Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Mechanical and Maintenance Engineers
• Reliability and Rotating Equipment Engineers
• Maintenance Technicians and Supervisors
• Plant and Operations Engineers
• Equipment Inspectors and Condition Monitoring Personnel
• Anyone involved in the maintenance and reliability of rotating machinery

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

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DAY 1

Introduction to Gearboxes and Power Transmission Systems

• Welcome and introduction
• Pre-test
• Overview of rotating machinery and power transmission
• Types of gearboxes: spur, helical, bevel, worm, planetary
• Gear terminology: pitch, module, backlash, gear ratios
• Selection criteria for gearboxes in industrial applications
• Gearbox design fundamentals and load calculations
• Common failure modes and root causes in gearboxes
• Case study

DAY 2

Bearings – Types, Selection, and Operation

• Introduction to bearings and their role in machinery
• Types of bearings: ball, roller, thrust, plain, sleeve
• Bearing materials and their selection
• Load ratings and life expectancy (L10 life)
• Installation, alignment, and handling of bearings
• Vibration, noise, and temperature indicators of bearing issues
• Case study

DAY 3

Lubrication Principles and Best Practices

• Basics of lubrication: functions, types, properties
• Lubricant selection for gearboxes, bearings, and seals
• Lubrication regimes: boundary, mixed, hydrodynamic
• Lubrication methods: splash, forced-feed, grease vs. oil
• Oil analysis and monitoring techniques
• Lubrication management and contamination control
• Lubrication failure modes and troubleshooting

DAY 4

Mechanical Seals – Operation and Maintenance

• Introduction to sealing systems and their importance
• Types of seals: lip seals, packing, mechanical seals
• Components of mechanical seals and sealing faces
• Seal material selection for various process fluids
• Seal support systems: flush plans, barriers, and buffers
• Installation and alignment of mechanical seals
• Seal failure analysis and troubleshooting methods

DAY 5

Troubleshooting, Condition Monitoring, and Case Studies

• Integrated troubleshooting approach for gearboxes, bearings, seals
• Vibration analysis and thermography
• Preventive vs. predictive maintenance strategies
• Maintenance planning and recordkeeping
• Case studies of common failures and solutions
• Group workshop
• Post-test
• Certificate ceremony