Course Overview

Misalignment is one of the main causes of vibration in rotating equipment. This leads to increased maintenance and reduced machine life. Appropriate alignment could save maintenance and operational costs for the organisation. Misalignment of shafts causes stresses on the rotating and stationary components.

Even if couplings do not fall under such conditions, bearings and seals most definitely will. Shaft alignment includes positioning of the rotational centres of two or several shafts so that they are collinear when the machines are running under normal operating conditions. Ball and rolling bearings can operate under proper conditions when lubricated.

The lubricant reduces friction between the internal service of both the bearing components. Lubrication, especially circulating oil, helps remove heat from the bearings.

Vibration analysis refers to the process of checking vibration levels and frequencies of industrial machinery to determine the health of the machinery. It aims to reduce maintenance costs and machine downtime.

This Zoe training course will empower you with a complete understanding of all critical aspects related to industrial machinery, that is, precision shaft alignment, bearing lubrication and vibration analysis. Through this course, you will handle any challenge concerning industrial machinery, thus enhancing your professional portfolio and inviting several opportunities for career progression.

Course Objectives

The primary objective of this Couplings and Shaft Alignment training course is to empower professionals with—

• complete understanding and knowledge of precision shaft alignment, bearing lubrication and vibration analysis
• the confidence and skill to not only oversee shaft alignment but practically do it when necessary, thus making one dynamic in his or her role
• the understanding and experience of bearing lubrication to choose the appropriate lubricant and detect problems related to bearing lubrication
• the analytical skills and capabilities to conduct vibration analyses and determine the maintenance required and decide on replacement of the machine, thereby influencing maintenance and operational costs in a positive way with timely action
• the confidence and knowledge to train other professionals on shaft alignment, bearing lubrication and vibration analysis
• the capabilities to contribute to organisational development by reducing maintenance and operational costs through regular audits of machines to check machine health and increase machine longevity
• the experience and knowledge to ensure that all operations and activities within the plant are carried out in compliance with laws and regulations
• the dynamic skillset and capabilities to handle all major responsibilities related to machine health, that is, shaft alignment, bearing lubrication and vibration analysis, thus making one dynamic and enhancing one’s professional portfolio for greater opportunities across industries

Training Methodology

All courses at Zoe Talent Solutions are customisable to suit the audience to the closest degree possible. Thus, before the commencement of each training program, the courses are thoroughly reviewed to check for relevance to the professional backgrounds of the training audience.

Training is delivered by an experienced professional, using audio-visual presentations. Group assignments, projects, role-plays and active case study discussions foster trainee participation too.

The above format of training is unique to Zoe Talent Solutions and is called the Do–Review–Learn–Apply Model.

Organisational Benefits

By professionals registering for this Couplings and Shaft Alignment training course, organisations will derive the following benefits:

• Better maintenance of machines and eradication or timely detection of problems of shaft alignment, bearing lubrication and vibration because of management by trained and experienced professionals
• Greater machine life and hence lesser maintenance and operational costs, in turn, contributing to greater savings
• Regular training of new and existing employees on handling machines to avoid shaft alignment, bearing lubrication and vibration issues, and troubleshooting effectively in case of issues
• Prevention of occupational hazards through appropriate repair measures
• Organisational growth and development because of better machines and reduced costs
• Application of advanced methods and techniques for shaft alignment, bearing lubrication and vibration analysis to ensure that issues do not recur
• Adherence to international standards and guidelines for maintenance of machines

Personal Benefits

Professionals registering for this coupling and Shaft Alignment training course will derive the following benefits:

• Detailed knowledge and understanding of shaft alignment, bearing lubrication and vibration analysis
• Increased confidence and knowledge to train other professionals on best practices of shaft alignment, bearing lubrication and vibration analysis
• Greater understanding of advanced techniques and concepts for shaft alignment, bearing lubrication and vibration analysis
• Increased confidence and experience to regularly audit and inspect machines to ensure optimal capacity and efficiency and take action, if needed, on time
• Greater exposure and information to ensure that organisational processes and systems are in alignment with international standards
• Increased ability to contribute to organisational savings through reduced operational and maintenance costs, thereby contributing to organisational growth and development
• Enhanced skill to ensure proper shaft alignment, bearing lubrication and vibration analysis, if needed, to prolong machine life and prevent occupational hazards
• Enhanced, dynamic skillset and capabilities to handle all major issues occurring about shaft alignment, bearing lubrication and vibration, thereby increasing one’s potential to assume higher responsibilities within or outside one’s organisation

Who Should Attend?

• Engineers and other employees working on processes of shaft alignment, bearing lubrication and vibration analysis
• Managers and leaders overseeing end-to-end operations at plants
• Senior members of the management of an organisation responsible for decisions about finance of the organisation for expenses on machinery
• Finance and accounts managers responsible for managing expenses and releasing or holding costs incurred by the organisation
• Compliance officers and quality checkers responsible for ensuring that all operations and machinery meet international standards and benchmarks
• Any other professional interested in knowing more about shaft alignment, bearing lubrication and vibration analysis

Course Outline

The course Couplings and Shaft Alignment training course  covers the following areas for effectively understanding shaft alignment, bearing lubrication and vibration analysis:

Module 1 – Different Alignment Parameters

• Angularity
• Offset
• Gap

Module 2 – Types of Alignment Conditions

• Horizontal angularity
• Horizontal offset
• Vertical angularity
• Vertical offset

Module 3 – Errors Minimised by Roughing

• Radial stresses in shafts and couplings
• Reduced clearances in bearings
• Assembly errors in coupling
• Imparting strain in mechanical systems

Module 4 – Benefits of Precision Shaft Alignment

• Reduced energy consumption
• Reduced incidence of repairs
• Longer machine life

Module 5 – Types of Bearings

• Deep groove ball bearings
• Angular contact ball bearings
• Self-alignment ball bearings
• Thrust ball bearings
• Spherical roller ball bearings
• Cylindrical roller ball bearings
• Tapered roller ball bearings
• Needle roller ball bearings

Module 6 – Overview of Bearing Lubrication

• Concept
• Oil lubrication
• Grease lubrication

Module 7 – Advantages of Oil Lubrication

• Easy to distribute
• Lubes with other components
• Less drag
• Easier to drain out and change
• Better for high temperature

Module 8 – Advantages of Grease Lubrication

• Remains in place
• Does not leak out easily
• Improves sealing
• Does not require monitoring

Module 9 – Types of Vibration

• Free vibration
• Forced vibration
• Damped vibration

Module 10 – Overview of Vibration Analysis

• Concept and principles
• Time–waveform analysis
• Phase analysis

Module 11 – Types of Vibration Monitoring

• Motor vibration monitoring
• Bearing condition monitoring
• Gearbox vibration monitoring
• Rotor vibration analysis

Module 12 – Steps in Vibration Analysis

• Calculate the expected vibration spectrum
• Establish the baseline
• Digitise the signal
• Convert to frequency space
• Review harmonics