Industrial Maintenance Roundtable Common Interest Working Group

Condition Monitoring
Failed

Condition Parameter

Prognosis for Failure

Maxim ise life w ith Minim um Risk. Repair w ith Precision

Diagnose Cause Mitigate Deterioration Detect Fault

Post Mortem , RCA & Docum ent Trend Check

Ideal

Startup Checks

Time

Diagnose

Plan

Schedule

Information produced from Australian South East IMRt Common Interest Work Group (CIWG) on Condition Monitoring (CM). The main issues dealt with include: Condition Monitoring systems used by members Organisational structures & management systems for CM Condition Monitoring techniques Skills Development, training and accreditation for CM Integration with Computerised Maint. Management Systems Condition Monitoring Reporting

Repair

Trend

Trend

Contents
Meeting Number 1. 15 July CUB Topic 1. Introductions, 2. Overview comparison of practices at the various sites, 3. Planning the forthcoming meetings. 1. Structures and management systems for condition monitoring 2. Plant technology and plant life cycle. 3. A focus on the following types of CM techniques; a. Thermography, b. Use of SCADA and DCS c. Energy Power usage, Air flow, load changes 1. Developing the people. Developing the skills, providing the training and defining and maintaining the standards. 2. A focus on engaging people in using the five senses to deliver condition monitoring. 1. Integrating the Computerised Maintenance Management System and the Condition Monitoring System. 2. A focus on NDT, on Ultrasonics and on Motor Circuit Analysis. 1. 2. 3. 4. Comparison of reporting systems. Reports from the contractors In-house reporting Bringing it all together.

Number 2. 15 September SIRF RT offices

Number 3. 10 November SIRF RT offices

Number 4. 9 February Yallourn Energy

Number 5.

Meeting 1 - Main Condition Monitoring Systems used by IMRt Members

CMMS Computerised Maintenance Management System REPORTING Self rating of maturity of reporting system. 10 best Frequency of taking readings Reporting process VIBRATION ANALYSIS Self rating of maturity of vibration analysis system Frequency of taking samples Contracted or Inhouse Service provider Type of equip OIL ANALYSIS Self rating of maturity of system 8 5 4 5 6 Service provider ALS. 3 day turnaround with results to web In house. Now have a dedicated lubrication team. CSI Oilview. Shell for detailed oil analysis. Shell have carried out site wide review. Belray does oil analysis Oil sampling inhouse. Also use Oiltest in Singleton and Shell - Amdel Oil sampling inhouse. Also use Shell - Amdel In house sampling. Use Oilview Mobil Oilview AlS for oil analysis. Making greater use of filtergrams, have own microscope. 3 monthly for critical ALS. 3 day turnaround with results to web Company

CUB

Various at diff sites MPAC

Report by exception

1 monthly

Contractor gathers and interprets

CSI

MSC

Monthly for critical equipment, others 3 monthly.

Yallourn

Maximo

Report on line for routine. Report face to face for exceptions. Report by exception. One page maximum. Face to face for routine. Use RBMware and WAN

Mostly in house Inhouse sampling by 3 techs

CSI

Mostly inhouse but refer to MSC for assistance.

Murray Goulburn

BuildPro from OCS

CSI. Four Mostly in2120 house but analysers Mostly in house. refer to Use MSC for RBMware and assistance. WAN MSC CSI and Mostly inhouse. InBently Nevada for on house contractor line. CSI and Bently Mostly inNevada for on house. line. CSI Mostly inhouse.

Kraft

Avantis

Quarterly on Contractor gathers big equip and interprets

Aust Paper Burnie

PBS4 Today system

Dependent on user.

Mostly in house.

Aust Paper Maryvale

PBS4

Generally by exception, targetted Monthly report

14000 points. Check every 35 days

Mostly in house.

PPG

Maximo 5.2

6 on critical plant

Dedicated inhouse analyst.

Qenos

SAP

MSC standard report. RBMware

In house sampling

Mostly inCSI and house. Also On line = Bently MSC and 10, Portable Nevada for on Burdett =5 line. Engineering

Onesteel

SAP

Developing a new reporting system

Generally in-house

Mostly inhouse.

