Practical Plant Failure Analysis Training

Class Number: MANF 8013 (62533)
Class Dates:     August 26-28, 2014
Class Times:    8 a.m. – 4:30 p.m.
Location:         PDCCC Franklin Workforce Center
Tuition:            $975.00
*Optional supplemental texbook– $95. (can be reviewed and purchased during the class)

PPFA Training Background
Practical Plant Failure Analysis Training has been available to industrial and commercial customers since 1987. Hundreds of public and private courses have been presented across North America and Europe to various industries, including: Pulp & Paper, Power, Petro-Chemical, Mining, Steel, Aluminum, and Pharmaceutical Industries. Class is targeted to increase the knowledge and skills of new and seasoned maintenance personnel as well as plant engineers. The multi-day course is conducted in a manner to foster learning and development by:

  • Reaching a common understanding of the multiple causes that contribute to all failures
  • Raising awareness of the prevalence and pervasive nature of human error
  • Introducing some basic physics and material properties
  • Applying these basic concepts to specific mechanical components and machinery types
  • Reinforcing classroom learning with extensive hands-on failure analysis

Students work with their fellow classmates utilizing hands-on failure analysis exercises with examples of provided failed components as well as failed components that students bring to the course. The course material and hands-on exercises provide the students with:

  • A basic understanding of how mechanical components function
  • What factors are critical to their continued reliable operation
  • Common causes of failure
  • How to accurately diagnose failure

 The training course focuses on the Concepts/Inspection Methods/Components listed in the table below. Based upon the experience level within each class, our instructors tailor the discussions to be general or more advanced…this is dependent upon group discussion and the needs of participants.

Concepts Inspection Methods Components
Practical Plant Physics Preventive Maintenance Fasteners
Basics of Materials Predictive Maintenance Pumps
Failure Mechanisms & Appearances Vibration Analysis Gears
Corrosion V-Belts
Lubrication Synchronous Belts
Wear Mechanisms Chains and Sprockets
Couplings and Alignment
Rolling Element Bearin

3-Day Course Outline:

Day 1
The Roots of Failures:  Introduction to the differences between physical, human, and management system (latent) failure roots; the pervasive nature of human error; how failures always result from multiple causes.

Material Properties:  Discussion about the basic properties of common materials of construction used in industrial plants.

Failure Mechanisms and Fracture Identification:  The differences between overload and fatigue as failure mechanisms. Introduction to the concepts of stress concentrations and residual stresses…showing how these factors result in different fracture appearances.

Hands-on Failure Analysis:    Looking at failed components provided by ATS and students, we look at and discuss each sample to determine the failure mechanism(s) and the forces involved.

Day 2
Fastener Failures:  A review of the importance of uniform tightening procedures and adequate clamping force, including a discussion of torque vs. tightness.

Lubrication:  Introduce the 3 different lubrication regimes and how different loads require different lubricant properties. Discuss the thermal effects on lubrication quality. Discussion of proper viscosity specifications, lubrication additives, and lubrication frequencies.

Roller Bearings:  How rolling element bearings work and how they fail. The action of Hertzian fatigue versus surface fatigue.

Hands-on Failure Analysis:    Looking at failed components provide by ATS and students, we look at and discuss each sample to determine the failure mechanism(s) and the forces involved.

Day 3
Gears: Discussion of materials of construction, the effect of loads and lubrication, and failure identification.

Corrosion Recognition:  Review of factors that affect corrosion, material loss, and cracking damage.

Power Transmission Elements:  Discussion of: V-Belts, Synchronous Belts, Chains & Coupling operation and failure identification.

Centrifugal Pumps:    Discussion of pump curve versus system curves and the common causes of pump failure.

Hands-on Failure Analysis:    Looking at failed components provided by ATS and students, we look at and discuss each sample to determine the failure mechanism(s) and the forces involved.

For additional information or questions, call the Workforce Office at 757.569.6050 or send an email to