Preventive and Predictive Maintenance
الصيانة الوقائية والتنبؤية
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- Available in-house
- Fees from
- —per delegate
- Formats
- In-house training0 sessions
- Duration
- 5 daysCertificate
Overview
Unplanned equipment failures are one of the biggest causes of lost production, high maintenance costs and safety incidents in oil, gas and industrial facilities. Many organisations still rely heavily on breakdown maintenance or on fixed-interval tasks that do not reflect how equipment actually fails. Preventive and predictive maintenance aim to detect and prevent failures before they occur, using planned inspections, servicing and condition monitoring technologies. When these approaches are well designed and properly executed, they improve availability, reduce costs and extend equipment life.
This course provides a practical understanding of preventive and predictive maintenance in industrial operations. Participants learn maintenance strategies, failure patterns and the P-F curve, and how to select the right strategy for each type of equipment. The course covers developing preventive maintenance programmes, task intervals and job plans, and the main condition monitoring techniques, including vibration analysis, oil analysis, thermography, ultrasound and motor current analysis. It also explains condition monitoring programme design, data trending and alarm limits, the role of the computerised maintenance management system, planning and scheduling, measuring maintenance performance and continuously improving maintenance programmes.
Objectives
- Compare maintenance strategies and understand equipment failure patterns
- Apply the P-F curve to select inspection and monitoring intervals
- Develop preventive maintenance programmes, job plans and task intervals
- Describe vibration, oil, thermography, ultrasound and electrical monitoring
- Design condition monitoring programmes with trends and alarm limits
- Use the CMMS for planning, scheduling and maintenance history
- Measure maintenance performance and improve programmes continuously
Who should attend
Maintenance engineers and supervisors, reliability engineers, planners, condition monitoring technicians and maintenance managers.
Training methodology
The course combines explanation of maintenance strategies with practical exercises using real equipment data, maintenance histories and condition monitoring reports. Participants select strategies for different equipment, apply the P-F curve to set intervals, write preventive maintenance job plans and interpret vibration, oil analysis and thermography results. CMMS data are analysed to calculate key performance indicators and find improvement opportunities. Demonstrations of monitoring instruments support learning where available. Case studies show how organisations moved from reactive to proactive maintenance. Each day ends with a short quiz.
Programme outline
Day1Maintenance Strategies and Failure Patterns
- The cost of unplanned failures and the business case for proactive maintenance
- Maintenance strategies such as run-to-failure, preventive, predictive and proactive maintenance approaches
- Equipment failure patterns and why many failures are not related to equipment age
- The P-F curve and how it guides inspection and condition monitoring intervals
- Criticality ranking of equipment to focus limited maintenance resources where they matter most
- Selecting the most suitable maintenance strategy for each type of equipment
- Practical exercise: ranking equipment criticality and selecting suitable maintenance strategies for each item
Day2Preventive Maintenance Programmes
- Developing preventive maintenance tasks from manufacturer advice and failure experience
- Setting task intervals based on failure data, risk and operating conditions
- Writing clear job plans with steps, tools, spares, safety precautions and acceptance criteria
- Lubrication, cleaning, adjustment and other basic care tasks that prevent failures
- Operator-based maintenance and the role of operators in early detection of problems
- Reviewing and optimising existing preventive maintenance programmes to remove waste
- Practical exercise: writing preventive maintenance job plans for a pump and a fan
Day3Condition Monitoring Techniques
- Vibration analysis basics, including measurements, spectra and the most common machine faults
- Oil analysis covering wear particles, contamination, viscosity and overall lubricant condition
- Infrared thermography for the inspection of electrical and mechanical equipment in plants
- Ultrasound for leak detection, bearing monitoring and electrical discharge detection
- Motor current and electrical signature analysis used to monitor the condition of electric motors
- Performance monitoring of pumps, compressors and heat exchangers using process data
- Practical exercise: interpreting real vibration, oil analysis and thermography reports from plants
Day4Condition Monitoring Programme Design
- Selecting monitoring techniques and measurement points for each machine type
- Route-based monitoring compared with online continuous monitoring systems for critical machines
- Baselines, trend analysis and the setting of alert and danger limits
- Turning monitoring findings into maintenance work orders and timely actions
- Integrating condition monitoring data with the computerised maintenance management system
- Skills, certification and the organisation of effective condition monitoring teams
- Practical exercise: designing a condition monitoring programme for a compressor station
Day5Planning, Performance and Continuous Improvement
- Maintenance planning and scheduling and the benefits of well-prepared work packages
- Using the CMMS to record history, failure codes and maintenance costs
- Key performance indicators such as availability, MTBF, PM compliance and work backlog
- Analysing maintenance data to identify bad actors and recurring failures
- Continuous improvement through root cause analysis and regular reviews of maintenance programmes
- Group exercise: developing a roadmap from reactive to predictive maintenance
- Final assessment and discussion of maintenance practices at participants' plants
Dates and fees
There are no scheduled dates for this course at the moment. Request it as in-house training, or ask us about the next date.
Certificate
Every delegate who attends the full programme receives a Harfard Technology certificate of completion stating the course title, duration, dates and venue.
Frequently asked questions
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