Upon completion of this course, participants will be able to:

• Differentiate between Preventive Maintenance (PM) and Predictive Maintenance (PdM) strategies.
• Explain the fundamental principles and application of vibration analysis.
• Use infrared thermography to detect electrical and mechanical anomalies.
• Interpret oil analysis reports (wear, contamination, chemistry) for equipment health.
• Implement an ultrasonic inspection program for leak detection and bearing lubrication.
• Develop a comprehensive and optimized PdM route and scheduling process.
• Justify the ROI of PdM technology investment to management.
• Integrate CM data and alarms directly into the CMMS for work order generation.

• Maintenance Engineers and Technicians
• Condition Monitoring (CM) Technicians and Analysts
• Reliability Engineers
• Maintenance Supervisors and Planners
• CMMS Administrators focusing on PdM data integration
• Anyone responsible for asset health and continuous uptime

• Practical hands-on use of vibration and thermal imaging equipment
• Workshop on interpreting combined oil analysis and vibration reports
• Case studies demonstrating successful failure prediction across various asset types
• Group activity designing an integrated PdM route for a sample facility
• Individual presentation justifying the ROI of a specific PdM technology.

Unit 1: PdM Strategy and Fundamentals

• Defining the P-F Curve and the value of early detection.
• The role of PdM in an RCM-based strategy.
• Calculating the return on investment (ROI) for PdM programs.
• Integrating CM data into the maintenance work order flow.

• Analyzing the effectiveness of existing time-based PMs.
• Converting ineffective time-based tasks to condition-based monitoring.
• Techniques for PM task review and interval adjustment.

Unit 2: Vibration Analysis and Diagnostics

• Basic principles of machine vibration and its measurement.
• Selecting the appropriate sensors (accelerometers) and data collectors.
• Establishing baseline readings and alarm limits.

• Interpreting frequency spectra to diagnose unbalance, misalignment, and looseness.
• Identifying bearing and gearbox defect frequencies.
• Case studies of successful failure prediction using vibration data.

Unit 3: Infrared Thermography and Electrical Diagnostics

• Fundamentals of heat transfer and infrared physics (emissivity, reflectivity).
• Safe and effective thermal imaging techniques for electrical and mechanical systems.
• Setting alarm temperatures and severity assessment.

• Diagnosing electrical faults (loose connections, imbalanced loads).
• Detecting mechanical issues (bearing friction, steam trap failure).
• Documentation standards for thermography reports.

Unit 4: Lubricant and Ultrasonic Analysis

• Setting up an effective oil sampling and labeling program.
• Interpreting Wear Particle, Contamination, and Oil Chemistry reports.
• Establishing clean oil standards (ISO Cleanliness Codes) and filtration strategies.

• Application of airborne and structure-borne ultrasound.
• Using ultrasound for leak detection (compressed air, gas, vacuum).
• Ultrasonic condition monitoring of bearing lubrication and health.

Unit 5: PdM Program Management

• Designing efficient and comprehensive PdM data collection routes.
• Training and certifying PdM technicians for data quality.
• Managing the workload and data reporting for all technologies.

• Linking CM data points to assets and functional locations.
• Setting up automated work order triggers from PdM alarms.
• Archiving and retrieving historical CM data for trend analysis.