COURSE OVERVIEW:

Failure Modes and Effects Analysis (FMEA) is a systematic, proactive methodology used to evaluate the potential failures within a system and their impact on operational success. This course provides a specialized application of the FMEA process to rotating equipment, such as pumps, compressors, turbines, and gearboxes. Participants will learn how to break down complex machinery into its constituent components and identify the various ways those components can fail, ensuring that risks are mitigated before they lead to catastrophic events.

The scope of this training includes the calculation of the Risk Priority Number (RPN) through the assessment of failure severity, probability of occurrence, and detectability. We will examine common failure modes specific to rotating assets, including bearing fatigue, seal degradation, and shaft misalignment, and explore how these failures propagate through a process system. This structured approach allows maintenance and reliability teams to prioritize their resources on the most critical failure risks, optimizing the overall reliability of the plant.

Furthermore, the course emphasizes the transition from analysis to action. Attendees will learn how to develop targeted mitigation strategies, such as improved maintenance tasks, design modifications, or enhanced monitoring protocols, based on the findings of the FMEA. By mastering this analytical tool, technical personnel can significantly reduce the likelihood of unplanned downtime, improve safety performance, and foster a culture of proactive reliability that addresses the root causes of failure early in the equipment’s lifecycle.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the fundamental steps and benefits of the FMEA process.
2. Facilitate an FMEA workshop for rotating equipment teams.
3. Define the boundary and functions of a rotating equipment system.
4. Identify potential failure modes for bearings, seals, shafts, and couplings.
5. Analyze the local and system-wide effects of specific failures.
6. Assign accurate scores for Severity, Occurrence, and Detection.
7. Calculate and interpret the Risk Priority Number (RPN).
8. Differentiate between Design FMEA (DFMEA) and Process FMEA (PFMEA).
9. Develop actionable recommendations to reduce high-risk RPN scores.
10. Link FMEA results to the development of a Preventive Maintenance (PM) program.
11. Use FMEA data to justify the implementation of Predictive Maintenance (PdM).
12. Update FMEA documents following equipment modifications or major failures.
13. Integrate FMEA into a broader Reliability Centered Maintenance (RCM) study.

TARGET AUDIENCE:

Reliability Engineers, Maintenance Managers, Rotating Equipment Specialists, Design Engineers, and Quality Assurance Professionals.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.