZD + GST

Course Type

Onsite

No. of Attendees

15 Max

Category

Work Execution

Bearing Handling and Storage Course Outline Learn How - to identify bearings from samples Learn What - bearing part numbers mean Learn Why - do you need so many types? Learn Where - to store bearings and how to handle them Learn Where - to find relevant information you need to know Who Should Attend Any personnel involved with selecting, requesting, identifying and issuing bearings (i.e. Purchasing, Stores, Tradesmen, Fitters, Maintenance and Mechanical / Electrical Apprentices) Course Information Duration

1/2 Day

Course Fee

$3,600 AUD + GST $3,600 NZD + GST

Course Type

Onsite

No. of Attendees

15 Max

Category

Work Execution


Onsite Short Courses Introduction to Oil Seals

V Belts and Pulleys

Course Outline • Seal Design • Seal types and applications • Shaft tolerances and their effect on seal life • Identification • Materials • Compound compatibility • Recommended operating conditions • How to select • Product descriptions • Standardisation and rationalisation

Course Outline • Identification and Types • Handling and Storage • Matched Sets • Correct Fitting and Alignment • Maintenance • Drive design • Upgrades for longer life • Standardisation and Rationalisation

Who Should Attend Any personnel involved with selecting, requesting, identifying and issuing seals (i.e. Engineers, Draftsmen, Purchasing, Stores, Tradesmen, Fitters, Maintenance and Mechanical / Electrical Apprentices)

Course Information


1/2 Day

Course Fee

$3,600 AUD + GST $3,600 NZD + GST

Course Type

Onsite

No. of Attendees

15 Max

Category

Work Execution

Introduction to Epoxy and Sealant Applications Course Outline • Thread locking • Retaining • Thread sealing • Instant Adhesives • Epoxies • Lubricants • Belt Repair • Cleaners • Machining Compounds • Special Products • Flange Sealing and Gasketing • Contact and Structural Adhesives • Flex 80 Urethanes and Rust Prevention • Precautions, Handling and Care Who Should Attend Any personnel involved with selecting, requesting, identifying and issuing bearings (i.e. Purchasing, Stores, Tradesmen, Fitters, Maintenance and Mechanical / Electrical Apprentices) Course Information


Who Should Attend Any personnel involved with selecting, requesting, identifying and issuing V Belts and Pulleys (i.e. Design Engineering, Purchasing, Stores, Tradesmen, Fitters, Maintenance and Mechanical / Electrical Apprentices)

Duration

1/2 Day

Course Fee

$3,600 AUD + GST $3,600 NZD + GST

Course Type

Onsite

No. of Attendees

15 Max

Category

Work Execution

Duration

1/2 Day

Course Fee

$3,600 AUD + GST $3,600 NZD + GST

Course Type

Onsite

No. of Attendees

15 Max

Category

Work Execution

Introduction to Condition Based Maintenance Course Outline • Failure Based Maintenance • Planned Maintenance • Condition Based Maintenance • Vibration Monitoring • Laser Alignment • Lubrication Analysis • Equipment / Tools • Reducing Total Cost of Operation Who Should Attend Any personnel involved with structuring, planning and undertaking maintenance (i.e. Reliability Engineers, Draftsmen, Maintenance Planners and Tradesmen) Course Information Duration

1 Day

Course Fee

$5,750 AUD + GST $5,750 NZD + GST

Course Type

Onsite

No. of Attendees

15 Max

Category

Work Identification



• Understand the fundamentals of rolling bearing operation and what influences reliability • Learn to recognise the common failure modes and causes • Understand appropriate fitting and maintenance techniques

Course Content Basics of Bearings and Their Applications • • • • • • •

Spherical roller and plain bearings Tapered roller bearings Cylindrical roller bearings Clearance and preload settings Plummer block assemblies Unit roller assemblies Principles of mounting and dismounting bearings

Sealing Requirements • • • • • • • •

Oil seals V-rings Large diameter seals Split seals Expeller seals Customised seals Plummer block seals Function and selection

Fundamentals of Lubrication • Selection criteria and common mistakes • Lubrication issues, contaminants, chemical resistance, cooling water • Lube/ oil analysis • Grease application • Automatic lubricators • Centralised lubrication systems

Condition Monitoring Techniques • Understand condition monitoring principles • Review of condition monitoring technologies • Basics of vibration • Reliability issues and failure modes Applications / Machines • Crushers • Grinding mills • Gearboxes • Electric motors

• • • •

Vibrating screens Conveyors Slurry pumps Fans


Who Should Attend Maintenance fitters; lubrication technicians; reliability technicians.

Optional Study

Level 1 Courses

On completion of this course, students will be able to:

In addition to in-person training, students can also update their skills by participating in the following self-learning PC based study. SLT 6 – Basics of Rolling Element Bearings SLT 7 – Mounting of Rolling Element Bearings SLT 8 – Dismounting of Rolling Element Bearings and Failure Analysis SLT 9 – Vibration Analysis of Rolling Element Bearings

Level 2 Courses

Key Learning Outcomes

* Self learning 24/7 PC based training. Please contact SKF for pricing on the optional study modules. For more information on each module, refer to page 33 in the SKF Training Handbook.

Course Information 8.30am – 4.30pm

Time

2 days

Days Course Fee

$9,450 AUD + GST $10,800 NZD + GST

Exam Fee

N/A

Course Type

Onsite

Category

Work Execution

Certification

N/A

†

Level 3 Courses

Avoid common pitfalls leading to reduced rolling bearing service life in mining fixed plant applications.

Service and Maintenance Issues • Preventive and predictive maintenance fundamentals • Introduction to bearing failures and their causes • Identify and interpret actual bearing failures

Product Training

Course Objectives

Basic Courses

The course provides comprehensive information on the behaviour of bearings within the Mining and Mineral Processing industry. Understanding and applying the proper techniques of bearing and seal selection, installation, lubrication and maintenance and, understanding issues relevant to bearing system performance.


Course Overview


Improving Bearing Reliability in Mining and Mineral Processing

† Course Fee for a maximum of 15 attendees per class.




Improving Bearing Reliability in Aggregate and Cement WE212 Course Overview Participants will learn about real solutions to real problems related to bearing reliability and maintenance in machinery used in the aggregate and cement industry.

Course Content

Pre-Study

Bearing Reliability in Aggregate and Cement Machinery uses a combination of lecture, video, discussion and hands-on activities. Specific topics include:

E-Learning courses* GRB002 Spherical Roller Bearings GRB005 Taper Roller Bearings

• Bearings in aggregate and cement making machinery

Reading material* RB04001 Cement Industry RB04005 Bearing Arrangements for Cement Industry Fans RB04007 Drive Shafts for Grinding Mills RB04008 Hammer Mills and Impact Crushers

• Crushers, conveyors, vibrating screens

* E-learning material at www.aptitudexchange.com

• Aggregate and cement industry overview • Mounted and unmounted rolling element bearings

• Kilns, coolers, roller presses • Auxiliary equipment: pumps, gearboxes and motors • Bearing installation and maintenance • Mounting and dismounting of rolling element bearings • Fault detection • Bearing damage examples • Hands on exercises • Impact of safety in the industry

Who Should Attend Plant Engineers, Maintenance/Engineering Managers, Rotating Equipment Managers/ Engineers, Reliability Managers/Engineers, Maintenance Supervisors, Foremen/Team Leaders, General Maintenance and Mechanical Foremen, Lubrication Engineers/Technicians, Plant and Maintenance Planners, Mechanical Shop Managers, Foremen and Technicians, Mechanical Repair Services Providers, Maintenance Services Contractors/Technicians, Maintenance Operations Coordinators, Millwrights, Maintenance Administrators and Technical Maintenance Trainers.

Optional Study In addition to in-person training, students can also update their skills by participating in the following self-learning PC based study. SLT4 – Vibration Diagnostics of Cement Plant Machinery SLT 6 – Basics of Rolling Element Bearings SLT 7 – Mounting of Rolling Element Bearings SLT 8 – Dismounting of Rolling Element Bearings and Failure Analysis SLT 9 – Vibration Analysis of Rolling Element Bearings * Self learning 24/7 PC based training. Please contact SKF for pricing on the optional study modules. For more information on each module, refer to page 33 in the SKF Training Handbook.


Time

2 days

Days Course Fee

$9,450 AUD + GST $10,800 NZD + GST

Exam Fee

N/A

Course Type

Onsite

Category

Work Execution

Certification

N/A

†








Improving Bearing Reliability in Fans WE213 Course Overview The course provides information for the improvement of the service life of rolling element bearings in industrial fans.

Course Content

Who Should Attend

Bearing basics • Learning the fundamentals of rolling bearing technology, care, types, nomenclature, bearing components, terminology, loads and lubrication for industrial fan applications • The factors affecting the performance of rolling bearings in industrial fans • Gaining a basic understanding of bearing failure modes in industrial fan applications

Application Engineer, Condition Monitoring Engineer/Technician, Electrical Engineer/Fitter/ Manager/Supervisor/Technician, Engineering Draftsman/Manager/Supervisor, Mechanical Maintenance Engineer/Manager/Supervisor/ Technician/Fitter/Lubrication Fitter, Operations Manager/Supervisor, Planning Manager, Quality Engineer, Reliability Engineer/Manager/ Supervisor, Store Supervisor.

