This practical course provides a thorough foundation in the inspection, troubleshooting, and hands-on maintenance of essential mechanical systems found across all industrial sectors. The focus is on implementing best practices for common components like bearings, belts, chains, and couplings to ensure optimal function and reliability. Participants will gain specific knowledge on precision installation techniques, defect identification, and standardized repair procedures necessary to reduce post-maintenance failure and maximize equipment uptime. The course is ideal for technicians and engineers who perform or supervise mechanical work in the field.
Mechanical Systems Inspection and Maintenance
Maintenance and Engineering
October 25, 2025
Introduction
Objectives
Upon completion of this course, participants will be able to:
- Perform precision installation and maintenance on anti-friction bearings.
- Apply best practices for V-belt and chain drive alignment and tensioning.
- Diagnose and troubleshoot common mechanical coupling failures.
- Implement effective preventative maintenance plans for gearboxes and speed reducers.
- Understand the principles of welding inspection and non-destructive testing (NDT).
- Follow standardized procedures for pipefitting and flanged joint assembly.
- Utilize precision measurement tools (micrometers, dial indicators) effectively.
- Identify and correct common causes of machinery wear and premature failure.
Target Audience
- Mechanical Maintenance Technicians and Fitters
- Maintenance Supervisors and Team Leaders
- Junior Maintenance Engineers
- Apprentices and Trainees in Maintenance Trades
- Reliability Technicians focused on mechanical integrity
- Equipment Operators performing routine checks
Methodology
- Hands-on lab sessions on precision bearing mounting and dismounting
- Practical exercise using laser alignment tools and dial indicators
- Group activity on developing a torque sequence for a flanged joint
- Case studies on troubleshooting common gearbox and drive system failures
- Individual exercises using micrometers and precision gauges.
Personal Impact
- Significantly upgrade hands-on precision maintenance skills.
- Reduce rework and post-maintenance failures in mechanical tasks.
- Master best practices for critical components like bearings and seals.
- Gain confidence in performing complex alignment and installation procedures.
- Enhance ability to quickly diagnose and repair mechanical system faults.
Organizational Impact
- Reduce costly catastrophic failures by improving component installation quality.
- Extend the operational life of bearings, seals, and power transmission components.
- Minimize energy consumption by reducing friction from misalignment.
- Decrease maintenance costs by reducing the need for emergency repairs.
- Improve safety compliance by standardizing safe work procedures.
- Increase the reliability and availability of production machinery.
Course Outline
Unit 1: Bearings and Seals
Anti-Friction Bearing Maintenance- Bearing types, selection, and nomenclature.
- Proper bearing handling, cleaning, and storage.
- Thermal and hydraulic mounting and dismounting techniques.
- Diagnosing common bearing failure patterns (fatigue, contamination).
- The function of labyrinth, lip, and contact seals.
- Installation best practices for effective sealing and contamination exclusion.
- Understanding bearing isolators and advanced sealing solutions.
Unit 2: Power Transmission Components
V-Belt and Sheave Systems- Proper inspection and tensioning of V-belts.
- Techniques for parallel and angular sheave alignment.
- Calculating optimal belt length and service life.
- Inspection and lubrication of roller chain drives.
- Proper tensioning and alignment of sprockets.
- PM and oil sampling procedures for gearboxes and speed reducers.
Unit 3: Alignment and Couplings
Shaft Alignment Principles- Introduction to dial indicator and laser alignment techniques.
- Understanding soft foot and its correction.
- The importance of thermal growth compensation.
- Types of couplings (rigid, flexible, gear, grid).
- Installation and maintenance of various coupling types.
- Diagnosing failure modes related to coupling selection and installation.
Unit 4: Piping and Pressure Systems
Flange and Gasket Maintenance- Gasket types, selection, and storage best practices.
- Controlled bolting procedures and flange face inspection.
- Proper torque sequence application for leak-free joints.
- Inspection of pipe supports, hangers, and expansion joints.
- Common piping system damage mechanisms (corrosion, vibration).
- Fundamentals of pipefitting and welding inspection.
Unit 5: Troubleshooting and Inspection
Precision Tools and Measurement- Correct usage of precision tools (e.g., micrometers, verniers, feeler gauges).
- Tolerances and fits for shafts and bores.
- Documenting measurement results and acceptance criteria.
- Structured visual inspection techniques for mechanical assets.
- Introduction to basic Non-Destructive Testing (NDT) methods.
- Identifying signs of fatigue, fretting, and corrosion.
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