Course Title: Introduction to Maintenance Engineering
Course Number: 484
Professor: Belle R. Upadhyaya
Nuclear Engineering Department
209 Pasqua Engineering Building
Ph: 865-974-7576  Fax: 865-974-0668
E-mail: bupadhya@utk.edu

Course Description and Goals:

The objective of this senior-level/beginning graduate-level course is to study the basics of maintenance engineering and maintenance management. Students learn the principles of various maintenance technologies as they are currently practiced by U.S. industry. Lectures will include presentations and demonstrations by the course instructor and by experts from industry. This is one of the courses required for the UTK Reliability and Maintainability Center (MRC) certificate. Students are required to work on a project during the semester. The use of Internet and other electronic information systems is strongly recommended. All course materials and other relevant information will be posted on a password-protected Blackboard course site managed by UTK Innovative Technology Center (ITC).

Prerequisite: Senior standing; consent of professor

Text: Introduction to Maintainability Engineering
Author:  Belle R. Upadhyaya

Additional course material will be provided during the semester. Students are encouraged to review recent publications on advances in machinery condition monitoring and other course-related topics. The Blackboard course site at The University of Tennessee is also used for posting current information about the course and reference material. All students must track this course site in order to keep updated on the course activities.

References:

1. J.D. Campbell, "Strategies for Excellence in Maintenance Management," Productivity Press, Portland, OR, 1995.
2. P.D.T. O'Connor (Editor), "Reliability Engineering," Hemisphere Publishing, New York, 1988.
3. H.P. Bloch and F.K. Geitner, "An Introduction to Machinery Reliability Assessment," Gulf  Publishing, Houston, 1994.
4. R.B. Northrop, "Introduction to Instrumentation and Measurements," CRC Press, Boca Raton, 1997.
5. R.C. McMaster (Editor), "Nondestructive Testing Handbook," American Society for Nondestructive Testing, Columbus, OH, 1982-86.
6. "NDE for Engineers," Electric Power Research Institute, December 1991.
7. "Maintenance Technology," The magazine of plant equipment reliability, maintenance, and asset management, Barrington, IL.
8. Proceedings of the Maintenance and Reliability Conference (MARCON), Sponsored by The University of Tennessee Reliability and Maintainability Center.
9. A.R. Crawford, "The Simplified Handbook of Vibration Analysis," Volumes1&2, Computational Systems, Inc., Knoxville, 1992.
10. E.A. Elsayed, "Reliability Engineering," Addison Wesley, Reading, MA, 1996.
11. T. Wireman, "Developing Performance Indicators for Managing Maintenance," Industrial Press, New York, 1998.
12. J. Moubray, "Reliability-Centered Maintenance," Industrial Press, New York, 1997.

Web site of Maintenance Technology magazine: www.mt-online.com

Course Outline

The following topics will be presented during the semester. Some variations in the course material should be expected. The course format consists of lectures using Centra Symposium and the SMART Board, laboratory demonstrations, and on-line discussion. Each student will work on a technology project, in teams of two each.

1. Overview of Maintenance and Reliability Engineering

• Scope of industrial preventive/predictive maintenance programs.
• Definition of terminology.
• An example of establishing equipment maintenance program.
• Overview of condition-based 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.
• Monitoring transients such as machinery start-up and coast-down events.
• Demonstration of a typical data acquisition and analysis system.
• Case studies of machinery monitoring for predictive maintenance.

3. Vibration analysis and rotating machinery condition monitoring. Case studies and demonstration.

• Vibration and its causes. Classification of frequency ranges. Imbalance, misalignment, looseness, bearing defects, and their characteristic frequencies.
• Understanding vibration of a second order system.
• Instrumentation for vibration monitoring.
• Description of a typical vibration monitoring 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.
• Laboratory demonstration using the SpectraQuest machinery monitoring system.

4. Maintenance planning, management, and evaluation.

• Maintenance planning, management and designing an effective maintenance organization.
• Information systems organization and asset management.
• Evaluating maintenance performance. Cost-benefit analysis.

5. Site visit to an industrial facility. Review of maintenance practices at this site.

6. Lubrication oil analysis and tribology

• Scope of lubricationoil 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

7. 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.

8. Mid-term Examination

9. 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.
• Structural monitoring with fiber-optic sensors.
• Applications and demonstrations.

10. Monitoring and maintenance of process instruments

• Principles of temperature, pressure, and flow transmitters.
• 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.
• Wireless communication, smart sensors, smart machinery, and other advanced technologies.

11. Electrical signature analysis for machinery condition monitoring

• Objectives of electrical system condition monitoring. Types of electrical faults.
• Principles of motor current, voltage and flux measurements.
• Electric motor monitoring and diagnosis using electrical signatures (motor as a transducer).
• Case studies of motor monitoring using motor current, flux, power, and RF signals.
• Laboratory experiments using induction motors.

12. Presentation of student projects

• Course review and Final Examination

Student Projects

Students will work in small teams (two per team) 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 technical in nature and constitutes a substantial part of the course effort. The Discussion Board feature of the course site must be used for posting all the information about the project activities and for communication and discussion between team members. Weekly electronic reports must be submitted to the instructor stating the progress made, problems encountered, and other matters of interest, thus facilitating the timely completion of the project.

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. The use of library material, technical web sites, and communications with industry experts are strongly recommended. Your contributions to the project will be evaluated by your peers and by the instructor.

Report Format

• Executive Summary
• Introduction, Background, and Objectives
• Body of the Report (including results and discussion)
• Conclusions (including your comments)
• References
• Appendices

Course Grading

• Homework assignments: 15%
• One-hour test 10%
• Mid-term examination: 15%
• Final examination: 30%
• Project: 30% (report + presentation)

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