Shell

SAP

Pacer spreadsheet

10

Priority equip 1 / month while others monthly.

2 dedicated inhouse people

CSI

Mostly inhouse.

Main Condition Monitoring Systems used by IMRt Members (cont)

CMMS Computerised Maintenance Management System REPORTING Self rating of maturity of reporting system. 10 best Frequency of taking readings Reporting process VIBRATION ANALYSIS Self rating of maturity of vibration analysis system Frequency of taking samples Contracted or Inhouse Service provider Type of equip OIL ANALYSIS Self rating of maturity of system 3 N/A 4 4 4 7 7 N/A ABB 5 Service provider In house sampling. Use Mobil for analysis No routine lubrication anlaysis but ensure good lubrication standards. N/A Monthly on critical plant. Only on major equipment Analysis only on hydraulics only. 6 Monthly Hydraulics monthly, gearboxes quarterly N/A Atlas Copco Atlas Copco BP Detecta (ALS) Shell (Amdel) for general station imported into Entek CM software for reporting and exceptions, Oiltech for specific tests Varies

Company

Loy Yang

Passport

Report on exceptions

2 in-house techs for sampling and analysis

Entek in station and CSI in mine, Bently Nevada on line on turbines

Mostly inhouse.

Nufarm

Mex

By exception verbally

Critical every 2 to 3 months

Bladett engineering

Australia Post

SAP

Not applicable

N/A

Trialed but did not add value

N/A

N/A

N/A

N/A

Orica

Trending and Mainpac detailed exception reports.

10

Monthly

Contracted out. Previously in house.

SKF Microlog

Industrial Machine Analysis

10

ADI

BPIX Maximo

Not formal. Done by exception

In-house

Pruftechnique

Bluescope Steel

MIMS

Report by exception Exception reporting for monthly management report and ability to view condition on all machines currently being put on intranet Monthly & by exception By exception Monthly

Typically monthly

In house

Entek / Tensor Systems Bentley Nevada

Burdett engineering for some balancing

Edison Mission

MPAC

2 weekly, 1 monthly & 2 monthly depending on equipment

In house

Entek Bentley Nevada & Oros

3 monthly

WMC

SAP

Vary by criticality Only on indication of fault Monthly

Central group & Contractors Contractor gathers and interprets Contractor

Mostly CSI

Local service providers Pannasic Eng ABB

Frequency on criticality 1,3 or 6 M No oil analysis Monthly

Kodak Pilkington

SAP Mex SAP

7 2

Entek

Meeting 2 - Structures and Management Systems for Condition Monitoring Summary

A range of organisational structures and management systems for CM are possible and can be successful. Strong central control/co-ordination gives better rigour and technical control. Strong local control can achieve better local ownership, coordination, teamwork and solution/recommendation implementation. Organisations may tend to swing between these two approaches. If a strong long-term local management commitment to CM can be maintained then decentralised management of CM has advantages (Bluescope). Where a long-term commitment to rigorous application of CM is not likely to be maintained it is better to mange CM centrally (Maryvale Paper). A middle ground is local personnel doing data collection with centralised analysis of the data (Edison Mission). In all approaches there is a requirement for a strong organisational champion for CM. Use of CM contractors for collection and analysis of CM data can be successfully applied (CUB & WMC). Where CM contractors lack local equipment and process knowledge there is a requirement for local CM expertise to interpret reports and coordinate maintenance responses (CUB). Some contractors may have enough local equipment and process knowledge they can produce sensible CM recommendations and follow-up on the maintenance responses (WMC). A rigorous process to determine CM requirement for equipment involving local and technical expertise can have major benefits in getting local commitment and achieving the required equipment reliability result (WMC). At the data collection level a number of options were mentioned, any of which may be best suited for a particular application. Options are listed below. The greater the percentage of the time dedicated to the role the more successful it is likely to be. o Operators collection of CM data (better if are trades based) and a CM technician analysing the data. o Local maintenance trades personnel collection of CM data and a CM technician analysing the data. o Local maintenance trades personnel collection of CM data and doing a first level analysis of the data. A CM technician can do a second level analysis of the data if required and carry out specialist diagnostics. o A CM technician doing all collection and analysis of data for a particular area. o Another approach is for operators or local maintenance personnel to use simple monitoring technologies such as vibration pens and call in specialists only when diagnostics are required.

