Course Overview
This 5-day expert-led program equips reliability engineers, maintenance professionals, and asset managers with advanced techniques for implementing comprehensive condition monitoring programs. Participants will master predictive maintenance technologies, data analysis methods, and failure prevention strategies to optimize equipment reliability across industrial operations.
Course Objectives
Upon completion, participants will be able to:
- Design condition monitoring programs aligned with criticality analysis
- Implement vibration analysis (ISO 10816, ISO 20816) for rotating equipment
- Conduct thermographic inspections (ISO 18436) of electrical/mechanical systems
- Perform oil analysis (ISO 4406) and wear particle monitoring
- Utilize acoustic emission and ultrasonic testing for leak detection
- Develop predictive maintenance strategies using machine learning
- Interpret equipment performance trends and failure patterns
- Integrate CM data with CMMS/EAM systems
Who Should Attend
This course is essential for:
- Condition Monitoring Engineers
- Reliability Engineers
- Predictive Maintenance Technicians
- Rotating Equipment Specialists
- Maintenance Managers
- Asset Integrity Engineers
- Plant Operations Engineers
Course Modules
Module 1: Condition Monitoring Fundamentals
- PdM vs. CBM vs. RCM methodologies
- Equipment criticality assessment (API 580)
- Failure modes and effects analysis (FMEA)
- Cost-benefit analysis of CM programs
Module 2: Vibration Analysis (Hands-on)
- Time waveform and FFT spectrum analysis
- Bearing defect frequencies (BPFO, BPFI, BSF)
- Misalignment and unbalance detection
- Case studies on pump/motor/compressor failures
Module 3: Thermography & Electrical CM
- IR camera operation and settings
- Electrical component failure patterns
- Mechanical friction and heat patterns
- Compliance with NFPA 70E standards
Module 4: Lubrication & Wear Particle Analysis
- Oil sampling best practices
- Ferrography and particle counting
- Contamination control strategies
- ISO cleanliness code implementation
Module 5: Emerging CM Technologies
- Acoustic emission for leak detection
- Motor current signature analysis
- Wireless sensor networks
- AI-powered anomaly detection
Module 6: Data Integration & Decision Making
- CM software platforms overview
- Alarm threshold setting strategies
- Root cause analysis techniques
- Integrating CM with maintenance planning
Module 7: Program Implementation
- Developing CM procedures and workflows
- Personnel certification requirements
- Performance metrics and KPIs
- Continuous improvement processes