5022 – Component Failure: Identify and Control
Course Content
This intensive hands-on training builds on foundational craft skills and focuses on identifying and controlling component failures in rotating equipment. Technicians will gain practical knowledge in bearing systems, lubrication, couplings, and sealing methods—skills essential for improving reliability and reducing downtime.
1. Machinery Inspection Techniques
- Visual, audible, and tactile inspections
- Vibration and temperature measurements
- Dynamic performance measurement exercises
- Failure symptom recognition and documentation
2. Rolling Element Bearings
- Bearing types, nomenclature, and typical applications
- Dismounting and mounting techniques
- Use of installation/removal tools and oil injection systems
- Shaft and housing preparation & fit checks
- Bearing heaters, adapter sleeves, and hydraulic nut installation
- Precision installation of mounted bearings
- Exercises: removal, installation, and clearance setting
3. Power Transmission Devices (Couplings)
- Coupling types and selection criteria
- Failure modes and inspection techniques
- Installation and lubrication best practices
- Hands-on coupling exercises
4. Lubrication Fundamentals
- Purpose and types of lubricants
- Lubricant film formation and viscosity
- Contamination control and cleanliness standards
- Delivery systems and hands-on installation (e.g. Trico)
- Field sampling, testing (odor, CCO), and vacuum pump usage
- Patch testing and water removal methods
- Real-world troubleshooting exercises
5. Shaft Sealing Systems
- Introduction to sealing methodologies
- Compression packing: types, installation, and adjustment
- Mechanical seal types and flush systems
- Split seal installation techniques and exercises
6. Applied Hands-On Practice (50% of Class Time)
- Live demonstrators and dynamic testing
- Real-time application of theory
- Performance-based feedback and report-outs
- Exercises each day to reinforce key concepts
Who should follow this course
This course is designed for professionals involved in the maintenance, reliability, and performance of rotating equipment. It is particularly valuable for those seeking to deepen their practical understanding of failure prevention and machinery component performance.
Ideal participants include:
- Craft technicians
- Maintenance and reliability technicians
- First-line maintenance and operations supervisors
- Reliability engineers
- Planners and schedulers
- Mechanical engineers
- Team leaders and managers
Prerequisite
To ensure participants can fully benefit from the course content and hands-on activities, the following prerequisites are recommended:
- Completion of 5021 – Machinery Installation and Assembly or equivalent training in precision assembly and machine installation.
- Basic understanding of rotating equipment such as pumps, motors, gearboxes, and fans.
This course is designed as an intermediate to advanced level training.
Detailed Course Overview
5022 – Component Failure: Identify and Control
5022 – Component Failure: Identify and Control – Identify and Control is a five-day, performance-based training course specifically designed to deepen the practical knowledge of craft technicians, maintenance personnel, and reliability professionals. The course provides an advanced, hands-on approach to identifying and controlling the most common causes of machinery component failure. By building on the foundational skills covered in “Essential Craft Skills 1,” this course focuses on practical, application-based techniques to improve reliability and reduce unplanned downtime.
In today’s industrial environment, component failure remains a leading cause of equipment downtime and reduced asset performance. Contrary to popular belief, many failures are not caused by misalignment or imbalance. Instead, they stem from issues with components such as bearings, lubrication systems, couplings, and shaft sealing mechanisms. This course targets these failure points and teaches participants how to detect, analyze, and mitigate them using proven, precision maintenance techniques.
Course Objectives
- Develop an analytical approach to failure detection and prevention
- Learn proper machine disassembly techniques to preserve failure evidence
- Master bearing identification, removal, and installation
- Understand and apply lubrication best practices
- Gain hands-on experience with power transmission and coupling inspection
- Learn to recognize common shaft sealing system failures
- Improve reliability through quantifiable inspection and documentation methods
What You Will Learn
This training provides a deep dive into the core elements that contribute to machinery failure. The focus is not only on theory but also on real-world application with approximately 50% of the course dedicated to hands-on exercises using dynamically running demonstrators.
1. Machine Inspection Techniques
- Visual, audible, and tactile inspection methods
- How to quantify inspection results
- Use of vibration and temperature data to support diagnosis
- Dynamic measurement exercises for immediate feedback
2. Rolling Element Bearings
- Identification and interpretation of bearing failure types (e.g., spalls, fatigue, contamination)
- Correct dismounting and mounting techniques
- Use of specialized tools for bearing removal and installation
- Oil injection systems for hydraulic dismounting
- Bearing nomenclature, grades of precision, and application use cases
- Bearing installation using bearing heaters, adapter sleeves, and hydraulic nuts
3. Power Transmission Devices
- Introduction to couplings inspection and installation: rigid, flexible, and specialty types
- Coupling selection criteria and failure analysis
- Precision inspection and installation techniques
- Lubrication requirements for different coupling types
4. Lubrication Best Practices
- Properties, types, and application of lubricants
- Lubricant film theory and contamination control
- Selection of appropriate delivery systems (e.g., Trico systems)
- Practical field analysis and sampling exercises
- Vacuum pump sampling, patch testing, and oil odor recognition
- Lubricant maintenance procedures for asset longevity
5. Shaft Sealing Systems
- Introduction to mechanical seals, compression packing, and split seals
- Installation and adjustment methods
- Understanding of seal flush and cooling systems
- Recognition and correction of common failure modes
Daily Breakdown
Day 1
- Inspection techniques: visual, tactile, audible
- Measuring and interpreting vibration and temperature
- Bearing removal techniques with cylindrical and withdrawal sleeve exercises
Day 2
- Shaft and housing preparation
- Shaft and housing fit exercises with real-time feedback
- Bearing nomenclature and precision grade overview
Day 3
- Use of bearing heaters and hydraulic nuts for installation
- Adapter sleeve and tapered sleeve installation with exercises
- Coupling types and lubrication review
Day 4
- Lubrication properties, contamination sources, and delivery system installation
- Vacuum pump sampling and odor/CCO exercises
Day 5
- Patch testing and interpretation
- Belt-drive pre-checklist overview
- Seal installation exercises with mechanical and split seals
- Final review and certification ceremony
Conclusion
“5022 – Component Failure: Identify and Control” is a must-attend course for professionals looking to elevate their understanding of component machinery failure identification mechanisms and precision maintenance. With its strong emphasis on hands-on learning, real-world application, and industry-relevant techniques, this course empowers technicians to reduce downtime, extend asset life, and improve plant reliability. Whether you’re a craft technician, supervisor, engineer, or reliability leader, the skills acquired in this training will deliver immediate and measurable impact in the field.