Suggestions from the group for an output from the CIWG on Structures and Management Systems are listed below. Listing of elements to consider and options when deciding on structures and management systems for the support of CM. Information useful for Benchmarking of a CM practices within companies. An attempt was made in the meeting to setup a matrix to define good practice for CM structures and management systems but the group struggled with the complexities in this task because of the large range of variables involves. An updated version of the Condition Monitoring Practices Self Assessment initially reviewed by the WA IMRt in 2003 is included at the end of this report. Plant Technology & Plant Life Cycles Summary The concept of equipment and plant life cycles may not always be applicable as some equipment can be maintained indefinitely without replacement. There are plants and equipment that are promoted as maintenance free but this does not tend to work in practice. In most situations technology improvement drives major equipment replacement. Where equipment is subject of wear, usually from aggressive process mediums or fatigue, life cycle replacement is applicable LCC is a method used to justify these replacements (WMC). An analysis of different monitoring approaches was carried out for plant other than typical rotating equipment. This information is presented below

Plant Technologies and Condition Monitoring Methods

Plant Types/ Equipment Technologies Civil Structures & Buildings Small scale high speed processing plant Monitoring Characteristics, Parameters Temperature and Humidity Delicate - Large number of small components Visual inspection and temperature Ultrasonic non-contact Thermograph Sonic View 7000 Ultrasonic thickness testing Visual inspection Visual inspection Maintaining air cleanliness Solenoid problems monitored by audible noise PM change-outs Oil analysis - Keep oil clean - ISO cleanliness testing Good installation practice & good commissioning Use good quality desiccant filters on breathers Thermograph on accumulators and cylinders Performance monitoring - cycle times Contact ultrasonic monitoring of internal leakage Commissioning alignment and vibration baselines

Tank pipework & vessels Small non-rotating equipment - Pneumatic

Hydraulic equipment

Thermography Summary Common in the group was the use of thermography for monitoring electrical equipment and was considered normal practice and did not require discussions. Other applications for thermography are many and varied and the technology is often used as a diagnostic and problem solving tool an much as a monitoring tool. Use of the technology is only limited by the imagination. Current high quality cameras cost between $25K to $50K with lower cost systems down to $3K. Simple non-contact temperature guns are widely used as a monitoring tool. Reports benefit from the including of digital photos with thermal images. SCADA & DCS Systems Summary Process computers are generally underutilised by maintenance as a monitoring tool. Applications such as monitoring motor amps, flow, pressure, temperatures and auto instrument calibration were mentioned. Recording equipment run hours was also mentioned. There are a number of advantages for monitoring batch processes where routine monitoring would be difficult to coordinate. Performance Monitoring Summary Two portable instrument liquid flow measurement technologies are very useful. o Transit time flow measurement for clean fluids o Doppler effect flow measurement for less clean fluids.

Meeting 3 - Condition Monitoring Skills Development, Training & Accreditation

Skill Development
Basic condition monitoring and inspection skills development is worthwhile for shop floor maintenance trades and operations personnel. There was general recognition of the importance of and interest in non-technical 5 senses inspection skills (look, listen & feel). This is a key area that requires initial development for all operator and maintenance personnel and is the starting point of good condition monitoring personnel. Supplying CM training to maintenance planning and other maintenance personnel has benefits by getting a better commitment in implementing condition monitoring recommended actions. Approaches that give CM and inspection roles high profile, desirable, respected or exclusive will be a advantage in ongoing management of a program. The level of interest and motivation of the individuals involved is a key issues for selecting good condition monitoring personnel.