Mounting and dismounting • Study the proper bearing mounting and dismounting procedures of spherical, cylindrical and CARBTM roller bearings as well as self-aligning ball bearings. A variety of mounted bearings are also covered • Participate in hands-on demonstrations using specialised tools to correctly mount and dismount ball bearings, roller bearings, mounted bearings and bearings with sleeves • Learn about specialised fan bearing arrangements such as two-bearing units, unitised bearings and special seals • Discuss the effects of shaft and belt alignment and imbalance on fan system life Fundamentals of lubrication • Learn how important it is to select the proper lubricant and lubrication program for fan applications • Learn to maximise bearing life through an improved understanding of proper lubricating principles and functions

In addition to in-person training, students can also update their skills by participating in the following self-learning PC based study. SLT3 – Vibration Analysis of Industrial Fans SLT 6 – Basics of Rolling Element Bearings SLT 7 – Mounting of Rolling Element Bearings SLT 8 – Dismounting of Rolling Element Bearings and Failure Analysis SLT 9 – Vibration Analysis of Rolling Element Bearings * Self learning 24/7 PC based training. Please contact SKF for pricing on the optional study modules. For more information on each module, refer to page 33 in the SKF Training Handbook.


Time

2 days

Days Course Fee

$9,450 AUD + GST $10,800 NZD + GST

Exam Fee

N/A

Industries that will benefit

Course Type

Onsite

• Mining • Mineral Processing • Pulp and Paper • Chemical • Pharmaceutical • Oil and Gas • Power Generation • Maintenance Contractors • Consultancy Service Providers • Industries where fans are used

Category

Work Execution

Certification

N/A

Bearing failure causes and analysis • Identify and interpret fan bearing failures


Optional Study

†



Level 1 Courses General understanding of the subject

Before we explore the technical details of strategy, we must know about each organisation, what their issues are, why these issues matter, and how the issues can be incorporated into a plan. There must be a documented need to look at an existing maintenance strategy or create a new one for the right and unique business reasons. Maintenance Strategy is the key to asset reliability and availability, thus achieving overall organisational goals. How do you know if a review of your maintenance strategy is required and why?

• understand that there are different types of criticality at various levels of maintenance • understand what will likely be involved in total to conduct the right analysis, but then what the implications are of making the strategy work • recognise the commonalities and differences in possible strategies • understand that the conduct of MSR has important implications to spares • understand that certain classes of equipment require specialised approaches to strategy review (i.e., SCS > via SIL/IPF, etc.)

Course Content The purpose of this course is to make users aware of MSR and how they can apply it within their work. These are the topics: Chapter 1: Conceptual models and business context Chapter 2: Obtain a common understanding of terminology Chapter 3: Standards, models, and excellence Chapter 4: Understanding the current situation Chapter 5: The essential link - failure and strategy Chapter 6: What is strategy? Chapter 7: Mutual understanding and readiness Chapter 8: Can we conduct MSR?

• Maintenance, Plant/Facility Engineering staff, rotating equipment Engineers and Maintenance Supervisors • Managers at industrial plants, reliability engineers and those interested in rotating equipment performance

Pre-Study E-Learning courses* MS100 Asset Efficiency Optimisation (AEO) Basics MS130 Maintenance Strategy Review

Basic Courses Industry Application Courses

• understand the importance of identifying and categorising assets

Who Should Attend

Level 1 Courses

• recognise the importance of data structure and content before any kind of strategy work is commenced

Chapter 12: How MSR forms the basis of Predictive and Proactive Reliability Maintenance programs

Reading material* MB03006 Maintenance Strategy Review Methods MB03032 Managing Asset Integrity * E-learning material at www.aptitudexchange.com

Course Information

Level 2 Courses

• know if a review of strategy is required and why

Chapter 11: Performance management and measurement

8.30am – 4.30pm

Time

3 days

Days Course Fee

$2,145 AUD + GST $2,575 NZD + GST

Exam Fee

N/A

Course Type

Onsite & Public

Category


Certification

N/A

†

Level 3 Courses

The course objectives are to ensure that each participant will:

Chapter 10: How to implement well


Product Training

Course Objective


Course Overview


Maintenance Strategy Review (MSR) Awareness - Level 1 MS230

Chapter 9: A blend of MSR types


Noise and Vibration Troubleshooting - Level 1

Course Overview This course teaches the basics of noise and vibration. It assumes no previous knowledge and starts from the ground up. It will also provide an introduction to the FFT analyser as a diagnostic tool. This course will explain the ‘How?’ and ‘Why?’ of signal analysers, and give practical examples and case histories of how they can be used to solve problems.


Spectral Analysis and Phase Analysis

On completion of this course, students will understand:

• FFT based signal analysis for engineers (the what, why and how of the FFT) • Care and attention check list for setting up instrumentation and sensors • FFT ‘samples’ and ‘lines of resolution’ • Windows explained – hanning, flat top, uniform, force / exponential • Averaging types – linear, exponential, peak hold and time • Cursors – normal, delta power and harmonic • Phase measurement for diagnostics

• How to take a basic vibration or noise measurement • Understand why problems might be occurring on their product • Understand how an instrument can be used to analyse a noise of vibration problem in more detail and offer practical solutions

Course Content Vibration Basics

Also Available: Vibration Analysis Level 2 (pg. 91) Vibration Analysis Level 3 (pg. 103) SmartStart Microlog Product Training (pg. 114)

• What is vibration • Vibration characteristics • When to use displacement velocity of acceleration • Types of vibration transducers – how to select the appropriate transducer • Transducer location and mounting methods • What is vibration spectrum • Understanding phase and its application • Resonance / mode shapes / operating deflection shapes • Alarm Methods and Setting Alarm Limits • Setting limits in accordance with standards like ISO, API, BS and IEE • Assessing overall vibration severity • Phase alarms Basics of Sound • • • • • •

What is sound pressure and the decibel Sound pressure vs. sound power The difference between noise and sound What are A and C weighting Sound propagation The practical sound field and its effect on sound quality • Addition and subtraction of sounds – coping with background noise • Frequency of sound and its effect on sound quality • The practicalities of taking a basic noise measurement


Vibration Signal Processing Methods • • • • •

Synchronous Time Averaging (STA) Enveloping for rolling elements and gears Spectral Emitted Energy (SEE™) Harmonic Analysis (HAL) High Frequency Detection Course Information 8.30am – 4.30pm

Time

2 days (including exam)

Days Course Fee


Exam Fee

N/A

Course Type

Onsite

Category

Work Identification

Certification*

N/A

†



Infrared Thermography Workshop - Level 1

Course Overview Many people buy an infrared camera with little more than a sales demonstration, and with the false assumption that a camera is simply point and shoot. With limited knowledge of the camera operation, and even less understanding of the camera’s actual measure capability it is a daunting task to be sent out in the field to collect meaningful data and present this information to clients of superiors.


Who Should Attend

Upon completion, students will understand how to use an infrared camera within the scope of its capabilities, understanding its limitations, and applying basic theory in a practical manner to avoid common errors.

The Infrared Thermography Workshop is a first step for people just starting out in this field. It is aimed at inexperienced or first time users who want to gain practical experience and insight into the operation of infrared cameras and to start them on the right path for practical use of their instrument in the field.

Course Content • Why we use infrared – common applications • Understanding the nature of infrared radiation

Also Available: IR Thermography Analysis Level 2 (pg. 93)

8.30am – 4.30pm

Time

1 day

Days

• How an infrared camera works

Course Fee

• How to operate an infrared camera – focus, range and palette selection, sensitivity optimisation

$975 AUD + GST $1,170 NZD + GST

Exam Fee

N/A

Course Type

Onsite & Public

• Understanding the capabilities and limitations of an infrared camera

Category

Work Identification

Certification*

N/A

• Basic introduction to infrared theory and how it relates to practical use • Awareness of errors such as emissivity, reflectance, emittance, distance, and target size • Advanced Camera operation – Hands on tutorial


Course Information

†


Introduction to SKF Training Handbook | 63

Infrared Thermography - Level 1 WI230 (cont.) Course Content (cont.) Implementing an IR Predictive Maintenance Program • Nine steps to setting up a program • Integrating with other predictive technologies • Cross-verifying with other predictive technologies • Why programs fail, how they succeed • Generating standards compliant reports

Who Should Attend Infrared Thermography – Level 1, is a five-day course for the application of qualitative thermal imaging for P/PM, condition assessment, condition monitoring and electrical engineers / supervisors, mechanical maintenance, operational reliability, quality assurance, forensic investigations and building sciences. Course Information Time

8.30am – 4.30pm

Days

5 days (including exam)

Course Fee†

$2,495 AUD + GST $2,995 NZD + GST

Exam Fee*

Included

Course Type

Onsite & Public

Category

Work Identification

Certification*

Infraspection Institute Level 1 Certified Infrared Thermographer

† Course fee is per person and Public courses. Contact SKF for Onsite course fees. Refer to Enrolment Form on page 119. * This course and examination can qualify you for the Level 1 certification in accordance with ASNT SNT-TC-1A.



