Course Outline

The following topics will be presented during the semester.  The course format consists of lectures, laboratory demonstrations and site visits.  Each student will participate in a project related to maintenance technology of interest to his/her engineering discipline.  Selection of topics related to current research findings is encouraged.

1. Overview of Maintenance and Reliability Engineering
• Scope of industrial preventive/predictive maintenance programs.
• Definition of terminology.
• An example of establishing equipment maintenance program.
• Summary of predictive maintenance technologies.
2. Digital signal processing (DSP) and information extraction from machinery measurements.  Demonstration of data acquisition and analysis
• Instrumentation systems and measurements.
• Data acquisition from machinery sensors, data sampling.
• Signal conditioning: digital filters and signal preprocessing.
• Time-domain and frequency-domain signatures.
• Demonstration of a typical data acquisition and analysis system.
• Case studies of machinery monitoring for predictive maintenance.
• Hands-on activity by students is encouraged to familiarize with measurements and data analysis.
3. Vibration analysis and rotating machinery condition monitoring.  Case studies and demonstration
• Vibration and its causes; classification of frequency ranges.
• Instrumentation for vibration sensing.
• Description of a typical vibration monitoring system.
• Principle of vibration of a second order system.
• Vibration signatures, data trending and alarming techniques.
• Case studies of vibration monitoring: turbine imbalance, pump  misalignment, pump looseness, boiler feed water pump anti-friction bearing monitoring, pump journal bearing monitoring, rolling mill gearbox problem, transient vibration analysis.  Rolling element bearing defect characteristic frequencies.
4. Robotics in Remote Handling and Maintenance
• Principles of remote handling and robot systems.
• Applications of robotic systems in industrial maintenance.
• Remote handling in hazardous conditions.
• Case studies of industrial applications of robotics.
• The use of virtual reality in periodic and corrective maintenance.
5. Lubrication oil analysis and tribology
• Scope of lubrication oil analysis and wear particle analysis.
• Classification of lube oil test methods.
• Lube oil degradation monitoring;  demonstration of equipment.
• Lube oil contamination analysis.
• Lube oil wear particle analysis.
• Case studies of industrial applications.
6. Nondestructive examination (NDE) methods and applications
• Overview of nondestructive examination; typical applications; standards and regulations.
• Visual examination, penetrant testing and magnetic particle testing.
• Ultrasonic testing.
• Eddy current testing.
• Radiographic testing.
• Thermographic testing.
• Acoustic emission testing.
• Applications and demonstrations.
7. Site visit to an industrial facility.  Review maintenance practices at this site.
8. Reliability engineering and failure models
• Reliability, availability and maintainability.
• Reliability models and failure distributions.
• Reliability function estimation.
• Residual life estimation as a prognosis activity; model development and forecasting.
• Case studies of applications to rotating machinery and heat exchangers.
9. Mid-term Examination
• Maintenance planning and management
• Computerized maintenance management systems (CMMS).
• Interaction between the production line and maintenance strategy.
• Criteria for evaluating maintenance performance; cost-benefit analysis.
10. Monitoring and maintenance of process instruments
• Principles of temperature, pressure and flow transmitters.
• Principles of motor current, voltage and flux measurements.
• Description of a typical instrumentation channel and classification of problems.
• Scope and purpose of instrument surveillance and calibration reduction.
• Validation of plant sensors using digital signal processing techniques.
• Case studies of applications to process sensors.
• Instrumentation maintenance, smart sensors,...
11. Electrical signature analysis for machinery condition monitoring
• Objectives of electrical system condition monitoring; types of faults.
• Methods of monitoring integrity of cables, instrument channels and case studies.
• Electric motor monitoring and diagnosis using electrical signatures
• (motor as a transducer).
• Case studies of motor monitoring using motor current, flux and power.
12. Fatigue of  materials and life prediction
• Material properties and fatigue of materials.
• Characterization of structural fatigue.
• Fatigue failure models.
• Estimation of remaining operable lifetime of process equipment.
13. Presentation of student projects
14. Course review

Students will work in small groups on projects related to maintenance and reliability engineering, with emphasis on current advances.  The project topics will be finalized with the approval of the instructor.  The project must be presented in a well-written report format (approximately 20-30 pages).  All the students are expected to make oral presentations of their work to the class.  The project constitutes a substantial portion of student activities.  The use of library material, technical web sites, and communications with industry experts are strongly recommended.

REPORT FORMAT

Abstract
Introduction, Background and Objectives
Body of the Report
 

Conclusions (include your comments)
References
Appendices

Course Grading

• Homework assignments:  30% (includes weekly e-mail reporting of project progress)
• Mid-term examination:  15%
• Final examination:  30%
• Project:  25% (report + presentation)

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