Getting the right culture of rigorous CM, inspections, PMs and planning is difficult as trades personnel tend to think of themselves as repairers which tends to support a breakdown culture. When the main additional financial reward is Overtime, this also support a breakdown culture. Annualised salaries if well managed can tend to support good CM and planning cultures. Where there is other effective systems of rewards that support good maintenance performance, this also support good CM and planning cultures. The greater the percentage of time a person is doing condition monitoring and inspection work the greater the skill level that can be achieved. Personnel who are only very occasionally required to do CM data collection work will probably not be very motivated or successful.

Training
Yallourn Energy has developed there own level 1 vibration training material Training involves classroom presentations and computer based modules Vibration training software system used is i Learn within the training process and there was suggested to be a good system. Available as a single user system or as a network system This vibration training has been set up as a special local TAFE accredited training module for Yallourn. The person who does the training is a local Yallourn person. Existing generic CM TAFE modules (18-10 & 18-16) do not fully cater for the training requirement. The technical side of CM is generally well catered for by the current condition monitoring equipment and service suppliers such as Rockwell, CSI and ALS. Noria oil analysis courses are recognised as excellent training. Some good examples of the effectiveness of peer to peer training were given. Where CM personnel are based in local teams there is increased difficulty in building and maintaining expertise. Having locally based personnel come to a central location, where technical support is available, to download and analyse data has advantages in ongoing training and support. Networked CM software has advantages for support of less experienced personnel especially if support personnel are some distance away from the user. It is important to have someone who is a CM coordinating role in a larger organisation to ensure standardisation of approach, manage skill development and to audit compliance to the current condition monitoring strategy. Process of regular monthly meetings of CM personnel is a good opportunity to present case studies and technical information as a part of an ongoing training process for CM personnel who are locally based. Systems where tradesmen are paid for completing training have not been as successful as where people are paid for using skills.

Accreditation
One issue with CM accreditation is if organisations can see the benefits they will get out of paying extra to get there personnel Certificated. This needs to be promoted. The individual benefits from completing accredited training by having recognised skills that are transportable. A major advantage of a well accepted training accreditation system is that a company can advertise for personnel of a certain level and have good confidence that the person they hire will have the required competencies. ISO Standards have a standard on Condition monitoring an diagnostics of machine Requirements for training and certification of personnel. There are several parts to the standard, most of which are still in draft form. They are: o 1 - Requirements for certifying bodies and the certification process o 2 Vibration condition monitoring and diagnostics o 3 Requirements for training bodies o 4 Lubrication management and analysis o 5 Thermography o 6 Diagnostics and prognostics o 7 Condition monitoring specialists Vibration CM and lubrication management will have 4 levels of certification with level 1 basic data collection and oil sampling respectively. Thermography will have 3 levels of certification. It is currently proposed that the accreditation body for training in Australia will be the AINDT. AINDT is already managing the thermography certification for CM personnel which should be similar under the ISO standard. The first new system of accreditation for CM training in Australia will likely be for Lubrication management and analysis. Accreditation for vibration condition monitoring training may be a considerable time before it is in operation

Operator and Maintenance Front Line Personnel Involvement, Communication and Processes
CUB has a system of coloured tags that operators attach to their equipment to identify faults and the colours define the priority that the maintenance personnel should apply to the repair and follow-up actions. Some organisations have white board systems to record issues and their priorities. Capturing and actioning the items that piss operators off with the equipment and getting things done is very important in building relationships and teamwork. This is especially so where there is large backlogs of uncompleted maintenance and improvement work. The process of carrying out lubrication on equipment and the motivation and ownership of the personnel involved are very important. Application of 5 senses inspection and simple CM during lubrication is strongly supported.

CM Techniques
Timely systems that monitor water in oil with direct feedback to cleaning crews on the job has been successful in reducing water entry into oil compartments.

