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Understanding & Preventing Major Machine Failures
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Understanding & Preventing Major Machine Failures

2-Day Training Course: Utilising Design, Maintenance & Procurement Principles to Maximise Productive Life of Assets. Build your understanding of the structural intricacies of large, complex machines; the interaction between their mechanical, electrical, control & structural systems, & learn strategies for avoiding asset failures through design, monitoring & control.

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overview

Key Learning Objectives

  • Examine the design and structural behaviour of large machinery
  • Identify the causes of structural failures of assets
  • Examine how to control machine loads and prevent overloads
  • Understand fatigue and fatigue failures in assets
  • Consider design the construction/ quality interactions and trade offs
  • Address how to monitor machinery, assess and manage risk
  • Respond accurately and effectively to structural problems when discovered
  • Develop long-term strategies for prolonging machine survival
  • Reflect and apply knowledge through various machine specific case studies

About the Course

This course has been designed to provide participants in the mining, materials handling and related industries who are involved in the management, operation and maintenance of large and/or complex machines/assets, with an understanding of the causes of structural failures, and the strategies for avoiding such failures.

You will review machinery used in these industries, and the interaction between the mechanical, electrical, control and structural systems which comprise such machines. The effect of these interactions on loads generated and how this is dealt with in design will be used as a basis for addressing the nature and causes of structural failures typically encountered in such assets.

More detailed background will be provided on the structural design of such machines for strength and fatigue. Particular consideration will be given to fatigue behaviour, and the nature and causes of asset fatigue failures.

An understanding of structural and fatigue behaviour will be used as the basis for exploring approaches to the investigation of problems and failures encountered in machines. Strategies for avoiding problems through pre-emptive investigations, monitoring, and control measures for optimising asset management will be developed and reviewed.

Who Will Benefit

The course is particularly suited to engineers involved in the procurement, supply, management, operation and maintenance of large or complex equipment, where the machine ‘structure’ is critical to the long term survival and safe operation of the machine.

Engineers and designers of machinery and plant operations will also find this of benefit.

Having a background in engineering is beneficial as this is a technical course.

Testimonials

Bringing together a better understanding of theories of various engineering disciplines ie. Structural and mechanical and the gaps.
Principal, Aspect Engineering

Terms & Conditions

To read the training course terms and conditions read more here

Course Outline

MACHINES AND MACHINE STRUCTURES – AN OVERVIEW

  • Overview of machines used in the mining and materials handling industries
  • What is the machine structure?
  • How do machines fail?
  • How do machine structures fail?

DESIGNING MACHINES – AN OVERVIEW

  • The design concept and design assumptions
  • Design for performance and survival
  • Design evolution
  • Resolving conflicts and the procurement process

CASE STUDIES OF MACHINE FAILURES

  • Failures due to fatigue
  • Failures due to unexpected loads

DESIGNING MACHINE STRUCTURES – AN OVERVIEW

  • Overview of machine design principles
  • Structural design loads
  • Structural capacity
  • Structural stability
  • Upper limiting loads
  • Reliance on mechanical ‘fuses’
  • Reliance on control and protection systems
  • Theoretical vs. actual loads
  • Feedback loops and verification
  • Analysis techniques – understanding behaviour

ACTIVITY

  • Calculate sample loads for some machines
  • Stacker stability calculations
  • Nominal vs. dropped charge mill load
  • Shiploader chute – spout deflection load

FAILURE OF MACHINE STRUCTURES

  • How do machine structures fail?
  • Primary failure modes (plastic collapse, fracture and buckling)
  • Secondary modes (fatigue, corrosion, SCC, wear and etc.)
  • Serviceability failures (deflection, vibration)
  • Interactions between modes
  • Structural criteria
  • Manufacturing requirements (ductility, tolerances and mating)

CONSEQUENCES OF COMPONENT FAILURES

  • Failure modes effects and criticality assessment
  • Risk assessment approach
  • Code requirements in the risk assessment context
  • Scenario reviews as part of risk assessment

RISK ASSESSMENT EXERCISE

  • Initiation of exercise
  • Stacker bearing changeout
  • Presentations by delegates
  • Management decisions
  • Engineering decisions
  • Contractor decisions
  • Shutdown decisions

FATIGUE BEHAVIOUR AND PERFORMANCE

  • Fatigue of metals
  • Historical perspective
  • Initiation and propagation of fatigue cracks
  • Initiation and propagation thresholds
  • Unwelded vs. welded components
  • S-N (stress life) approach
  • E-N (strain life) approach
  • Scatter and reliability

FATIGUE CRITERIA AND DESIGN

  • Fatigue codes – welded structures
  • Fatigue codes – unwelded structures
  • Stress range criteria
  • Effect of mean stress
  • Residual stress and effect of stress relieving
  • Effect of detail and weld improvements
  • Fatigue life vs. risk

ACTIVITY

  • Sample fatigue calculations
  • Non-welded – comparison of codes
  • Weldment – comparison of codes
  • Effect of weld improvements

FATIGUE FAILURES IN BOLTS

  • Fatigue resistant joints
  • Joint requirements
  • Bolt requirements
  • Practical requirements for bolts and joints

FRACTURE MECHANICS PRINCIPLES AND TECHNIQUES

  • Basic principles (WTIA tech note)
  • Relevant codes (BS7910)
  • Fracture behaviour
  • Cracks vs. other defects
  • Linear elastic fracture mechanics
  • Use at design stage
  • Use at monitoring stage
  • Use at investigation stage

MONITORING AND MANAGEMENT

  • ‘Maintenance’ of machine structures
  • Approach to monitoring
  • Methods available for monitoring
  • Access and time for monitoring
  • Cleanliness and information requirements
  • Documentation and response
  • Monitoring of loads
  • Systematic approach
  • ‘Traceable inspection system’
  • Feedback loops

SUMMING UP

  • Structures the ‘poor cousins’
  • Structures need maintenance
  • Production pressures and conflicts
  • Feedback through the ‘machine community’
  • Wrap up and feedback
  • Questionnaire and requests

On-site & in-house training

Deliver this course how you want, where you want, when you want – and save up to 40%! 8+ employees seeking training on the same topic?

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