Machinery Lubrication and Oil Analysis - Level 1 (cont.) Preventive and Predictive Maintenance

Course Information

• Lube routes and scheduling • Oil analysis and technologies to assure lubrication effectiveness • Equipment tagging and identification

Time

8.30am – 4.30pm

Days

3 days + half day exam

Course Fee†

$1,920 AUD + GST $2,300 NZD + GST

Oil Sampling

Exam Fee


Course Type

Onsite & Public

Category

Work Identification

Certification

Lubrication Analysis 1

• Objectives for lube oil sampling Sampling methods • Managing interference - Bottle cleanliness and management - Flushing - Machine conditions appropriate for sampling Lubricant health monitoring • Lubricant failure mechanisms 1. Oxidative degradation - The oxidation process - Causes of oxidation - Effects of oxidative degradation 2. Thermal degradation - The thermal failure process - Causes of thermal failure - Effects of thermal degradation 3. Additive depletion/degradation - Additive depletion mechanisms - Additives at risk for depletion/ degradation by the various mechanisms • Testing for wrong or mixed lubricants - Baselining physical and chemical properties tests - Additive discrepancies • Fluid properties test methods and measurement units - applications and limitations Wear Debris Monitoring and Analysis • Common machine wear mechanisms

Who Should Attend All Maintenance Professionals Reliability Engineers Lubrication Engineers Craftsmen and Millwrights Equipment Operators Maintenance Managers Lubrication Technicians Manufacturing and Industrial Engineers Maintenance Supervisors Predictive Maintenance Technicians Lubricant Industry Professionals Laboratory Analysts Operations Managers 66 | SKF Training Handbook


Get Certified! SKF is an “Authorised Training Body” by CMSkills. Our training course follows the ISO 18436.4 Category 1 Standard. CMSkills ISO Cat 1 Lubrication Analysis Certification Exam available at the end of the course.* Certification also requires practical experience. * Please confirm with SKF prior to the course

Course Content

Exams

• • • • • • • • •

At the end of the course all candidates will sit for a Level 1 exam. Each candidate will be a certified NDT UT Level 1 Engineer upon successfully passing the exam.

• Mining • Cement • Steel • Mineral Processing • Printing • Pulp and Paper • Oil and Gas • Pharmaceutical • Manufacturing • Petrochemical • Power Generation • Municipal Utilities

Candidates will receive results immediately after the exam at the end of the training. For certification related training course, candidates will receive their certificates 1-2 weeks after the exam. Candidates who fail to achieve a pass score will be required to sit the exam again.

Who Should Attend Condition Monitoring Engineer/Technician, Electrical Manager/Supervisor, Engineering Manager/Supervisor, Mechanical Maintenance Engineer/Manager/Supervisor, Operations Manager/Supervisor, Quality Engineer, Reliability Engineer/Supervisor/Manager.

• Motor Rewinders

Course Information

• Maintenance Contractors

Time

• Timber

Days

• Pump Manufacturers

Course Fee

$1,950 AUD + GST $2,340 NZD + GST

Exam Fee

Included

Course Type

Onsite & Public

Category

Work Identification

Certification

International NDT UT Level 1

• Chemical

Level 2 Courses

• Food and Beverage

Candidates are encouraged to bring an electronic calculator. Programmable calculators are permitted as long as it does not have an alphanumeric keyboard. No other books, paper, or charts will be allowed.

8.30am – 4.30pm 4 days + 1 day exam †


Level 3 Courses


The examination will be in accordance with ASNT Standard and SNT-TC-1A Level 3 Professional.

Product Training

Basic principle of acoustics Equipment testing methods Calibration Straight beam examination Angle beam examination Evaluation of base material product forms Evaluation of weldments Discontinuity detection Evaluation

Basic Courses

It is recognised that the effectiveness of Non Destructive Testing (NDT) applications depends upon the capabilities of the personnel who are responsible for and perform Ultrasonic Testing (UT). This recommended practice has been prepared to establish guidelines for the qualification and certification of NDT personnel whose specific jobs require appropriate knowledge of the technical principles underlying the Ultrasonic tests they perform witness, and monitor, or evaluate. This course also certifies all delegates who complete all formalities of the training module with a Level 1 Ultrasonic Testing Certification as per ASNT-SNT-TC-1A-20.


Course Overview

Level 1 Courses

WI320



Ultrasonic Testing - Level 1


Maintenance Planning and Scheduling - Level 1 WC200 Course Overview Planning and scheduling is one of the most important activities to increase the efficiency in a maintenance organisation and to reach “Maintenance in World Class.” Surveys show that planning increases the productivity of work performance by as much as 77%. The service technician needs to communicate and cooperate in the right way with schedulers, work management, and Production/Operations. This requires a clear and communicated work process among the personnel involved, and not least, knowledge and skills necessary for planning and scheduling of maintenance job plans.

Course Content

• Understand planning roles and relationships

The objective of this training is to give the basic principles for planning and scheduling of maintenance work. The participants will understand the necessity of planned work and its effect on interest groups and on maintenance measurements.

• Understand the components of a data driven maintenance job plan

Course Topics The course contains the following topics: • Roles and responsibilities • Work flow • Error notification • Prioritising of work orders • Planning – Theory

• Understand the benefits of performance measurement

• Understand when to create a maintenance job plan • Demonstrate the knowledge and skills necessary to write a data driven maintenance job plan

Who Should Attend Personnel from Production/Operations and Maintenance/Planners and Schedulers and Personnel responsible for Spare Parts

Pre-Study

– Theory

E-Learning course* WC130 Spare Parts Management Reading material* JPG_RB04012 Maintenance Planning & Scheduling Fundamentals MB03013 Planning, Scheduling, and Work Orders MB04021 Calculating Wrench Time

– The process

* E-learning material at www.aptitudexchange.com

– The process – Standard work – Planning and reservation of material • Scheduling

– Handling of backlog • Efficient planning and scheduling meetings • Shutdown planning • Improvements • Follow up and key performance indicators (KPIs)

Key Learning Outcomes After completing the course, participants will be able to: • Understand the importance and impact of Planning and Scheduling • Learn and apply Planning and Scheduling principles and methodology • Derive Planning and Scheduling work flow models



Time

2 day

Days Course Fee

$1,475 AUD + GST $1,770 NZD + GST

Exam Fee

N/A

Course Type

Onsite & Public

Category

Work Control

Certification

N/A

†


Level 2 Courses

Course Objective

Case studies

The course objectives are to provide participants with a sound knowledge and understanding of:

The purpose of the case studies is to provide participants with an opportunity to apply the gained knowledge and understanding in practice.

• Identifying, structure, and classifying spare parts on their criticality, (re)order parameters, and other spare parts characteristics • Applying basic analysis techniques to optimise the availability of spares and cost-effectively handle obsolete spares • Key institutes and reference material on spare parts and inventory management

Course Content

Engineers, Supervisors and Managers from the following functions: Inventory control, purchasing, reliability and maintenance engineering, logistic support, quality, production and warehouse management

E-Learning course* WC130 Spare Parts Management Reading material* RB02028 Spare Parts Management GS03005 Inventory Management * E-learning material at www.aptitudexchange.com

Course Information

SKF spare part management and inventory optimisation training has been developed to support SKF customers (industrial end-users), improving their bottom line results.

Time Course Fee

$1,475 AUD + GST $1,770 NZD + GST

This course will consist of the following modules:

Exam Fee

N/A

Course Type

Onsite & Public

Category

Work Control

Certification

N/A

Module 0: Introduction Module 1: Spare parts management (SPM) Module 2: Maintenance and spare parts strategy Module 3: MRO inventory management Module 3-A: MRO inventory management – Basics Module 3-B: MRO inventory management – work processes and CMMS Module 4: Obsolete management


Pre-Study Level 1 Courses

• The importance and relations of spare parts and inventory management with respect to business goals

Who Should Attend

8.30am – 4.30pm 2 day

Days †

Level 3 Courses

• Basic spare parts and inventory management terminology


Product Training

• Spare parts and inventory management processes and principles

Basic Courses

In a maintenance repair and operating (MRO) environment, spares and inventory management refer to those activities in an organisation that ensure at any time the optimal and timely availability of spare parts in order to meet maintenance demands. In today’s competitive environment, it is important that the management and optimisation of spares inventory is always considered in the context of supporting the maintenance function to meet its operational and business goals. Simply reducing inventory is not enough. Ideally, the aim must be to maintain sufficient inventory and no more such that production is never impacted by stock-outs whilst keeping inventory costs to a minimum. In this way, inventory management and optimisation add real value to any business.


