Gearbox Technology: Design, Analysis, Testing, Maintenance, Lubrication, and Failure - YOGYAKARTA

Gearbox Technology: Design, Analysis, Testing, Maintenance, Lubrication, and Failure - YOGYAKARTA

Hotel  IBIS  Yogyakarta| Yogyakarta  10 – 13 Mei 2011 |IDR  6.500.000,-
Hotel  IBIS  Yogyakarta | Yogyakarta  21 – 24 Juni  2011|IDR 6.500.000,-

 

OBJECTIVES

1. Understand the standard of setting up plan for gearbox


2. Make the gearbox recalculation and planned


3. Classification and analysis of gear


4. Gear Box Maintenance


5. Measurement Technique and gear Box testing


6. Gearbox failure Analysis

 

COURSE OUTLINE

A. Introduction

• Application of Gear System


• Gear Classification


• Gear Nomenclature


• Power Train


• Gear Standard


• Unit System

B. Gear Analysis

• Power Train


• Stress and Deflection


• Strength/ Allowable Stress


• Fatigue


• Gear Design Life

C. Gear Design

• Spur Gear


• Helix Gear


• Gearbox


• Case Study

• o Spur Gear Design


• o Helix Gear Design

D. Measurement and Testing

• Principles of Measurement


• Geometry Measurement


• Vibration Measurement


• Noise Measurement


• Gear System Efficiency


• Gear Testing

E. Maintenance and Lubrication

• Maintainability and Maintenance


• Maintenance in Product Life Cycle


• Life Cycle Cost


• Why We Need the Maintenance


• Maintenance Category


• Gear Maintenance


• Lubrication


• Gear Lubrication


• Power Losses in Gear


• Type of Gear Lubrication


• Lubrication for Loaded Gear


• Influence of Gear Lubrication on Surface Distress

F. Gear Failure

• Failure Classification


• Wear


• Surface Fatigue


• Plastic Flow


• Breakage


• Hertz Contact


• Case Study of Gear Failure

 

PARTICIPANTS

Mechanical Engineers, Maintenance Engineers and supervisors, Service Engineers and supervisors and everyone who want to enlarge their knowledge

 

METODE

lecturing, workshop, interactive consultation, and case study

 

INSTRUKTUR

Dr. Ir Viktor Malau DEA

 

WAKTU

• Yogyakarta  10 – 13 Mei 2011


• Yogyakarta  21 – 24 Juni  2011

 

TEMPAT

Hotel Ibis Yogyakarta

 

INVESTASI

• IDR  6.500.000 – (non residential )


• (termasuk picking-up service dari Bandara/Stasiun KA ke hotel, training modul, training kit, 2x coffee break, 1x lunch, souvenir, dan sertifikat)

 

LUBRICATION AND BEARING TECHNOLOGY

LUBRICATION AND BEARING TECHNOLOGY

Hotel Banana Inn, Bandung | 2 – 6 Mei 2011 | Rp 7.750.000/person
Hotel Banana Inn, Bandung | 26 – 30 September 2011 | Rp 7.750.000/person

LATAR BELAKANG :

Bearing adalah komponen mesin yang mendukung  dan memposisikan  rotor mesin yang bersangkutan pada posisi yang benar. Didukung dengan pelumasan yang tepat, maka

• Rotor berputar dengan alignment yang benar


• Mesin terbebas dari vibrasi yang berlebihan


• Rotor dan stator terhindar dari gesekan yang berlebihan sehingga pasokan daya masih dalam rentang yang  wajar


• Rotor dan stator  terhindar dari keausan yang berlebihan

Dengan kondisi tersebut di atas maka peluang terjadinya kegagalan operasi dapat diperkecil.

 

TUJUAN TRAINING :

Setelah Pelatihan para peserta diharapkan akan lebih :

• Memahami parameter-parameter serta pengaruhnya dalam operasi roller bearing dan pelumas (lubricant)


• Memahami cara-cara melakukan operasi dan perawatan roller bearing yang tepat


• Memahami faktor-faktor penyebab kemerosotan pelumas


• Mampu mencari penyebab kegagalan dan cara penanganannya

 

CAKUPAN MATERI TRAINING :

1.    Fundamental lubrication

• teori gesekan  dan pelumas


• jenis jenis pelumas

2.    Oli

• viskositas


• mengukur viscositas, efek temperatur dan tekanan.

3.    Memilih dan menentukan  viskositas
4.    Additive.

• Unsur unsur additive


• additive pada gearbox, motor bakar.