List of IMRt member participants involved with CIWG. (Will be completed after
next meeting)

Self-Assessment of the Health of Your Condition Monitoring Practices

The following are "self assessment" items for making a "first pass" assessment of the practices that support condition monitoring at a site. (Please review) 1 A formal, periodic equipment inspection system is in place that is consistent with manufacturers' specifications and in compliance with government regulations. 2 Predictive maintenance inspection routes have been established and inspections are made on schedule. 3 Inspections are always carried out exactly as specified and at the specified inspection frequency. 4 Discrepancies are always accounted for in an appropriate manner before the process/equipment is returned to operation. 5 A lubrication program is in place to ensure equipment is lubricated routinely and adequately with the proper lubricant. 6 Critical equipment (based on impact on safety, production, quality, environment, cost etc) have been identified and listed for the purpose of applying predictive maintenance techniques. 7 Alert and danger limits for parameters have been established and published.

8 Records are formalised and trend analysis Is routinely used to monitor equipment condition. 9 A system of inspections have been developed for; 1. Noise level 2. Leaks or emissions 3. Hot spots 4. Physical condition (paint- corrosion, loose parts, missing nuts or bolts, deteriorated insulation- etc) 10 11 12 13 A system is in place to ensure that inspection occurs. Equipment specifications are maintained and are easily retrieved when needed. There is always a follow up on observations made by personnel carrying out inspections. Service providers carry out work to an agreed and appropriate standard and are audited.

14 A methodical process, based on recognized principles, has been used to customize asset management strategies, alarm limits and frequencies. The process includes review of the cost effectiveness of condition monitoring. 15 Steps are taken to ensure readings are taken in a repeatable way. For example the accelerometer is placed in exactly the same way and the pump is operated under the same process conditions. 16 The system provides appropriate feedback. For example (1) Inspectors are able to see what actions are taken on their observations, (2) Appropriate "post mortems" are carried out on failed parts. 17 Formal roles, responsibilities and range are defined for condition monitoring and follow up action and personnel have appropriate skills. 18 Failure Mode Effects and Criticality Analysis (FMECA) or Root Cause Analysis (RCA) is used to assess critical failure modes and appropriate precautions are in place. Planning systems, history archives and the use of arc appropriately integrated. 19 Trades people and operators believe that leadership promotes and provides appropriate ownership and management of condition monitoring. 20 A system is in place for the calibration of instrumentation, both process instrumentation and instrumentation used in condition monitoring.
Deleted: 20

Formatted: Bullets and Numbering

Appendix 1 Yallourn Condition Monitoring Training Session Plans

Condition Monitoring Training

Session Plan 1: Maintenance Concepts Organisation: Section: Duration: Trainer: Participants: Location of Training: Learning Objective: Yallourn Energy Alliance Support Team 2 Hours Danny Shine Maintenance Fitters Learning Center To understand the principles behind the various maintenance strategies and provide knowledge of condition monitoring and a trademens role in condition monitoring. (Performance Criteria MEM 18.10A.1.1) Explain how maintenance has evolved over time to become a very competitive and value adding function of industry and the growing demands on plant to perform when required. Definition of maintenance. Importance of maintenance for plant reliability. Maintenance practices Reactive maintenance Preventive maintenance Condition based maintenance Proactive maintenance Costs/Benefits Introduction into condition monitoring. Role of tradesmen in Condition based maintenance. Discussion, work book, overheads, demonstration, I Learn Interactive. Participants will: By multiple choice question exam explain the objectives and principles of maintenance and

Introduction:

Main Points:

Training Methods: Assessment:

how the different maintenance approaches can be used at Yallourn Energy. Conclusion: This unit covers the underpinning knowledge required to recognize all types maintenance and how condition monitoring is used to support maintenance. PC projector, White board, Work Book. Interactive (common maint practice introduction). - (cond mon-why do we do it)

Resources:

Condition Monitoring Training

Session Plan 2: Condition Monitoring Methods Organisation: Section: Duration: Trainer: Participants: Location of Training: Learning Objective: Yallourn Energy Alliance Support Team 1 Hour Danny Shine Maintenance Fitters Learning Center By the end of the session students will be able to describe the failure cycles of machinery and the range of methods that are used at Yallourn Energy to perform Condition Monitoring. Explain the basic causes of machinery failure through the life cycle. The phases of wear and concepts of Condition Monitoring and include how it can be used in Predictive Maintenance. Highlight the various technologies and equipment used today to perform Condition Monitoring. Machinery failure modes and causes. Machinery life cycle- Bath Tub Curve Basic sensory perceptions Sight - Hearing - Touch