Course Overview


Spare Parts Management and Inventory Control - Level 1 WC230


Proactive Maintenance Skills - Level 1 WE241 Course Overview This course will teach the mechanic an understanding of the precision and proactive practices necessary to maintain a machine to the highest possible level. Students will learn techniques that aid in the assembly and setup of machinery that provide measurable improvements in machine performance as measured with basic vibration readings. Students will also understand the current trends in maintenance methodologies, and how precision and proactive approaches and their direct interaction with machinery fit into an overall reliability program. By attending this course, students can also claim certification to various National Unit Standards as listed below

Course Content Overview of Proactive and Maintenance • Proactive maintenance as part of an overall maintenance strategy

Improving Rotor Balance through Precision • Assembly • Troubleshooting and analysis techniques • Practical methods with basic instruments

• Relationship between failures and their sources

• Examples of advanced techniques used by analysts

• Impact of maintenance practices on machinery

• Proactive and precision tolerances

Fundamentals of Machine Condition • Vibration as an indicator of machine health and an indicator of precision

• The effects of assembly on rotor balance Belt-Driven Machinery • Identification of common belt drive configurations

• Introduction to condition monitoring terminology and technologies

• Troubleshooting techniques

• Indications of machinery health problems

• Examples of advanced techniques used by analysts

• Basic vibration measurements

• Belt failure modes – root cause analysis

• Relationship between the components in the machine and vibration frequencies

• Pre-alignment / belt installation and inspection

• Fault diagnosis

• Practical assembly methods with basic instruments

Maximising Roller Bearing Life • Introduction to proactive bearing installation

Machinery Troubleshooting

• Failure detection methods

• Machinery troubleshooting process

• Basic seal types - Installation & Lubrication

• Identification of the true root cause – cause and effect relationships

• Progression of typical bearing failures

• Analysis techniques

• Practical inspection methods with basic instrumentation

• Resonance troubleshooting

• Advanced methods used by vibration analysts

Precision Shaft Alignment • Need for precision • Misdiagnosis and thermal growth correction • Types of misalignment • Alignment tolerances • Precision versus manufacturer’s and industry specifications

• Bearing, shaft and housing tolerances and fits • Relationship of tolerance, clearance, and bearing precision • Functions of lubrication Lip and Mechanical Seals • Maximising life • Controlling and positioning of shafts

• The different alignment methods – advantages, disadvantages • Misalignment effects on bearing loads, seals and motor load

CONTINUES NEXT PAGE 70 | SKF Training Handbook


Bearing Technology and Maintenance - Level 1 WE201 Course Overview Learn world’s best practice in bearing applications, principles of mounting and dismounting from engineers using the correct fitting & removal tools and techniques. SKF has aligned this course to the National Metal & Engineering Competency Standards Unit MEM18005B in Australia and Maintenance & Diagnostics in Mechanical Engineering Standards Unit 19873 and 19874 in New Zealand. SKF delivers this course under the auspice of Box Hill Institute of TAFE in Australia and Manukau Institute of Technology in New Zealand. The Bearing Technology and Maintenance Course together with Root Cause Bearing Failure Analysis course covers all the elements of Unit MEM18005B


Who Should Attend

At the end of this course students will be able to perform routine bearing checks during operation and non operation, identify bearing requirements for replacement or installation, and remove and install bearings.

Service, maintenance, machine repair, plant/ facility engineering staff, managers, technicians, rotating equipment engineers, reliability engineers, mechanics and maintenance supervisors of an industrial plant, OEM facility, public utility using roller bearings and related equipment.

Course Content

Also Available: Root Cause Bearing Failure Analysis Level 2 (pg. 97)

Basics of Bearings and Their Applications • Rolling bearing theory • Anti-friction bearing types and applications • Plain bearing types and applications • Meaning of “L 10 Life” and “Service Life” • Application of fits and tolerances Fundamentals of Lubrication • How bearing lubrication works • The importance of selecting the proper lubricant for an application • Maximise bearing life through understanding of proper lubricating principles and functions • How much and how often to lubricate rolling bearings Seal Types and Application • Contact seals, Non-contact seals • Housing seal types Principles of Mounting and Dismounting Bearings • Cylindrical seating • Tapered seating • Adapter and withdrawal sleeves • Cold and hot mounting and dismounting • Mounting and dismounting using oil injection • Principles of mounting plain bearings Introduction to Bearing Failures and Their Causes • Identify and interpret actual bearing failures Practical Mounting and Dismounting of Bearings • Preparation for mounting and dismounting • Checking the components • Mounting and dismounting tools • “Hands on” exercises

Pre-Study • E-Learning course* - GRB001 Bearing Basics - GRB006 Deep Groove Ball Bearings • Reading material* - RB02002 Bearing Basics - GS04012 Bearing Dismounting Methods - RB02017 Tips for Bearing Mounting * E-learning material at www.aptitudexchange.com

Industries that will benefit Cement, Chemical, Food and Beverage, Manufacturing, Mineral Processing, Mining, Motor Rewinders, Municipal Utilities, Oil and Gas, Petrochemical, Pharmaceutical, Power Generation, Printing, Pulp and Paper, Pump Manufacturers, Steel, Maintenance Contractors, Timber Course Information 8.30am – 4.30pm

Time

3 days

Days Course Fee

$1,475 AUD $1,475 NZD

Exam Fee

Included

Course Type

Onsite & Public

Category

Work Execution

Competency

Maintenance and Diagnostics

Certification

Australia MEM18005B* New Zealand – 19873, 19874

†

† Course fee is per person and Public courses. Contact SKF for Onsite course fees. Refer to Enrolment Form on page 119. * Australia MEM18005B includes modules: MEM18005B1, MEM18005B3, MEM18005B4, MEM18005B5, MEM18005B6


Sealing Solutions Technology Seals for Rotary Applications - Level 1 Course Overview This course is designed to develop knowledge in industrial sealing products for rotary motion, application fundamentals and competence in devising effective sealing solutions. The information and training will enable students to understand the concepts and application of sealing solutions to achieve optimum seal, bearing and equipment performance. This comprehensive course uses a combination of hands-on training, visual theory knowledge, case study participation and discussion opportunities

Course Objective

Who Should Attend

• To provide the participants with the fundamentals of lip seals, principles of sealing operations, elastomeric materials and their properties, and the effects of operating parameters in seal performance

Machinery Designers, Mechanical Draftspersons, Reliability Engineers, Maintenance Engineers and Technicians, Consultants

• To have an understanding of the various seal designs, their applications and seal design development trends • To learn a systematic approach to “Sealing System Failure Analysis”, most common failure modes; includes participation in actual case studies • To provide an overview of common rotary sealing components used in various industrial applications and a guide to sealing system designs in heavy industry segments • To learn appropriate handling and installation procedures, methods, tools and parameters; includes a workshop environment for hands-on experience • To provide an overview of other sealing systems and services including SKF custom sealing solutions

Course Content Introduction • General industrial and catalogue shaft seals • Design features – machined rotary seals Radial Lip Shaft Seals • Radial lip shaft seals • Choosing an elastomer material Design Requirements for other components • Shaft and bore recommendations Failure Analysis • Seal failure modes • Failure analysis methods • Application troubleshooting Installation Procedures • Basic handling and installation procedures – theory • Hands-on seal installation practice Specific market segment applications and case studies


Pre-Study Industrial Seals Self Study Guide (supplied on request after enrolment). Course Information Time

8.30am – 4.30pm

Days

2 day

Course Fee†


Exam Fee

N/A

Course Type

Onsite & Public

Category

Maintenance Strategy; Work Execution

Certification

N/A



Dynamic Balancing - Level 1 WE250 Course Overview This course delivers hands-on balancing exercises, using demo rotor kits and instruments using optical, laser and strobe light accessories for phase reference. Proper vibration analysis techniques are reviewed to differentiate imbalance from other problems such as misalignment and resonance. Course features case histories to illustrate single plane (static), two-plane (dynamic) and the static and couple approach to balancing rotors of all types. This course covers elements of the National Code MEM1800B under maintenance and diagnostics competency field. SKF delivers the course under the auspice of Box Hill Institute of TAFE, Victoria.


Who Should Attend

At the end of this course, students will be able to determine the most appropriate procedure to be applied to selected balancing situations, identify the main causes of unbalanced equipment, and understand the procedures for operating the balancing equipment.

Application Engineer, Condition Monitoring Engineer/Technician, Electrical Engineer/Fitter/ Manager/Supervisor/Technician, Engineering Draftsman/Manager/Supervisor, Mechanical Maintenance Engineer/Manager/Supervisor/ Technician/Fitter/Lubrication Fitter, Operations Manager/Supervisor, Planning Manager, Quality Engineer, Reliability Engineer/Manager/Supervisor, Store Supervisor.

