PRECISION TROUBLESHOOTING FOR ROTATING EQUIPMENT: ADVANCED METHODS
Mastering Diagnostic Techniques to Prevent Failures and Improve Equipment Uptime
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 03 – 07 Nov 2025 | London – UK | USD 3495 per delegate |
Course Introduction
Rotating equipment such as pumps, compressors, turbines, motors, and fans are vital to industrial operations. When these machines fail, it can lead to costly downtime, safety incidents, and maintenance overruns. Precision troubleshooting is critical to detecting early signs of failure, identifying root causes, and restoring equipment to optimal performance.
This advanced-level course delivers a practical, methodical approach to diagnosing and solving rotating equipment issues. Participants will gain hands-on knowledge in vibration analysis, thermography, lubrication analysis, alignment, and root cause methodologies to significantly reduce failure rates and increase equipment reliability.
Course Objectives
By the end of this course, participants will be able to:
• Apply precision troubleshooting techniques to various types of rotating machinery
• Interpret vibration, thermal, acoustic, and oil analysis data for condition monitoring
• Diagnose root causes of recurring faults in rotating equipment systems
• Use alignment, balancing, and reliability tools to prevent equipment degradation
• Enhance reliability-centered maintenance (RCM) practices with precision tools
Key Benefits of Attending
• Learn industry best practices for troubleshooting pumps, compressors, turbines, and motors
• Reduce equipment failures and emergency shutdowns through predictive techniques
• Strengthen diagnostic and analytical capabilities for maintenance teams
• Understand how to combine condition-based and precision maintenance strategies
• Advance your role as a reliability or maintenance expert in critical system
Intended Audience
This program is designed for:
• Maintenance and reliability engineers
• Rotating equipment specialists
• Mechanical and plant engineers
• Maintenance planners and supervisors
• Condition monitoring and vibration analysts
Individual Benefits
Key competencies that will be developed include:
• Vibration analysis interpretation and fault pattern recognition
• Precision alignment and balancing techniques
• Root cause failure analysis (RCFA) for rotating equipment
• Oil analysis and thermographic inspection skills
• Integration of predictive and preventive maintenance approaches
Organization Benefits
Upon completing the training course, participants will demonstrate:
• Improved equipment availability and reliability
• Reduction in unplanned maintenance costs and downtime
• Early detection of critical machinery defects
• Better asset life cycle management and failure prevention
• Enhanced safety and operational continuity across facilities
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
• Strategy Briefings – Failure mechanisms, RCM, and condition-based diagnostics
• Case Studies – Real-world equipment failures and resolution methods
• Workshops – Hands-on data interpretation, troubleshooting logic, and repair planning
• Peer Exchange – Experience sharing on complex maintenance issues
• Tools – Diagnostic flowcharts, troubleshooting checklists, and vibration data templates
Course Outline
Detailed 5-Day Course Outline
Training Hours: 7:30 AM – 3:30 PM
Daily Format: 3–4 Learning Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Foundations of Precision Troubleshooting
Module 1: Overview of Rotating Equipment (07:30 – 09:30)
• Pumps, motors, fans, turbines, gearboxes – operating principles and configurations
Module 2: Failure Modes and Effects (09:45 – 11:15)
• Mechanical, hydraulic, thermal, and electrical failure causes
Module 3: Workshop – Failure Symptom Mapping (11:30 – 01:00)
• Relating performance symptoms to probable faults
Module 4: Peer Exchange – Most Challenging Failures Faced (02:00 – 03:30)
• Group discussion on past breakdowns and lessons learned
Day 2: Vibration and Dynamic Troubleshooting
Module 5: Vibration Analysis Fundamentals (07:30 – 09:30)
• Frequency, amplitude, phase, spectrum, and waveform analysis
Module 6: Diagnosing Common Faults via Vibration (09:45 – 11:15)
• Misalignment, imbalance, looseness, bearing defects
Module 7: Workshop – Interpreting Vibration Data (11:30 – 01:00)
• Analyze sample vibration plots and diagnose faults
Module 8: Case Study – Recurring Pump Vibration (02:00 – 03:30)
• Troubleshooting a chronic instability issue
Day 3: Thermography, Lubrication, and Root Cause Analysis
Module 9: Infrared Thermography Techniques (07:30 – 09:30)
• Heat signatures in mechanical and electrical systems
Module 10: Oil and Lubricant Analysis (09:45 – 11:15)
• Contaminants, wear particles, and viscosity trends
Module 11: Workshop – Root Cause Failure Analysis (RCFA) (11:30 – 01:00)
• Use cause-mapping and fault trees to determine origin of failure
Module 12: Peer Exchange – Sharing RCFA Practices (02:00 – 03:30)
• Industry experience on RCFA success and pitfalls
Day 4: Precision Maintenance and Optimization Techniques
Module 13: Laser Alignment and Shaft Coupling Techniques (07:30 – 09:30)
• Vertical/horizontal corrections, soft foot, thermal growth
Module 14: Field Balancing of Rotating Components (09:45 – 11:15)
• Single and two-plane balancing using vibration tools
Module 15: Workshop – Alignment and Balancing Simulations (11:30 – 01:00)
• Practical demo (simulated or video-guided) of alignment steps
Module 16: Case Study – Bearing Wear Prevention (02:00 – 03:30)
• Optimizing lubrication and alignment to reduce wear
Day 5: Troubleshooting Strategy and Reliability Integration
Module 17: Building a Troubleshooting Protocol (07:30 – 09:30)
• Systematic approach to repeatable problem solving
Module 18: Integrating with RCM and Predictive Maintenance (09:45 – 11:15)
• Condition-based triggers and data-driven interventions
Module 19: Final Project – Troubleshooting Plan for Rotating System (11:30 – 01:00)
• Develop and present a real-world equipment troubleshooting solution
Module 20: Wrap-Up, Feedback, and Certification (02:00 – 03:30)
• Closing discussion and certificate distribution
Certification
Participants will receive a Certificate of Completion in Precision Troubleshooting for Rotating Equipment, confirming their ability to diagnose and resolve complex mechanical issues using advanced troubleshooting and reliability-centered methods.