Predictive maintenance attempts to detect the onset of a degradation mechanism with the goal of correcting that degradation prior to significant deterioration in the component or equipment. The diagnostic capabilities of predictive maintenance technologies have increased in recent years with advances made in sensor technologies. These advances, breakthroughs in component sensitivities, size reductions, and most importantly, cost, have opened up an entirely new area of diagnostics to the O&M practitioner.

The reason that plants implement predictive maintenance programs is also changing, as with the introduction of any new technology, proper application and training is of critical importance. This need is particularly true in the field of predictive maintenance technology that has become increasingly sophisticated and technology-driven.

This course provides thorough discussions on the various technologies and techniques that includes vibration monitoring and analysis, thermography, tribology, process parameters, visual inspections, operating dynamics analysis and failure-mode analysis. This course also covers how to establish organizational programs to manage predictive maintenance.

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

Ø  Gain and apply knowledge on introduction to predictive maintenance

Ø  Explain the impact of maintenance

Ø  Describe the theory, roles, benefits, application and safety considerations of predictive maintenance technologies

Ø  Discuss the classification of vibration monitoring and analysis and thermography, tribology, process parameters and ultrasonic

Ø  Implement visual inspection and methods

Ø  Apply the maintenance strategy and formulating plan for your own environment

This course is intended for plant, process, maintenance and reliability managers and engineers.

Day 1:

Impact of Maintenance

·         Maintenance management methods 

·         Optimizing predictive maintenance

Financial Implications and Cost Justification 

·         Assessing the need for condition monitoring

·         Cost justification

·         Justifying predictive maintenance

·         Economics of preventive maintenance

 Role of Maintenance Organization 

·         Maintenance mission

·         Evaluation of the maintenance organization 

·         Designing a predictive maintenance program

Benefits of Predictive Maintenance

·         Primary uses of predictive maintenance

Day 2:

Machine-Train Monitoring Parameters

·         Drivers 

·         Intermediate drives

·         Driven components

Predictive Maintenance Techniques

·         Vibration monitoring

·         Thermography

·         Tribology

·         Visual inspections

·         Ultrasonic

·         Other techniques

Vibration Monitoring and Analysis 

·         Vibration analysis applications

·         Vibration analysis overview 

·         Vibration sources

·         Vibration theory 

·         Machine dynamics

·         Vibration data types and formats

·         Data acquisition 

·         Vibration analyses techniques 

Thermography

·         Infrared basics 

·         Types of infrared instruments

·         Training

·         Basic infrared theory

·         Infrared equipment

·         Infrared thermography safety

·         Infrared thermography procedures

·         Types of infrared problems.

Day 3:

Tribology 

·         Lubricating oil analysis

·         Setting up an effective program

Process Parameters

·         Pumps 

·         Fans, blowers, and fluidizers 

·         Conveyors 

·         Compressors 

·         Mixers and agitators

·         Dust collectors 

·         Process rolls

·         Gearboxes/reducers

·         Steam traps 

·         Inverters

·         Control valves

·         Seals and packing 

Ultrasonic

·         Ultrasonic applications

·         Types of ultrasonic systems

·         Limitations

Visual Inspection

·         Visual inspection methods 

·         Thresholds 

Day 4:

Operating Dynamics Analysis

·         It’s not predictive maintenance

Failure-Mode Analysis 

·         Common general failure modes

·         Failure modes by machine-train component 

Establishing a Predictive Maintenance Program

·         Goals, objectives, and benefits

·         Functional requirements

·         Selling predictive maintenance programs

·         Selecting a predictive maintenance system 

·         Database development

·         Getting started 

Day 5:

A Total-Plant Predictive Maintenance Program

·         The optimum predictive maintenance program 

·         Predictive is not enough

Maintaining the Program

·         Trending techniques

·         Analysis techniques

·         Additional training

·         Technical support

·         Contract predictive maintenance programs

World-Class Maintenance 

·         What is world-class maintenance?

·         Five fundamentals of world-class performance

·         Competitive advantage

·         Focus on quality

·         Focus on maintenance

·         Overall equipment effectiveness

·         Elements of effective maintenance

·         Responsibilities

·         Three types of maintenance

·         Supervision

·         Standard procedures 

          Workforce development 

A variety of methodologies will be used during the course that includes:

·         (30%) Based on Case Studies

·         (30%) Techniques 

·         (30%) Role Play

·         (10%) Concepts

·         Pre-test and Post-test

·         Variety of Learning Methods

·         Lectures

·         Case Studies and Self Questionaires

·         Group Work

·         Discussion

·         Presentation

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Daily Course Timings:

    08:00 - 08:20       Morning Coffee / Tea

    08:20 - 10:00       First Session

    10:00 - 10:20       Coffee / Tea / Snacks

    10:20 - 12:20       Second Session

    12:20 - 13:30       Lunch Break & Prayer Break

    13:30 - 15:00       Last Session