Course Objectives

• Understanding principles of balancing • Selecting the most appropriate procedure to be applied to selected balancing situations • Understanding procedures for setting up the component to be balanced • Understanding procedures for operating the balancing equipment • Understanding procedures for recording out of balance readings • Learn methods of rigid and flexible rotation balancing • Understanding the techniques of single and multiple plane balancing • Learn the appropriate balancing technique for given balancing situations • Learn procedures for balancing out of balance equipment

Course Content

1. Check balance • Principles of equipment balance testing are understood • Most appropriate balancing check procedure is selected • Component is set up correctly and to site/ manufacturer’s procedure for balance check • Balance/out of balance is determined and compared to specification requirements • Out of balance readings are recorded to prescribed procedures 2. Balance equipment • Principles and methods of rigid and/or flexible rotation balancing are understood • Techniques of single and/or multi-plane balancing are used appropriate to application • Equipment is balanced utilising correct procedures • Practical methods with basic instruments • Examples of advanced techniques used by analysts • Proactive and precision tolerances • The effects of assembly on rotor balance 76 | SKF Training Handbook

Industries that will benefit • Cement • Food and Beverage • Manufacturing • Mining • Municipal Utilities • Petrochemical • Power Generation • Pulp and Paper • Steel

• Chemical • Maintenance Contractors • Mineral Processing • Motor Rewinders • Oil and Gas • Pharmaceutical • Printing • Pump Manufacturers • Timber

Pre-Study E-Learning course* WE150 Balancing Basics Reading material* MB02004 Balancing * E-learning material at www.aptitudexchange.com

Course Information Time

8.30am – 4.30pm

Days

1 day

Course Fee†

$975 AUD $975 NZD

Exam Fee

Included

Course Type

Onsite & Public

Category

Work Execution

Competency

Maintenance and Diagnostics

Certification*

National: MEM18008B

† Course fee is per person and Public courses. Contact SKF for Onsite course fees. Refer to Enrolment Form on page 119. * To receive Tafe Accreditation, all course participants will be required to complete an onsite project as part of the assessment process.


Selecting and Maintaining Power Transmission Systems - Level 1 WE290

•

Serviceable items are repaired using appropriate maintenance procedures according to manufacturers’ specifications and standard workshop practices

•

Standard replaceable items are selected and obtained using manufacturers’ catalogues, spare parts lists, engineering specifications

•

Component parts are refitted to mechanical drive/transmission assembly using sound maintenance principles, techniques, tools and equipment in accordance with manufacturers’/site specifications

5. Final adjustment and commissioning • Using applicable maintenance principles and procedures, drive/transmission components are tensioned, balanced, aligned or adjusted to suit specifications and operational requirements •

• •

Who Should Attend Application Engineer, Condition Monitoring Engineer/Technician, Electrical Engineer/Fitter/ Manager/Supervisor/Technician, Engineering Draftsman/Manager/Supervisor, Mechanical Maintenance Engineer/Manager/Supervisor/ Technician/Fitter/Lubrication Fitter, Operations Manager/Supervisor, Planning Manager, Quality Engineer, Reliability Engineer/Manager/ Supervisor, Store Supervisor.



8.30am – 4.30pm

Drive/transmission assembly is checked after adjustment and operational performance is analysed

Days

2 days

Course Fee†

Assembly is commissioned to specifications.

$1,475 AUD $1,475 NZD

Exam Fee

Included

Course Type

Onsite & Public

Category

Work Execution

Competency

Maintenance & Diagnostics

Certification*

MEM18007B

Service report is completed


Mechanical drive/transmission assembly is dismantled using appropriate maintenance principles, techniques, tools, equipment and safe workshop practices

Basic Courses

•


Tools and equipment are selected according to the type of assembly being serviced

• Cement • Chemical • Food and Beverage • Maintenance Contractors • Manufacturing • Mineral Processing • Mining • Motor Rewinders • Municipal Utilities • Oil and Gas • Petrochemical • Pharmaceutical • Power Generation • Printing • Pulp and Paper • Pump Manufacturers • Steel • Timber


Level 2 Courses

•


Level 3 Courses

assemblies • Service reports are read and visual and sensory inspection of the drive/ transmission assembly is undertaken

* To receive Tafe Accreditation, all course participants will be required to complete an onsite project as part of the assessment process.

Product Training

4. Repair mechanical drives/transmission

Level 1 Courses

Selecting and Maintaining Power Transmission Systems (cont.)


Electric Motor Maintenance - Level 1

Course Overview Electric motors are among the highest in reliability incident reports. For many companies, this leads to a continual cycle of costly repairs and unplanned downtime factors that can hurt the bottom line. Since 40% to 70% of motor failures are related to bearings, it’s no surprise that high-quality bearings are key for reliable motors. The right bearings alone won’t deliver the results you need. How parts are installed, lubricated, handled, stored, aligned, and maintained is equally important This training course will train students to disassemble, inspect, maintain, and troubleshoot AC Induction motors including a practical motor overhaul.

Key Learning Outcomes 1. An effective implementation of electrical motor maintenance will translate into savings from production availability, reduced equipment repair costs and improved energy costs. 2. Students will have an appreciation and understanding to perform optimal diagnoses and repairs. 3. Students will learn the techniques and obtain valuable information to detect motor problems prior to failure, avoiding costly downtime.

Course Content Motor Maintenance

Bearing arrangements • Bearing basics: electric motor bearings • Locating / non-locating bearing arrangements • Thermal growth • Horizontal arrangement – medium size motors - small motors • Bearing arrangements: belt drive motors • Vertical electric motors • Variable speed motors Motor teardown and bearing dismounting • Identifying bearings for replacement • Bearing dismounting methods - Hydraulic puller - Arbor press

• Motor parts overview

• Post dismounting procedures

• Repair overview

Shaft and housing fits

Electrical testing

• Checking fit integrity

• Predictive maintenance motor diagnostics • Electrical motor tests

• Mounting preparations • Bearing seat run-out and form tolerance

- Winding Resistance

• Radial and axial clearance

- Meg-ohm Test

Motor assembly and bearing mounting

- Polarisation Index (PI)

• Cold mounting

- Hipot Test

• Induction heating

- Surge Test • Turn to turn failure

Lubrication • Bearing life • Grease selection and procedures • Contamination • Typical lubrication mistakes • Grease ducts and fittings



Introduction to Static Testing and Dynamic Motor Monitoring - Level 1 WI261 Course Overview This introductory course will benefit the attendee by allowing them to obtain information from both technologies simultaneously. The first day and a half will be spent covering the concepts and theories of off-line motor testing and the second day and a half will cover the technical theory of online motor monitoring. The final day will be dedicated to more hands on and theory testing.



• Develop a general understanding of what static testing and dynamic motor monitoring involves

• Food and Beverage • Mining • Cement • Steel • Mineral Processing • Printing • Pulp and Paper • Oil and Gas • Pharmaceutical • Manufacturing • Petrochemical • Power Generation • Municipal Utilities • Motor Rewinders • Maintenance Contractors • Timber • Pump Manufacturers • Chemical

• Knowledge of what standards are used in testing electric motors • Develop a general understanding of electrical motor theory • Knowledge of general workings of instrumentation for both static motor testing and dynamic motor monitoring

Course Content Basic AC motor theory • Basic electromagnetic theory • Basic AC motor construction • Various types of motors Introduction to static motor theory • Insulation systems • Failure mechanisms • Testing methods and pass/fail criteria • Recommended test voltages • Test sequence overview Introduction to dynamic motor monitoring • Machine system overview • Properly connecting the Explorer • Obtaining quality data • Power, motor, load assessments

Who Should Attend Condition Monitoring Engineer/Technician, Electrical Manager/Supervisor, Engineering Manager/Supervisor, Mechanical Maintenance Engineer/Manager/Supervisor, Operations Manager/Supervisor, Quality Engineer, Reliability Engineer/Supervisor/Manager. Course Information 8.30am – 4.30pm

Time

4 days

Days Course Fee

$1,995 AUD + GST $2,395 NZD + GST

Exam Fee

N/A

Course Type

Onsite & Public

Category

Work Identification

Certification

N/A

†




Dynamic Motor Monitoring / Introduction to DC Motor Monitoring - Level 1 WI263 Course Overview This course will provide comprehensive technical theory on the concepts behind online motor monitoring along with plenty of hands on experience to help the attendee develop a true comfort level with the instrumentation. Comprehensive hook-up techniques and software training are included, along with safety precautions for use of the equipment.

Course Objective • Develop a general understanding of AC motor theory as it relates to online operation. • Develop an in-depth understanding of the capabilities and limitations associated with dynamic motor monitoring. • Gain a general understanding of all the parameters monitored by the Explorer and the relevance of these parameters to specific faults. • Develop an in-depth working knowledge of the Explorer as it relates to hands-on operation and software functionality.