5.    Grease

• consistency


• NGLI grade


• memilih grease


• additive pada grease


• Aplikasi pelumas untuk pabrik  kertas.

6.    sistem lubrikasi pada pompa.

• sistem  lubrikasi mesin diesel dan alat berat


• sistem lubrikasi pada steam turbine


• sistem lubrikasi pada kompresor


• sistem lubrikasi pada paper machine


• Maintenance total solusi - program lubrikasi

7.    Bagaimana merencanakan program preventive maintenance untuk lubrikasi.

• kerja kelompok : bagai mana membuat planning lubrikasi.

8.    Menentukan interval lubrikasi
9.    Phenomena Vibrasi dan problem yang ditimbulkan oleh pelumas /predictive

• Maintenance


• studi kasus :  analisa vibrasi.


• kerusakan bearing akibat kesalahan lubrikasi.

10.    Problem troubleshooting yang berhubungan dengan pelumas.
11.    keausan pada journal bearing.
12.    kerusakan pada bearing.
13.    kerusakan pada gearbox.
14.    Lube oil analysis.

• Standard oil testing. TAN Number, counting particle, ect.

15.    Reliability improvement on lube oil.
16.    Handling and storage pelumas dan Safety

 

TRAINING INSTRUCTOR

Ir. Deddy Nugraha

Ir. Deddy Nugraha is a dedicated experienced fulltime trainer and technical consultant since 2002. He holds a B.S. degree in Mechanical Engineering from ITB, Bandung. He has worked nationally in a wide variety of industries including: technology, aerospace, utilities, auditing, mining and institutions thus engaged as a corporate consultant. He also holds certifications for those particular fields from Snecma, France; Engine Support Inc., USA; Danobat, Spain; DNV, Singapore; MTU, Germany and FAA Auditor, USA. Mr. Nugraha is a member of Indonesian Society for Reliability and was elected as General Sectretay for 2004-2007 period. He has trained hundreds of managers, engineers and floor associates, subjects taught to include; CMMS, RCM, TPM, Project Management, Quality Process Control, Corrosion Control and Protection, Failure Analysis, Engineering Design, Instalation & Constrcution, Inventory Control and Management. Major clients include: Pertamina, British Petroleum, Petrochina, Siemen Power, PT. Indonesia Power, PT. Krakatau Steel, Freeport Indonesia, PT. Surveyor Indonesia, Chevron, Medco Energy, PT. Aneka Tambang, Garuda Maintenance Facility, PT. Perusahaan Gas Negara, PT. Semen Padang, PT. Semen Gresik, PT. Indah Kiat Pulp & Paper, PT. Tjiwi Kimia, PT. Pupuk Kujang and PT. Kaltim Prima Coal.

 

VENUE :

Hotel Banana Inn, Bandung

 

TRAINING DURATION :

5 days

 

TRAINING TIME  :

1. 2 – 6 Mei 2011


2. 26 – 30 September 2011

 

INVESTATION PRICE/PERSON :

1. Rp 7.750.000/person (full fare)  or


2. Rp 7.500.000/person (early bird, payment 1 week before training) or


3. Rp 7.250.000/person (if there are 3 persons or more from the same company)

FACILITIES FOR PARTICIPANTS:

1. Training Module


2. Training CD Contains Training Material


3. Certificate


4. Stationeries: NoteBook and Ballpoint


5. Jacket or Waistcoat or T-Shirt


6. Bag or Backpackers


7. Training Photo


8. Training Room with Full AC Facilities and multimedia


9. Once lunch and twice coffeebreak every day of training


10. Qualified  instructor


11. Transportation for participants from hotel of participants to/from venue of training(if minimal number of participants from one company is 4 persons)

 

 

Bearing and Lubrication System Analysis

Bearing and Lubrication System Analysis

Golden Flower Hotel, Bandung | April 26-30, 2010 | Rp.8.250.000,-

 

OBJECTIVES OF THE TRAINING PROGRAM

• Give better understanding to the general description of friction that enables participants to optimize the useful or useless friction


• Enhance fundamental knowledge of lubrication system to keep bearing operating condition safe and free from failure


• Improve knowledge how to monitor engine operating conditions and lubricant selection to keep bearing operation longer


• Give knowledge how to analyze the source of disturbance, and systematically analyze bearing failure

THE BENEFITS OF ATTENDING

• Better understanding of bearing and lubrication system and enable to modify lubrication supply system and construction to avoid repeating failures


• The participants will be able to shorten trouble shooting or repair time after having strong technical knowledge in approaching the systematic root cause analysis of bearing and lubrication system


• Capable and skillful to select types of bearing and lubricant fit to the operating condition

COURSE MATERIALS

A comprehensive set of lecturer notes for after course reading and reference:

• An extensive set of practical in-class "case study" exercises specifically developed to emphasize on the specification, maintenance, operation and troubleshooting.

