COURSE OVERVIEW:

Shaft repair, alignment, and balancing represent the three pillars of mechanical restoration for rotating equipment. The shaft is the primary transmitter of torque and power, and any deviation from its design geometry—whether through wear, bending, or mass imbalance—leads to accelerated failure of the entire machine train. This course provides a comprehensive roadmap for diagnosing shaft-related issues and implementing precision corrective measures to restore equipment to OEM specifications.

The scope of this course includes advanced metallurgical repair techniques such as metal spraying, sleeving, and submerged arc welding, alongside the critical machining processes required to restore concentricity. Participants will explore the science of shaft dynamics, learning how to straighten bent shafts and repair damaged bearing journals or seal areas without compromising structural integrity. The coverage extends to the dual disciplines of precision alignment and dynamic balancing, which are the final steps in ensuring a smooth-running asset after mechanical repairs are completed.

Furthermore, the training emphasizes the use of modern diagnostic tools, including laser alignment systems and digital vibration analyzers for field balancing. Attendees will learn to interpret vibration data to distinguish between a bent shaft, a misaligned coupling, and an unbalanced rotor. By mastering these integrated skills, participants will be able to extend the mean time between failures (MTBF), reduce energy consumption, and ensure that overhauled equipment operates at peak reliability levels upon return to service.

COURSE OBJECTIVES:

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

1. Identify the common causes of shaft failure and surface degradation.
2. Evaluate the feasibility of various shaft repair methods, including cold and hot processes.
3. Perform dimensional inspections to detect shaft runout and eccentricity.
4. Execute shaft straightening techniques using thermal and mechanical methods.
5. Apply precision measurement tools to verify journal and housing tolerances.
6. Understand the principles of shaft alignment and its impact on bearing loads.
7. Conduct soft foot detection and correction procedures prior to alignment.
8. Utilize laser alignment technology for complex machinery trains.
9. Distinguish between static, couple, and dynamic unbalance in rotors.
10. Perform single and two-plane field balancing using vibration analyzers.
11. Calculation required shim thickness and horizontal moves for precision alignment.
12. Interpret ISO 1940 balancing quality grades for different machinery classes.
13. Select appropriate coupling types based on alignment and torque requirements.
14. Document all repair, alignment, and balancing data for quality assurance.

TARGET AUDIENCE:

This course is designed for Mechanical Technicians, Workshop Supervisors, Maintenance Engineers, and Millwrights involved in the overhaul and maintenance of rotating machinery.

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.