Introduction:

Main Points:

- Smell Condition monitoring using portable test equipment. Training Methods: Assessment: Discussion, work book, overheads, demonstration, I Learn Participants will: By way of multiple choice question exam demonstrate knowledge of the machinery failure Bath Tub curve. Define the human senses that can be used for CM and the electronic technologies that can be used to enhance these senses. This unit covers the underpinning knowledge needed to identify the modes of machinery failure and methods used for condition monitoring. PC projector, White board, Work Book. I Learn (cond mon - introduction) - (cond mon technologies vibration analysis)

Conclusion:

Resources:

Condition Monitoring Training

Session Plan 3: Vibration Fundamentals Organisation: Section: Duration: Trainer: Participants: Location of Training: Learning Objective: Yallourn Energy Alliance Support Team 2 Hours Danny Shine Maintenance Fitters Learning Center By sessions end participants will understand the information that can found in a vibration spectrum that identifies machines faults and their condition.

Introduction:

Explain vibration in simplest form and how it is able to provide in comparison to other technologies the most information regarding a machines condition. Defining vibration Relationships of different ways of measuring vibration Methods for measuring vibration (frequency/amplitude Vibration unit relationships Vibration waveform and spectrum Basic machinery fault identification Alarm trending Discussion, notes, overheads, demonstration, I Learn Interactive. Participants will: By multiple choice question exam give evidence of understanding, in the definition of vibration and of 3 main units it can be measured, the difference between waveform/spectrum and the knowledge of basic machine faults and frequencies at which they occur. This unit covers the underpinning knowledge that will enable participants to take vibration measurements on rotating plant to Standard Operating Procedures and make Exception Analysis Reports from collected data. PC projector, White board, Work Book. I Learn (Vibration Fundamentals complete list)

Main Points:

Training Methods: Assessment:

Conclusion:

Resources:

Condition Monitoring Training

Session Plan 4: Use of Vibration Hardware/Software Organisation: Section: Duration: Yallourn Energy Alliance Support Team 3 Hours

Trainer: Participants: Location of Training: Learning Objective:

Danny Shine Maintenance Fitters Learning Center This session will provide students with the knowledge and skills to be able to demonstrate the correct use CSI 2120 vibration data collector to take machinery vibration data. It will also cover the use of CSI RBMWare software PC program used to record and analyse vibration data. (Performance Criteria 18.10A.1.3) Broadly explain the difference between the CSI 2120 data collector (Hardware) and RBMWare PC (Software) in the CM program and the role each plays as part of the CM program. Operation of CSI 2120 data collector:Taking route based data Reviewing measurement alarms Basic spectrum analysis Using Note Codes Taking exception data Measurement errors Reporting measurement point alarms Operation of CSI RBMWare:Demonstration of RBMWare program

Introduction:

Main Points:

Training Methods: Assessment:

Demonstration, discussion, notes, overheads. Participants will: Confirm via workshop demonstration and limited field examples that students can print previous condition reports from 80/20, Upload vibration measurement point route into CSI 2120 data collector, operate function keys of CSI 2120 data collector to take vibration readings, make field observations of plant condition & assess alarms and record Note Codes, down load measurement point readings into PC, print an Exception Analysis report and report findings.

Conclusion:

This unit covers the underpinning knowledge required to operate the CSI 2120 data collector and take vibration measurements. CSI 2120 data collector, CSI RBMWare, Work Book.