COURSE OUTLINE

1. Fundamental of Tribology
   
   
   
   • Conformal and non-conformal contact
   
   
   • Friction phenomena
   
   
   • Wear phenomena
   
   
   • Lubrication principle
   
   
   • Hydrodynamic bearing
   
   
   • Hydrostatic bearing
   
   
   • Rolling Element bearing
   
   
   
   


2. Wear Metal analysis (spectroscopy, analytical ferrography or micro patch)
   
   
   
   • Spectroscopy analysis
   
   
   • Ferrography analysis
   
   
   • Particle counter method
   
   
   
   


3. Wear phenomena, mechanism and it's causes
   
   
   
   • Wear phenomena
   
   
   • Wear mechanism
   
   
   • Causes of wear
   
   
   
   


4. Sources of wear metal and it's tolerance limit
   
   
   
   • Ferro
   
   
   • Lead
   
   
   • Nickel
   
   
   • Thin
   
   
   • Magnesium
   
   
   • Others minor metal
   
   
   
   


5. Lube oil chemical properties and it's damage causes
   
   
   
   • Base oil
   
   
   • Additives
   
   
   • Lubricant properties
   
   
   • Heat as main causes of lubricant performance degradation
   
   
   
   


6. Contamination control and analysis and it's severity levels
   
   
   
   • Water content
   
   
   • Viscosity and viscosity index
   
   
   • TAN/TBN
   
   
   • Metal content
   
   
   • Particles
   
   
   
   


7. Used oil analysis method and interpretation of it's reports
   
   
   
   • Principle of used oil analysis
   
   
   • Methods on used oil analysis
   
   
   • Reporting and interpretation
   
   
   
   


8. Additive in lube oil and it's damage causes
   
   
   
   • Viscosity index improver
   
   
   • Pour point depressant
   
   
   • Performance package
   
   
   
   


9. Thin film lubrication principle
   
   
   
   • Wedge effect
   
   
   • Squish effect
   
   
   • Stretch effect
   
   
   
   

WHO SHOULD ATTEND

• Mechanical Engineer /Supervisor/Superintendent


• Maintenance Engineer/Supervisor/Superintendent


• Rotating & Reliability Engineer /Supervisor/Superintendent


• Professional who are in charge in lubrication and bearing systems


• Everybody or professional who wants to broaden knowledge or gain benefits from this course

 

Instructor
Prof. Dr. Ir. Indra Nurhadi/ Prof. DR. Ir. IGN. Wiratmaja Puja

Prof. Dr. Ir. Indra Nurhadi is is a lecturer at Mechanical Engineering Department of ITB since 1975 and head of Computational Mechanics Laboratory since 1988 with nearly 30 years of experience in the industries. He received his bachelor degree in 1973 from Mechanical Engineering of ITB. His master and Ph.D degree were received in 1981 and 1985 from University of Wisconsin - Madison, U.S.A.

He regularly conduct seminars and training for the topics: Finite Element Method for Stress Analysis, Lubrication and Bearings, Selection and Design, Balancing and Alignment, Vibration Analysis for Machine Health Monitoring, Design of Machine Elements, Mechanical Design, Motorcycle Frame Analysis and Design.

Prof. DR. Ir. IGN. Wiratmaja Puja has 16 years continuous mechnanical engineering experience in failure and stress analysis, mining machinery and design as well as mechanical drawing and has been a consulting engineering expert in machinery and equipment maintenance for PT. Tambang Batubara Tanjung Enim, KONDUR Petroleum and PT. Kereta Api Indonesia. He also has served as an in-company training instructor for several major oil and gas companies such as PT. Badak LNG, PT. Freeport Indonesia, VICO and PT. Timah Tbk.

Mr. Wiratmaja has authored numerous publications and presentations related to mechanical engineering and mining machinery. He holds a M.Sc. and Ph.D. degree in Mechanical Engineering from the University of Kentucky, USA.

 

Schedule
April 26-30, 2010
5 days

Venue
Golden Flower Hotel, Bandung

Tuition Fee
Rp.8.250.000,- per participant, excluding accommodation & tax.