COURSE OVERVIEW:

Root cause bearing failure analysis is a critical discipline within reliability engineering that focuses on identifying the underlying reasons why a bearing ceased to perform its intended function. This process goes far beyond merely identifying the mode of failure, such as fatigue or wear, and delves into the systemic, operational, and environmental factors that contributed to the degradation. By systematically investigating these failures, organizations can transition from a reactive maintenance culture to a proactive one, significantly reducing downtime and extending the lifecycle of critical rotating assets.

The scope of this course encompasses the physical laws governing bearing operation, the metallurgical changes that occur during failure, and the various external influences such as lubrication chemistry and installation precision. Participants will explore the intricate relationship between machine dynamics and bearing longevity, learning how to interpret complex failure patterns. The Coverage includes a detailed examination of the ISO 15243 standards, which provide a unified classification system for failure modes, ensuring that all analysis is performed according to globally recognized engineering benchmarks.

Furthermore, the course addresses the practical application of analysis tools and methodologies, from visual inspection and microscopy to vibration data correlation. It emphasizes the importance of the "evidence chain," teaching participants how to preserve failed components and document the surrounding operational context. By the end of this program, attendees will possess the expertise to not only diagnose why a bearing failed but also to implement robust corrective actions that prevent recurrence, thereby optimizing the total cost of ownership for industrial machinery.

COURSE OBJECTIVES:

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

1.  Identify the fundamental mechanics of rolling element and journal bearing operations.

2.  Differentiate between primary failure modes as defined by the ISO 15243 standard.

3.  Apply systematic root cause analysis methodologies to complex bearing seizures.

4.  Interpret surface distress patterns to determine the adequacy of lubrication films.

5.  Recognize the distinct visual signatures of electrical discharge damage in bearings.

6.  Evaluate the impact of improper installation techniques on premature bearing death.

7.  Assess the role of contamination and ingress in accelerated abrasive wear cycles.

8.  Correlate vibration analysis data with physical findings during a teardown.

9.  Conduct metallurgical assessments of spalling and subsurface fatigue.

10.  Implement effective preservation techniques for failed components during transit.

11.  Develop comprehensive failure reports that communicate technical findings to stakeholders.

12.  Design specific corrective action plans to eliminate recurring bearing issues.

13.  Utilize advanced diagnostic tools for non-destructive testing of bearing surfaces.

14.  Optimize lubrication schedules based on analyzed failure data and environmental factors.

TARGET AUDIENCE:

This course is designed for Reliability Engineers, Maintenance Managers, Mechanical Technicians, Plant Engineers, and Condition Monitoring Specialists who are responsible for the health and performance of rotating equipment.

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.