Resources:

Condition Monitoring Training

Session Plan 5: Vibration Data Collection & Vibration Analyses/Reporting Organisation: Section: Duration: Trainer: Participants: Location of Training: Learning Objective: Yallourn Energy Alliance Support Team 8 Hours Danny Shine Maintenance Fitters Learning Center This session will provide students with the knowledge and skills to be able to demonstrate the correct use CSI 2120 vibration data collector for route based and exception vibration measurements. It will also provide knowledge on Uploading/Downloading on vibration measurement routes and producing exception reporting via RBMWare software. Explanation of route based vibration data collection and the procedure to follow i.e. (Guidelines Sheet for Vibration Monitoring) Uploading of vibration measurement routines Vibration measurement of rotating machinery (as per SOP 1 and Guidelines Sheet for Vibration Monitoring) Alarm assessment. Taking Exception vibration data Using Note Codes Downloading data collector to RBMWare. Exception analysis reporting (as per Guidelines Sheet for Vibration Monitoring)

Introduction:

Main Points:

Training Methods: Assessment:

Discussion, notes, overheads, demonstration. Participants will: Confirm via On Job demonstration that students can operate function keys of CSI 2120 data collector to take vibration readings, assess alarms, record Note Codes and take Exception Based vibration data. Upload and download vibration data from CSI RBMWare and produce an Exception Report to highlight faults for further analysis and follow-up by key personnel. This unit covers the underpinning knowledge required to achieve successful soft foot correction and identify Rotalign faults. CSI 2120 data collector, Networked PC with CSI RBMWare, Operational machinery, System Engineer.

Conclusion:

Resources:

Appendix 2 Yallourn Alignment Training Session Plans

Pruftechnik Laser Alignment Training

Session Plan 1: Principles of Shaft Alignment Organisation: Section: Duration: Trainer: Participants: Location of Training: Learning Objective: Yallourn Energy Alliance Support Team 1 Hours Danny Shine Maintenance Fitters Mine Condition Monitoring Team Office By the end of the training session students will be able to explain what shaft alignment means with regards to rotating machinery and be able to identify the four types of mis-alignment and explain their effect on machine reliability. Identify three different alignment tools including straight edge/feeler gauges, dial indicators and Laser. (Performance Criteria 18.9A.1.1) Introduce subject shaft alignment of rotating machines. Will cover what shaft alignment is, what affects mis-alignment has on plant, different alignment methods and alignment tolerances. Where Shaft Alignment is used and by who. Explanation of Alignment. Types of mis-alignment Vertical/Horizontal, Angular/Offset. (Show on test rig) Mis-alignment and machine reliability. Processes of aligning shafts straight edge, dial indicators, laser. Benefits and tolerances. Discussion, notes, overheads, demonstration. Participants will: By written test explain what alignment is and where it is used and the types of mis-alignment. Explain three different alignment methods and their advantaged/disadvantages.

Introduction:

Main Points:

Training Methods: Assessment:

Conclusion:

This unit covers the underpinning knowledge required to recognize all types of mis-alignment and the tools used to measure and correct alignment. Pruftechnik Rotalign Set, Overhead projector, White board, Handouts, Training rig, Dial indicator Bar Sag rig, Tool kit.

Resources:

Pruftechnik Laser Alignment Training

Session Plan 2: Safety Aspects of Laser Alignment Organisation: Section: Duration: Trainer: Participants: Location of Training: Learning Objective: Yallourn Energy Alliance Support Team Hour Danny Shine Maintenance Fitters Mine Condition Monitoring Team Office Students be able to identify the type of laser system used in laser alignment optics and understand the practices required to perform an alignment using lasers without harming themselves or others. Highlight that lasers are hazardous if used incorrectly and that personnel injury can result. Types of lasers available i.e. Class 1, 2, 3. Type of laser used in laser optics. Dangers of lasers and modifications to Rotalign. Safe use of lasers. Discussion, notes, overheads, demonstration. Participants will: By way of written assessment demonstrate knowledge of the safe use of lasers and the associated dangers. Define the type of laser used in alignment systems.

Introduction: Main Points:

Training Methods: Assessment:

Conclusion:

This unit covers the underpinning knowledge needed to identify Lasers used in alignment and their safe use. Pruftechnik Rotalign Set, Overhead projector, White board, Handouts, Training manual.