Course Content Dynamic motor monitoring theory • Power condition parameters • Motor performance/condition • Energy efficiency development • Torque waveform development Software training

• Food and Beverage • Cement • Steel • Mineral Processing • Pulp and Paper • Pharmaceutical • Petrochemical • Municipal Utilities • Maintenance Contractors • Pump Manufacturers

• Mining

• Printing • Oil and Gas • Manufacturing • Power Generation • Motor Rewinders • Timber • Chemical

Who Should Attend Condition Monitoring Engineer/Technician, Electrical Manager/Supervisor, Engineering Manager/Supervisor, Mechanical Maintenance Engineer/Manager/Supervisor, Operations Manager/Supervisor, Quality Engineer, Reliability Engineer/Supervisor/Manager. Course Information 8.30am – 4.30pm

Time

4 days

Days

• Creation and management of databases • Creation and editing electrical test models • Test acquisition setup • Data collection • Basic data interpretation and analysis

Course Fee

$1,995 AUD + GST $2,395 NZD + GST

Exam Fee

N/A

Course Type

Onsite & Public

Category

Work Identification

Intro to DC online analysis

Certification

N/A

• Basic DC motor theory and concepts • Ensuring proper connections • Software functionality • Basic DC analysis



†



BasP01(c)30( )30(C)43(o)28(u)32(r)23t7(e)31(s)]TJEq059.276841reWn3cms-vlhfQB/_[(I)31(n)28(d)35(u)36(sr)23r Eer& Introduction to Ap7(p5vn)3(P01(c)26(a)36(tabP )34(i)29(o)28(nP )30( vn )30(C0(t)43(o206 Coures )28(u)32(r)23t7(e)31(s)]TJEq059.276841reWn3cms-vlhfQB/_[(L0v87)35(v)40726(l40( )30(1)]TJ-0.19867d[(CTsa )43(o)28(u)32(r)23t7(e)31(s)]TJEq059.276841reWn3cms-vlhfQB/_[(L0v87)35(v)40726(lSol4 40( )30(2)]TJ-0.19867d[(Ct9f ions )43(o)28(u)32(r)23t7(e)31(s)]TJEq059.276841reWncm3s-vlhfQB/_[(L0v87)35(v)40726(l40( )30(3)]TJ-0.19867d[(C)43(oTra )28(u)32(r)23t7(e)31(s)]TJEq059.276841reWn3cms-vlhfQB/_[(P)403(o)2(d)35(u)28(c)8(t)]TJ-0.1567d[(T)89(r)26(a)38.260v7491

S3-10.496823-5

Course Content Important Topics Covered •


Reliability Centred Maintenance (RCM) - Level 2 MS332 Course Overview The aim of this training is to provide participants the necessary knowledge of the SKF maintenance strategy review to understand Reliability Centred Maintenance methodology.

Course Content Module I: Introduction • Discuss RCM terminology Module II: RCM overview and business context • Understand the evolution of RCM • Understand the business context of RCM • Know RCM standards Module III: RCM phase “what is important?” • • • •

Know what a criticality matrix is How to select which system to analyse Determine system boundaries Understand what failure modes, failure causes and failure effects are

Module IV: RCM phase “what should be done?” • • • •

Know what important failure characteristics are Know when to decide RTF maintenance Know when design changes are required How to prescribe maintenance to critical assets

• Understand criticality and the FMECA approach in RCM • Understand how to develop an RCM analysis as well as what the implications are of making the strategy work • Understand why to conduct a task comparison • Understand what work packaging is • Understand methods needed for RCM implementation • Recognise what a living program is • Know the content of a RCM project plan • Understand what risk based inspection (RBI) in the asset management support tool AMST is

Who Should Attend Maintenance, Plant/Facility Engineering staff, Rotating Equipment Engineers, Maintenance Supervisors, Managers at industrial plants, Reliability Engineers and those interested in rotating equipment performance.

Module V: RCM customisation and requirements

Pre-Study

• • • •

MS100 Asset Efficiency Optimisation (AEO) Basics MS130 Maintenance Strategy Review

Understand RCM customisation Understand the use of RCM template data Determine what data is required for RCM Become aware of the asset management support tool (AMST)

Module VI: Implementation and improvement • • • •

Understand what a job plan is Understand how to allocate tasks Understand how to implement RCM well Understand what feedback is

Module VII: RCM project • Know the steps in a RCM project Module VIII: RCM project • Understand the evolution of RBI • Understand variations of RBI • Understand the requirements for RBI

Course Objective Upon completion of this course, students will have the knowledge to: • Know how to describe RCM process flow • Understand the differences in RCM approach • Recognise the importance of data structure and content before performing any kind of strategy work • Understand the importance of identifying and categorising assets

E-Learning material*

Reading material* NC_0520 How to implement Reliability Centered Maintenance at Your Facility MB020008 Reliability Centered Maintenance MB02024 Using an RCM Appro02!y3




Oil Analysis - Level 2 WI240 Course Overview Learn how to read and understand oil analysis reports, set optimum oil analysis limits, reduce oil consumption and achieve maximum life out of lubricants.

Course Objectives Most maintenance programs achieve only 10% of the benefits available from oil analysis. Learn how to get the most out of oil analysis by attending these powerful training sessions.

Key Learning Outcomes • • • • •

Read and understand oil analysis reports Tell if you are using the wrong oil Squeeze maximum life out of lubricants Set optimum oil analysis limits Reduce oil consumption for easy, near-term savings

Who Should Attend

Also Available: Machinery Lubrication and Oil Analysis Level 1 (pg. 65)

Condition Monitoring Engineer/Technician, Electrical Manager/Supervisor, Engineering Manager/Supervisor, Mechanical Maintenance Engineer/Manager/Supervisor, Operations Manager/Supervisor, Quality Engineer, Reliability Engineer/Supervisor/Manager.

If you have any of the following machines this training is a must • Gear Boxes • Hydraulic Systems • Motor Bearings • Compressors • Final Drives • Diesel Engines • Paper Machines • Process Pumps • Steam Turbines • Gas Turbines • Blowers/Fans • Rolling Mills • Hydrostatic Transmissions

Course Content Introduction to Machinery Lubrication • Oil formulation and its importance in effective machinery lubrication • Key functions of lubricating oils • Primary lubrication regimes • Introduction to base oils and additives • Choosing the correct base-stock • Conditions that dictate use of synthetic oils • Antioxidant additives and their role in oil life • Dispersants and detergents - the key to controlling soot • Controlling wear with additive chemistry

Oil Sampling - The Very Best Practices • Simple steps to reliable and easy oil sampling • How to find the best sampling location • Sampling splash- collar- and ring-lubricated systems • How to sample circulating systems • Safe, effective high-pressure sampling from hydraulic systems • Using primary and secondary sampling points • A quick method for optimising sampling intervals • How clean should sample bottles be? • Sampling valves and hardware recommendations

Fundamentals of Friction and Machine Wear • Primary sources of friction in lubricated machinery • Wear mechanisms that reduce machine life • The most common wear modes in plain, rolling element and thrust bearings • Understanding gear wear • Understanding wear in hydraulic systems




Root Cause Analysis Workshop - Level 2 LP200 Course Overview This course will equip students with root cause analysis techniques in reliability and condition monitoring programs to enhance the scope and quality of onsite investigations. To provide students training in specialised techniques to identify the true root causes underlying a problem and to ensure that results of the study includes realistic corrective action.

Key Learning Outcomes • Understand the importance of RCA in delivering internal services and its role in relation to other tools, notably vibration diagnostics, bearing failure diagnostics and maintenance strategy • Become confident in building “why?” trees and the 7 steps of a root cause study • Be equipped with tools to assist in resolving complex problems and thinking laterally to fully explore possible causes of a problem

Course Content

Also Available: Bearing Technology & Maintenance Level 1 (pg. 72)

• Working from existing corporate information systems to capture events and incidents where RCA will be beneficial: – Machinery failures resulting in actual or potential loss of plant output – Machinery failure that represents a large or unbudgeted repair cost – Safety, health or environmental breaches – Repetitive failures that collectively represent an excessive maintenance cost – A nonconformance in maintenance strategy • Prioritise incidents and formally launch the RCA study by defining the problem • Collect and preserve evidence that will provide evidence on the incident • Expose the causes of the incident by building a “why?” tree. In general each incident will have three types of root cause: – Technical causes – the immediate technical cause of the failure – Human causes – actions or inactions that triggered the technical causes – Organisational causes – organisation factors that lie behind the human cause The key elements of an RCA process discussed include • Propose practical actions that will address the root cause of the incident and develop a business case for management approval of the resulting actions


• Following management approval, assign actions for implementation and track actions to completion • Measure the performance of the RCA program through appropriate KPIs

Who Should Attend • Service, maintenance, machine repair, or plant/ facility engineering staff of an industrial plant, or OEM facility • Managers, Technicians, Rotating Equipment Engineers, Reliability Engineers, Mechanics, and Maintenance Supervisors. • Those interested in rolling bearing and rotating equipment performance.

