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Hands-on Industrial Maintenance Training Program

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SpectraQuest Introduces
Maintenance 4.0 Solution for Manufacturing Workforce Skills Enhancement

Labsetup

– CompletePackage for Establishing On-site Hands-on Industrial Maintenance Training Program to Maximize Asset Uptime and Reliability

Spectra Quest, Inc. is pleased to introduce a turnkey program in the field of Maintenance and Reliability Engineering (M&RE) for implementation at community colleges and vocational training centers. This field is enormous, allowing ample room for growth at the baccalaureate, masters, and doctorate levels. This complete package includes the course syllabus, text, laboratory exercises, laboratory devices/simulators, and instructor lecture plans to initiate a comprehensive program for a solid foundation.

This material provides a unique program specializing in machine condition monitoring and diagnostics using vibration analysis and associated technologies to provide the essential training for the proper maintenance and monitoring of assets (machines). The objective is to extend asset life at the minimum possible cost. This program teaches an aspect of Reliability Centered Maintenance (RCM) that is critical but is often not addressed in detail due to the very technical knowledge and understanding required.

The following courses are included:

  1. Introduction to Industrial & Machinery Maintenance: This course provides students with the basic material to enter the field of industrial and machinery maintenance.Major topics include, but not limited to; safety requirements, common types of machinery, lubrication, bearings, installation and maintenance practices, mechanical drive systems including gears, belts, chains, sprockets, couplings, and drive shafts, types of maintenance, Run-to-Failure, Preventive Maintenance (PM) and Predictive Maintenance (PdM).
  2. Introduction to Machine Vibration Analysis (ISO CAT I): This course provides an introductory overview of the asset health monitoring concept with an emphasis on application of vibration monitoring and analysis.
  3. Machine Vibration Analysis (ISO CAT II): This course provides sufficient knowledge to collect vibration information and perform limited analysis.
  4. Introduction to Shaft and Sheave (pulley) Alignment: This course provides hands-on training in the use of dial indicators and laser alignment tooling to perform adequate alignment for smooth operation of the asset (machines).
  5. Rotating machine balancing: This course teaches how to balance the most common machinery using single and multiple plane balancing techniques.
  6. Introduction to IIOT PDM: This course provides introduction to industrial internet of things and the use of predictive maintenance in the era of Industry 4.0 smart (connected) manufacturing.
  7. Machine Vibration Analysis (ISO CAT III): This course provides the required knowledge to set up and implement a condition monitoring program in a plant. It also prepares the student to perform more extensive analysis.
  8. Machinery trouble shooting (diagnostics) and Root Cause Failure Analysis (RCFA): This course prepares student to be able collect required information to isolate the cause of machine malfunction and determine the root cause so corrective action can be taken to minimize future occurrences.
  9. Introduction to Reciprocating Mechanism Dynamics: This course teaches the mechanical workings of a reciprocating mechanism as used in production machinery and transportation.

1. Introduction to Industrial & Machinery Maintenance

A. Course Description: This course provides students with the basic material to enter the field of industrial and machinery maintenance. Topics include, but not limited to; safety requirements, common types of machinery, lubrication, bearings, installation and maintenance practices, mechanical drive systems including gears, belts, chains, sprockets, couplings, and drive shafts, types of maintenance, Run-to-Failure, Preventive Maintenance (PM) and Predictive Maintenance (PdM).

B. Objective: The objective is to educate the student on the expectations of the modern industrial maintenance department and tomake the student fully aware of the current state of technology and corporate expectations to achieve reliable machinery operation.

C. Skills Learned:

1.Typical modes of machinery failure from infancy to end of life
3. Types of maintenance philosophies and their application
4. How to set up an appropriate maintenance program to prevent or anticipate failure.
5. Preventive maintenance details
6. Concept of condition monitoring and implementing predictive maintenance with the goal to achieve maximum asset life at the lowest operating cost
7. Basic power transmission mechanisms such as gearing, shifting mechanisms, and belt and sprocket drives.
8. Learn to perform inspection and to take care of maintenance issues of these mechanisms
9. Types of couplings and care/inspection of same
10.Drive shafts and torque issues associated with transmission mechanisms


D. Prerequisites: Familiarity with machinery and general maintenance procedures

E. Teaching Aids: Power Transmission Simulator, text material, lesson plan, laboratory exercises

2. Introduction to Machine Vibration (ISO CAT I)

A. Course Description: This course provides an introductory overview of the asset health monitoring concept with an emphasis on application of vibration monitoring and analysis. The course provides the basic instruction required for the student to pass the vibration ISO CAT I certification exam.