Resources:

Pruftechnik Laser Alignment Training

Session Plan 3: Pre-alignment Machinery Checks Organisation: Section: Duration: Trainer: Participants: Location of Training: Learning Objective: Yallourn Energy Alliance Support Team 2 Hours Danny Shine Maintenance Fitters Mine Condition Monitoring Team Office By the end of the session students will be able to determine the correct tools and pre-alignment checks necessary to perform alignment accurately and efficiently. (Performance Criteria 18.9A.1.4, 18.9A.1.2, 18.9A.2.1, 18.9A.2.2) Explain benefits of alignment pre-checking and its ability to reduce total alignment and the effect incorrect tooling has on alignment accuracy and efficiency. Permit requirements Tooling requirements Shaft run-out checks Cleaning of machinery Soft foot inspection/correction Drive coupling inspections Discussion, notes, overheads and demonstration on training rig. Participants will:

Introduction:`

Main Points:

Training Methods: Assessment:

Provide written evidence of knowledge to correct tooling, cleaning and permit procedures required for machinery alignment. Provide a practical demonstration of shaft run-out, bearing clearance and soft-foot measurement and correction. Conclusion: This unit covers the underpinning knowledge that will enable Fitters to select the tooling required for alignment tasks and identifies checks and corrections before alignment. Pruftechnik Rotalign Set, Overhead projector, Handouts, Training rig, Tool kit

Resources:

Pruftechnik Laser Alignment Training

Session Plan 4: Alignment of Machinery using Pruftechnik Laser System Organisation: Section: Duration: Trainer: Participants: Location of Training: Learning Objective: Yallourn Energy Alliance Support Team 5 Hours Danny Shine Maintenance Fitters Mine Condition Monitoring Team Office This session will provide students with the knowledge and skills to be able to demonstrate the correct use Pruftechnik Rotalign and select the appropriate method for measurement taking to achieve alignment tolerance. (Performance Criteria 18.9A.1.3, 18.9A.1.5, 18.9A.2.3,) Explain importance of appropriate measurement method and reasons for storing alignment file information. Alignment procedures. Alignment techniques. Measurement taking. Interpretation of measurements. Calculation of machine movements to obtain tolerance.

Introduction:

Main Points:

Saving measurements to history. Saving alignment files. Training Methods: Assessment: Discussion, notes, overheads, demonstration. Participants will: Confirm via demonstration that students can select the appropriate leveling and aligning procedure. That measurements can be taken effectively and consistently and can be interpreted so the machine can moved to tolerance. Demonstrate file saving and recording on PC system. This unit covers the underpinning knowledge required to achieve accurate alignment with the use of Rotalign. Pruftechnik Rotalign Set, Overhead projector, Handouts, Training rig, Tool kit

Conclusion:

Resources:

Pruftechnik Laser Alignment Training

Session Plan 5: Trouble Shooting Organisation: Section: Duration: Trainer: Participants: Location of Training: Learning Objective: Yallourn Energy Alliance Support Team Hour Danny Shine Maintenance Fitters Mine Condition Monitoring Team Office Students to be able to identify the most common causes of Pruftechnik Rotalign faults and measurement inconsistency/error. To be able to measure, identify and correct the various forms of machine soft foot. Explanation of necessity of consistent measurements and the effect of soft foot on alignment tolerance.

Introduction:

Main Points:

What is soft foot? How to measure and correct different soft foot types. Trouble shooting Rotalign faults. Techniques to obtain consistent measurements. Limitation of lasers and environmental factors. Discussion, notes, overheads, demonstration. Participants will: Confirm through practical demonstration that student can effectively measure 3 different soft foot examples, create soft foot maps and correct soft foot error. Via written test identify 4 most common causes of Rotalign error and suggest remedies. This unit covers the underpinning knowledge required to achieve successful soft foot correction and identify Rotalign faults.

Training Methods: Assessment:

Conclusion:

Resources: Pruftechnik Rotalign Set, Overhead projector, White board, Handouts, Training rig, Tool kit