Pre-Study E-Learning material* WI140 Lubrication Analysis Basics MS101 Assessment Basics Reading material* NC_0702 Basic Elements of a Comprehensive Root Cause Analysis Program MB04034 PdM and RCFA-A Powerful Combination GS02003 Root Cause Analysis GS03008 RCFA Report Template * E-learning material at www.aptitudexchange.com


Time

2 days

Days Course Fee

$12,000 AUD + GST $14,400 NZD + GST

Exam Fee

N/A

Course Type

Onsite

Category

Maintenance Strategy, Living Program

Certification

N/A

†



Machinery Lubrication Technician - Level 2 WE266 Course Overview With hundreds of lubricant types, base stocks, additive packages and viscosity grades to choose from, how can a person decide which lubricant is right for a machine? The options are endless… synthetic or hydrocracked?… EP or AW?… naphthenic or paraffinic?… ISO VG 32 or 68? After attending these courses, you will be empowered with the knowledge to understand the important lubricant properties and how to strategically select the correct lubricant for each machine application.

Course Content

• High temperature greases

1. Maintenance Strategy

• Coupling greases

• The impact of lubrication on machine reliability

5. Lubricant Selection

• The impact of lubrication on lubricant life and consumption

• Viscosity selection/adjustments according to machinery condition/environmental conditions

• Maintenance program strategies for achieving lubrication excellence

• When to use synthetic lubricants

2. Lubrication Theory

• Lubricant consolidation

• Friction and Tribology

• Select lubricating oils for different applications

- Types of friction and wear - Wear modes and influencing factors - Machine frictional surfaces most at risk for specific wear modes (e.g., abrasion) - Mechanisms of Lubrication regimes - Boundary - Mixed film - Hydrodynamic - Elastohydrodynamic • Lubricant categories -

Gaseous Liquid Cohesive Solid

3. Lubricant Formulation • Base-oil Refining Methods and API categories • Mineral Base Oils • Vegetable Base Oils and Biolubes • Synthetic lubricant characteristics/ applications/compatibility • Food Grade lubricant Classification • Types and Functions of additives • Types and Functions of solid additives • Modes of additive depletion 4. Grease Application and Performance • Grease applications requiring high consistency • Grease applications requiring low consistency • Causes of grease separation • Multipurpose greases • Performance and application of specific grease thickeners

• When to use biodegradable lubricants

• Selecting greases for different applications • Lubricant Selection standards development • Procedures for testing and quality assurance of incoming lubricants • Procedures for approval of candidate lubricants


Dynamic Motor Monitoring - Level 2 WI364 Course Overview This course is designed to build on the knowledge obtained from previous course work and significant field experience with dynamic motor monitoring equipment. The course will provide instruction on detailed diagnosis of data through the use of case study presentations, hands-on data analysis of past problems, hands-on live motor acquisition, and analysis in a laboratory environment.

Course Objective


• Develop an in-depth understanding of dynamic motor monitoring equipment and the software interface • Gain an extensive understanding of motor monitoring applications • Develop an in-depth understanding of electric motor theory and how it pertains to motor monitoring • Hands-on training for familiarity with instrumentation connection and operation • Enhance the ability of the user to diagnose potential problems within electric motor systems

• Food and Beverage • Cement • Steel • Mineral Processing • Pulp and Paper • Pharmaceutical • Petrochemical • Municipal Utilities • Maintenance Contractors • Pump Manufacturers

Course Content Dynamic motor monitoring theory • Level I review, including basic DC analysis • Fundamentals of waveform and spectral analysis • Power condition • Motor performance/condition • Energy efficiency assessment • Motor load assessment • Torque analysis • Fundamental fault frequency characteristics Software training • Level I software review • Advanced data collection techniques • Intermediate waveform interpretation and analysis • Intermediate spectrum interpretation and analysis Case studies • AC case studies review and “hands on” analysis • DC case studies review


• Mining • Printing • Oil and Gas • Manufacturing • Power Generation • Motor Rewinders • Timber • Chemical


Pre-requisite Successful completion of Dynamic Motor Monitoring – Level 1 Course Information 8.30am – 4.30pm

Time

4 days

Days Course Fee

$2,100 AUD + GST $2,520 NZD + GST

Exam Fee

N/A

Course Type

Onsite & Public

Category

Work Identification

Certification

N/A

†


Level 3 Courses Good understanding of the subject with reference to the work types. Typically knowledge gained with 11 - 20 years of work experience.


Vibration Analysis - Level 3 WI204

It is expected that the participant is either the leader of the vibration team, or takes a leading role in diagnosing faults and making the final recommendation. This person must fully understand all of the data collector options, special test capabilities, and analysis tools; and must understand the widest range of fault condition.

ISO Category 3 The training course follows the ISO 18436.2 Category 3 Standard. Successful completion of the written exam will result in ISO Category 3 Certification.

se r uo C ci s aB Industry Application Courses Level 1 Courses

Who Should Attend


Time

4.5 days + half day exam

Days Course Fee

$3,540 AUD + GST $4,250 NZD + GST

Exam Fee


Course Type

Onsite & Public

Category

Work Identification

Certification*

Vibration Analyst 3 Certification

†

Level 3 Courses

Principles of vibration • Quick review of Category II fundamentals • Waveform, spectrum, phase, vectors and orbits • Transients, pulses, modulation, beating, sum/ difference • Force, response, damping, and stiffness • Cepstrum analysis Data acquisition • Special tests: phase, triggering, strobes, low speed machines and variable speed machines • Planning routes and route management • Optimizing test locations and setup options Signal processing • Sampling, resolution, Fmax, averaging, windowing, dynamic range, signal-to-noise ratio • A/D conversion: constant and variable sampling rate Vibration analysis • Spectrum analysis review - Harmonics, sidebands, and the analysis methodology • Time waveform analysis • Phase analysis: bubble diagrams and ODS • Orbit analysis • Analyzing enveloping/demodulation/ PeakVue, etc. data Fault analysis • Natural frequencies and resonances • Imbalance, eccentricity and bent shaft • Misalignment, cocked bearing and soft foot • Mechanical looseness • Rubs and instabilities • Rolling element bearing analysis • Analysis of turbo-machinery and sleeve bearings • Analysis of AC, DC and variable frequency drives • Analysis of gears • Analysis of belt driven machines • Analysis of pumps, compressors and fans • LOTS of case studies and exercises for participants Equipment testing and diagnostics • Impact testing (bump tests) • Phase analysis • Transient analysis • Operating deflection shape analysis

• Introduction to modal analysis • Cross channel measurements Corrective action • General maintenance repair activities • Balancing process: single-plane and two-plane • Review of shaft alignment procedures: dial and laser • Flow control and replacement of machine parts • Resonance control, isolation and damping Running a successful condition monitoring program • Managing a successful program • Reporting and financial management • Growing the program • Incorporating additional technologies Acceptance testing and Review of ISO standards

Product Training

Course Content

Level 2 Courses

The Vibration Analysis Level 3 course is intended for personnel who have at least two years vibration analysis experience and a good understanding of vibration theory and terminology. The course provides an in-depth study of diagnostic measurement techniques and the associated applications of the techniques. This course will give the analyst all of the skills and knowledge necessary to solve all fault conditions, and to run a successful condition monitoring program.


Course Overview

† Course fee is per person and Public courses. Contact SKF for Onsite course fees. Refer to Enrolment Form on page 119. * Certification complies with ISO 18436.2 Category 3 standard.


Applied Modal and Operating Deflection Shape Analysis WI305 Course Overview To provide students with a working knowledge of Experimental Modal Analysis and Operating Deflection Shape Analysis (ODS) from a field vibration analyst perspective.

Course Objectives Upon completion of this course, students learn how to: • Create computer models of plant machinery and structures • Acquire meaningful Modal and ODS measurements • Generate and import Modal and Operating Deflection Shape analysis measurements • Generate meaningful machinery computer animations needed to detect and resolve noteworthy problems such as resonance, structural weakness, foot related problems, design inadequacies, sources of excessive vibration.

Course Content Introductory analysis lecture This portion of the course provides background information on Experimental Modal and Operating Deflection Shape gff62Tw50n gdd5(vthis )rc p is


Dynamic Motor Monitoring, Advanced Diagnostics - Level 3 WI365 Course Overview This course is designed to build upon the knowledge obtained by previous course work and significant field experience with dynamic motor monitoring equipment. This course will provide instruction on advanced diagnosis of data through the use of case study presentations, hands-on data analysis of past problems, and hands-on live motor acquisition, and analysis in a laboratory environment.

