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Course Description

The Bearing Root Cause Failure Analysis (RCFA) training program is designed to equip participants with the technical knowledge and investigative skills needed to identify, analyze, and eliminate the true causes of bearing failures in rotating equipment. The course focuses on practical failure investigation techniques, bearing damage recognition, lubrication and contamination issues, installation errors, misalignment, vibration-related failures, and corrective action planning to prevent recurring breakdowns and improve equipment reliability.

Course Objectives

Upon the successful completion of this course, each participant will be able to:

  • Understand bearing types, functions, and common failure mechanisms.
  • Identify bearing failure modes using visual and physical inspection methods.
  • Interpret bearing damage patterns and link them to probable root causes.
  • Apply RCFA methodology to investigate bearing-related breakdowns.
  • Evaluate lubrication conditions and contamination effects on bearing life.
  • Analyze installation, alignment, and load-related bearing failures.
  • Use vibration and condition monitoring data to support failure analysis.
  • Develop corrective and preventive actions to avoid repeat failures.
  • Produce structured bearing failure investigation reports.
  • Improve reliability strategies and maintenance practices for rotating assets.

Who Should Attend?

This course is designed for maintenance, reliability, rotating equipment engineers, vibration analysts, mechanical technicians, and plant supervisors responsible for troubleshooting bearing failures and improving equipment reliability.

Course Agenda

Registration

Welcome & Introduction

Pre-Test

Day 1: Bearing Fundamentals & Failure Introduction 

  • Introduction to Bearing RCFA and reliability impact
  • Bearing functions and operating principles
  • Types of bearings (ball, roller, thrust, journal, etc.)
  • Bearing components and terminology
  • Bearing load zones and stress distribution
  • Basic bearing life concepts (L10 life, fatigue, load rating)
  • Overview of bearing failure mechanisms
  • Introduction to failure classification systems (ISO failure modes)

Day 2: Bearing Failure Modes & Damage Recognition 

  • Failure vs damage vs defect: correct definitions
  • Common bearing failure patterns and what they indicate:

          Spalling / fatigue flaking

          Smearing and scoring       

          Brinelling (true and false)    

          Fretting corrosion

          Cage damage     

          Cracking and fractures          

          Electrical fluting / EDM damage   

          Overheating and discoloration
  • How to read bearing surface evidence
  • Common misdiagnosis and false assumptions in bearing failure analysis
  • Activity/Workshop: Bearing failure photo analysis and classification exercise

Day 3: Root Causes – Lubrication, Contamination & Environment

  • Lubrication fundamentals for bearings
  • Grease vs oil lubrication selection criteria
  • Lubrication failure modes:
          Over-lubrication

          Under-lubrication

          Wrong lubricant selection

          Lubricant degradation (oxidation, thermal breakdown)

  • Contamination types and failure impact:

          Dirt and dust

          Water ingress

          Process chemical contamination

          Metal particles and wear debris

  • Sealing system failures and contamination entry paths
  • Practical best practices for bearing lubrication management
  • Lubrication condition monitoring and sampling interpretation

Day 4: Root Causes – Installation, Alignment, Load & Mechanical Conditions

  •  Installation errors and their damage signatures:

          Improper mounting force

          Wrong fit tolerances (shaft/housing fit)

          Improper heating methods

          Incorrect clearance adjustment

  • Alignment-related failures:

          Angular misalignment

          Parallel misalignment

          Soft foot effects

  • Load-related failures:

         Excessive radial/axial load

         Shock load and vibration

         Unbalance and resonance influence

  • Shaft runout, bent shaft, improper coupling effects
  • Thermal expansion issues and bearing creep
  • Bearing housing issues (looseness, ovality, cracks)
  • Activity/Workshop: Root cause mapping using real-life bearing failure examples
Day 5: Bearing RCFA Methodology, Reporting & Preventive Strategies

  • Step-by-step Bearing RCFA process:

           Data gathering and evidence preservation

           Failure timeline creation

           Cause-and-effect analysis

           Root cause validation techniques

  • Tools used in RCFA:

          5 Whys

          Fishbone Diagram

          Fault Tree Analysis (FTA)

          Cause Mapping

  • Using vibration analysis and condition monitoring data:

          Bearing defect frequencies overview

          How vibration trends support failure diagnosis

  • Corrective and preventive action development (CAPA)
  • Writing a professional bearing failure investigation report
  • Reliability improvement recommendations:

          Lubrication program enhancement

          Installation procedures and standards

          Condition monitoring strategies

          Spare parts handling and storage improvement

  • Final Workshop / Assessment: Full RCFA case study

Post Test

End of the Course

    Assessment Methodology

    All courses conducted by EdTech will begin with a Pre-evaluation and end with a Post-evaluation. The instructor will evaluate the knowledge and skills of the participants according to the feedback given by participants. This will help to recognize the benefits and the level of knowledge gained by participants through the course.

    Training Methodology

    Facilitated by a highly qualified specialist, who has extensive knowledge and experience; this program will be conducted using extensively interactive methods, encouraging participants to share their own experiences and apply the program material to real-life work situations in order to stimulate group discussions and improve the efficiency of the subject coverage.

    Percentages of the total course hour classification are:

    • ​40% Theoretical lectures, Concepts and approach
    • 20% Motivation to develop individual skill and Techniques
    • 20% Case Studies and Practical Exercises
    • 20% Topic General Discussions and interaction

    Course Manual

    Participants will be provided with comprehensive presentation material as reference manual. This presentation material is a compilation of core valuable information, references, presentation methods and inspiring reading which will be used as a part of the material guide.

    Course Certificate

    At the completion of the course, all participants who successfully accomplished the required contact hours will receive an EdTech Training Participation Certificate as a testimony to their commitment to professional development and further education.

    Why Edtech ?

    • Industry Experienced; Internationally Qualified Trainers
    • Hands-on Practical Sessions & Assignments
    • Intensive Study materials
    • Flexible Schedules
    • Realistic training methodology
    • High-Quality Training in Affordable Course Fees
    • Achievement Certificate, as approved by the Ministry of Education (Abu Dhabi Center for Technical and Vocational Education Training - ACTVET), HABC, AWS, IAOSHE, SHRM, etc.