B. Objective: Enable the student to appreciate benefits of vibration analysis and pass the ISO CAT I certification exam.

C. Skills Learned:

1. Understanding the role of machine condition monitoring and vibration analysis in maintenance.
2. Basic principles of vibration theory, how to measure and represent it.
3. Instrumentation and transducers used for vibration measurement
5. Use standards to check vibration severity
6. Basic knowledge of different equipment operation such as electric motors, fans, pumps, compressors, etc.
7. Basic knowledge of different faults typically found in industrial equipment
8. Familiarize with acceptance testing specifications and standards
9. All those listed as requirements to sit for ISO CAT I exam.

D. Prerequisites: Basic mathematics

E. Teaching Aids: MFS, data collector/analyzer, software, text material, lesson plan, laboratory exercises.

3. Machine Vibration Analysis (ISO CAT II)

A. Course Description: The course provides the fundamental instruction required for the student to pass the vibration ISO CAT II certification exam.

B. Objective: Enable the student to become a valuable part of a condition monitoring team and pass the ISO CAT II certification exam.

C. Skills Learned:

1. Knowledge of basic principles of vibration theory and procedures for determining resonance, critical speed, and damping
2. Instrumentation and transducers used for vibration measurement
3. Signal analysis and FFT concepts
4. Use standards to detect machine faults and learn how to check for severity
6. Identify the various frequencies present in a frequency spectrum, and associate them with various possible faults for a given machine
7. Perform basic balancing and alignment tasks
8. Perform acceptance testing specifications and standards
9. All those listed as requirements to sit for ISO CAT II exam

D. Prerequisites: Basic mathematics, trigonometry, algebra I, logarithms, hands-on practice collecting and analyzing machinery vibration.

E. Teaching Aids: MFS, data collector/analyzer, software, text material, lesson plan, laboratory exercises


4. Introduction to Shaft and Sheave (pulley) Alignment

A. Course Description: This course provides hands-on training in the use of dial indicators and laser alignment tooling to perform adequate alignment for smooth operation of the asset (machine).

B. Objective: Enable the student to perform professional machinery alignment on basic industrial machinery.

C. Skills Learned:

1. Use of dial indicators and laser alignment tooling for alignment
2. Use of appropriate software to perform quality machinery alignments
3. Use of different methodologies for different types and configurations of machine alignment
4. Learn how to use laser for pulley/sheave alignment
5. Learn to select fixed and movable machine for fast, convenient alignment task

D. Prerequisites: Experience with dimensional measurement devices and typical mechanical tooling for positioning machinery (hammers, levers, hydraulic jacks, hoists, etc.)

E. Teaching Aids: SAT, Power Transmission Simulator, alignment tooling (dial indicators, brackets, lasers, shims, etc.) software, text material, lesson plan, laboratory exercises.


5. Rotating Machinery Balancing

A. Course Description: This course teaches how to balance the most common machinery using single and multiple plane balancing techniques. It includes how to use a rotating machinery balancing program to correct balance issues.

B. Objective: Enable the student to perform hands-on balancing of typical industrial machinery as well as when to contact a specialist for very demanding situations.

C. Skills Learned:
1. Learn single and multi-plane balancing procedures using phase and without phase
2. Learn to balance rotors using single plane balance tools with and without phase.
3. Learn the importance of accurate measurement of the phase angle
4. Learn why it is hard to balance a rotor operating near critical speed
5. Learn to use single and two plane software with and without phase
6. Learn to select location of balancing weight and process of installation of balance weights.

D. Prerequisites: Basic vibration data collection and analysis, familiarity with rotating machinery.

E. Teaching Aids: BBS, balancing machine, balancing software, lesson plan, text material, laboratory exercises.


6. Introduction to IIOT PDM

A. Course Description: This course provides introduction to industrial internet of things and the use of predictive maintenance in the era of Industry 4.0 smart (connected) manufacturing.Industry internet of things (IIoT) will enable everyone in your operation to start seeing information in real-time, making data-driven decisions, and contributing to process improvements across plants located in different parts of the world.

B. Objective: Enable students to understand fundamentals of IIoT and learn how to connect plants located in different parts of the world to improve asset uptime and performance.