Course Objective


• Develop an advanced understanding of motor monitoring applications • Gain an advanced understanding of electrical motor and power quality theory and how it applies to motor monitoring • Develop a comprehensive understanding of the problems the instrument witnesses during operation • Hands-on training for familiarity with instrument connections and operation • Gain a general understanding of the internal workings of the Explorer to help diagnose data acquisition or various motor system related phenomenon

• Food and Beverage • Mining • Cement • Steel • Mineral Processing • Printing • Pulp and Paper • Oil and Gas • Pharmaceutical • Manufacturing • Petrochemical • Power Generation • Municipal Utilities • Motor Rewinders • Maintenance Contractors • Timber • Pump Manufacturers • Chemical

Course Content Dynamic motor monitoring theory • Level I and II review, including basic DC analysis • Advanced power condition • Motor performance/condition • Energy efficiency assessment • Sources of harmonics and strategies to reduce them • Advanced transient analysis • Advanced waveform analysis Software training • Level I and II software review • Advanced data collection techniques • Advanced waveform interpretation and analysis • Advanced Spectrum interpretation and analysis (Including demodulation) Case studies • AC case studies reviewed and “hands-on” analysis • DC case studies review


Pre-requisite Successful completion of Dynamic Motor Monitoring – Level 1 and Level 2 Course Information Time

8.30am – 4.30pm

Days

4 days

Course Fee†

$2,100 AUD + GST $2,520 NZD + GST

Exam Fee

N/A

Course Type

Onsite & Public

Category

Work Identification

Certification

N/A



Introduction to Training Solutions Energy and Sustainability Courses Basic Courses Product Training

Level 3 Courses

Level 2 Courses

Level 1 Courses

“We have always been a bit mystified about Root Cause Failure Analysis – it reminded us of root canal work, which nobody likes. Last year, several of our key maintenance people attended the SKF training course on this mystery subject and came back with an amazing grasp – and real-world answers to some of our most serious machine failure problems. We’ve eliminated expensive guesswork, and repairs are right the first time.”


We’ve become proficient at troubleshooting


Product Training General Understanding of the subject

SKF Training H25gN914072 124 0509

Training Products Workstation Toolkits


Product Training

Level 3 Courses

Level 2 Courses

Level 1 Courses


Basic Courses



Training Products

Shaft Alignment Training Educational Kit Laser Alignment is faster and more reliable Today, most of industry in Australia are using laser based techniques for shaft alignment of machinery. Easy-Laser® products are: • EASY to use • EASY to learn Easy-Laser® • Up to 5 times FASTER than dial gauges All calculations are carried out in the display unit then saved for documentation, and uploaded to a PC.

Shaft Alignment Kits:

E710 Wireless Bluetooth Series

D525 Series

The Easy-Laser® Shaft Alignment D450 D480, D505, D525 and Wireless E710 Kits: SKF have supplied “bearing fitting” training kits to many industries and now SKF can also supply a “shaft alignment” training kit which includes the following: • Easy-Laser® shaft alignment system • Static shaft demonstration stand* • Easy-Laser® pulley alignment unit D90* (*optional)

Price: $ POA

• • • •

CD with PC measurement data base software 3 large posters for wall mounting Shaft alignment training manual Training course in Microsoft PowerPoint


WICM232 MARLIN /Microlog Inspector and SKF @ptitude Analyst Inspector Course description Course topics are organised according to the steps necessary to operate the product. • Setup and utilise the MARLIN/Microlog Inspector Condition Detector (MCD) as a standalone probe to monitor overall machinery and bearing vibration and temperature

Course description Course topics are organised according to the steps necessary to set up a portable monitoring system and to operate the SKF Microlog AX/ GX SKF @ptitude Analyst software product.

Course Objective Participants will learn how to design and build an effective online system vibration measurement database, download measurements to online system local monitoring units, understand online system data collection processes, display and analyse the online system Event Log and online measurement data plots for detection and analysis purposes, and generate online system reports.

• Guidelines for Implementing a Portable Condition Monitoring Program – practical guidelines for Course Description implementing a portable condition monitoring Designed for maximum class participation, this program course is divided into sections that are viewed with presentations, computers practice, and • Introduction to Vibration Analysis – Discuss the reviewed with hands-on group exercises and advantages of various vibration signal processing techniques to isolate and detect specific machinery written reviews. faults (e.g., acceleration enveloping signal processing • SKF @ptitude Online Hardware System (H/W), for early detection of bearing faults) concept, product structure, and applications SKF product training topics • Set up default properties on the SKF @ptitude Analyst software • Learn to navigate the software using its menus, dialogs, windows, hierarchy, terminology, workspaces, etc • How to create a database of vibration measurements

• System checkout and troubleshooting procedures Software installation and setup • Hardware and software requirements • Windows® system settings and installation options • Installing SKF @ptitude Online H/W System

Level 1 Courses

Condition monitoring training topics • Condition based Maintenance Program Overview

NEW

Basic Courses

WICM270 Online Systems and SKF @ptitude


WICM264 AX/GX Series Microlog and SKF @ptitude Analyst


SmartStart™ Technology Training

• Operation and theory

• Online data collection process • How to operate the AX/GX Microlog data collector/ • Measurement process and Heartbeat concept analyser to collect both route and off-route • DAD communication and live data collection measurements process • Generate graphic plots and reports for analysing • Displaying Online data plots measured machinery condition (both software and • Generating and printing data reports AX/GX Microlog) • Advanced AX/GX Microlog application modules, multiple channel measurements, FRF measurements, balancing, etc Course Information


8.30am – 4.30pm

Days

3 days

Course Fee


Time

8.30am – 4.30pm

Days

3 days

Course Type

Onsite

Course Fee


Category

Work Identification

Course Type

Onsite & Public

Category

Work Identification

Level 3 Courses

• Parametric Gating and Control Points

Product Training

• How to set up default properties in the AX/GX Microlog

Level 2 Courses

• Download and upload measurements between SKF • Database configuration: ideology, application software and the AX/GX Microlog data collection device and best practices


SmartStart™ Technology Training WE255 Balancing with an SKF Microlog Course Objective This course is designed to understand and practice how to successfully balance common rotating machinery in the field to precision levels using any SKF Microlog data Collector/Analyser. Course Description Course topics are organised according to the steps necessary to operate the product •

Understand the three common types of unbalance (static, couple and dynamic)

•

Differentiate field and shop balancing tolerances

•

Identify the correct approach to use based on the machine’s L/D ratio, amplitude and phase readings, and response to the trail weight

•

Perform single and two plane balancing

•

Combine and split correction weights

•

Understand lag angle and influence coefficients

•

Appropriate real-world case histories will be used to illustrate balancing techniques for applications such as: fans, overhung and between bearings, paper rolls, flails, augers and hammermills, cooling tower fans, fin


UP-SKILL VIP Membership Program We value the loyalty of our customers continued participation in our training courses. As a reward for you, on behalf of SKF Reliability Systems, we welcome you to our UP-SKILL VIP Membership Program.

UP - SKILL VIP Membership Program - A smarter way to earn The UP - SKILL VIP Membership Program is a reward for all our loyal customers who participate in SKF Training Courses. Membership is free. Points are earned by participating in SKF Training Courses. All customers who have participated in SKF Training Courses in 2011 will automatically qualify and be enrolled in the UP-SKILL VIP Membership Program. The more training you do, the higher status you achieve and the bigger benefit you will receive. Starting from Bronze through to Platinum, the UP - SKILL VIP Membership Program offers you additional cost savings, priority course registration, Traning Needs Anaylsis (TNA) assessment for your employees and tangible benefits for your organisation.

Bronze Membership Benefits include: • Redeem 5% of amount spent on SKF Training courses, in the following calendar year for any future courses as per listed price in the SKF Training Handbook • Priority with registrations • Subscription to the SKF Training Newsletter

Silver Membership Benefits include: • Redeem 7% of amount spent on SKF Training courses, in the following calendar year for any future courses as per listed price in the SKF Training Handbook • Priority with registrations • Subscription to the SKF Training Newsletter • Free Training Needs Analysis (TNA) assessment for 5 employees

COMPETENCY & SKILL ANALYSIS

Gold Membership Benefits include: • Redeem 10% of amount spent on SKF Training courses, in the following calendar year for any future courses as per listed price in the SKF Training Handbook. • Priority with registrations • No cancellation fees • Subscription to the SKF Training Newsletter • Free Training Needs Analysis (TNA) assessment for 10 employees

Platinum Membership Benefits include: • Redeem 10% of amount spent on SKF Training courses, in the following calendar year for any future courses as per listed price in the SKF Training Handbook • Priority with registrations • No cancellation fees • Subscription to the SKF Training Newsletter • Free Training Needs Analysis (TNA) assessment for 20 employees


›

›

To find out more on our UP-SKILL VIP Membership Program, please call (Australia) +61 3 9269 0763 (New Zealand) 0800 753 872 or email us at [email protected]

www.skf.com.au/training

Product

The Power of Knowledge Engineering Drawing on five areas of competence and application-specific expertise amassed over more than 100 years, SKF brings innovative solutions to OEMs and production facilities in every major industry worldwide. These five competence areas include bearings and units, seals, lubrication systems, mechatronics (combining

® SKF, CARB, SRCM and System 24 are registered trademarks of the SKF Group. © SKF Group 2010 The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless written permission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein. PUB THB 2011-01 EN · November 2011

mechanics and electronics into intelligent systems), and a wide range of services, from 3-D computer modelling to advanced condition monitoring and reliability and asset management services. A global presence provides SKF customers uniform quality standards and worldwide product availability.

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SKF Training Handbook

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