C. Skills Learned:

1. Learn basic concept of the Industrial Internet of things (IIoT),
2. Learn concepts of smart manufacturing, connected factories and devices
3. Learn to communicate with plants located in different parts of the world
3. Learn how to use different network devices to extract relevant information to improve asset maintenance
4. Learn how to retrieve data locally and remotely to transfer to other devices
5. Learn the use of a variety of sensors such as temperature, vibration, noise, RFID, camera, and humidity

D. Prerequisites: Basic understanding of internet and computers

E. Teaching Aids: IIOT simulator, software, text material, lessonplan, laboratory exercises

7. Machine Vibration Analysis (ISO CAT III)

A. Course Description: The course provides basic instruction required for the student to pass the vibration ISO CAT III certification exam along with sufficient knowledge to set up an industrial condition monitoring program.

B. Objective: Enable the student to setup and implement a condition monitoring program and to pass the ISO CAT III certification exam

C. Skills Learned: A quick review of ISO CAT II and all requirements listed to sit for the ISO CAT III exam.

1. Sound knowledge of vibration theory and tests to determine resonance(s), critical speed(s), and damping
2. Ability to setup a condition monitoring program and maintain it.
3. More in-depth knowledge of signal analysis concepts
4. Identify fault frequencies present in a spectrum, and develop trend plots
5. Ability to perform machine fault diagnosis and detect their severity
6. Perform basic maintenance to correct problems
7. Conduct multi-plane balancing and shaft/pulley alignment on different equipment such as electric motors, fans, pumps, compressors, etc.
8. Perform equipment acceptance and resonance tests
9. All those listed as requirements to sit for ISO CAT III exam


D. Prerequisites: Basic mathematics, trigonometry, algebra, hands-on practice collecting and analyzing machinery vibration data, have ISO CAT II certificate.

E. Teaching Aids: MFS, data collector/analyzer, software, text material, lesson plan, laboratory exercises

8. Machinery trouble shooting (diagnostics) and Root Cause Failure Analysis (RCFA)

A. Course Description: This course provides basic instruction required for the student to effectively troubleshoot machinery problems of a mechanical nature and perform professional root cause failure analysis and corrective solutions.

B. Objective: Enable the student to become more proficient, self-reliant, and know the typical sources of information required to solve problems and recommend possible remedies.

C. Skills Learned:

1. A systematic approach to troubleshoot asset issues and evaluate options correction
2. Ability to detect various faults and their severity
3. Identify the root cause(s) and correct frequently recurring problems
4. Perform multi-plane balancing and shaft/pulley alignment tasks
5. Knowledge with equipment acceptance testing specification and standard
6. Knowledge of testing methods to determine resonance frequencies, critical speed, mode shape and damping

D. Prerequisites: ISO III certificate, mathematical skills to calculate natural frequencies, critical speed, hands-on practice collecting and analyzing machinery vibration, alignment, balancing, resonance, damping and machinery design fundamentals.

E. Teaching Aids: MFS, data collector/analyzer, software, text material, lesson plan, laboratory exercises.

9. Reciprocating Engine Dynamics

A. Course Description: This course teaches the mechanical workings of a reciprocating engine as used for transportation for examining vibration and timing issues. It includes a close-up visual instruction on the dynamics of the typical reciprocating engine.
B. Objective: Enable the student to thoroughly visualize the movements, the critical design points and adjustments, and how best to collect vibration information when troubleshooting.

C. Skills Learned:

1. The mechanical internal working of a reciprocating engine.
2. Valve timing issues and to set up proper timing to optimize engine performance
3. Install/un-install input/exhaust valves and manifold
4. How to balance reciprocating engine
5. Effects of flywheel on smoothing speed fluctuation
6. Difficulty with vibration signature/analysis of reciprocating engine
7. Pressure profile associated with valve opening and closing

D. Prerequisites: Basic vibration data collection and analysis, familiarity with rotating machinery.

E. Teaching Aids: Reciprocating engine simulator, text material, laboratory exercises, lesson plan.


SpectraQuest: A Valuable Resource for Keeping Companies Productive by Enhancing their Worker’s Skills

SpectraQuest offers a wide range of industrial machinery operational and training tools for productivity enhancement. Our simulators and software products are sold as comprehensive training packages. We continue to develop new and custom applications and improvements so that the investment you make in this important training tool will continue to provide value for many years to come.To learn more about the training products and how they can help you to keep your plant operating profitably, please call (804) 261-3300 or e-mail us at info@spectraquest.com.