Condition Based Maintenance, Awareness, Management and Applications

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Virtual or Classroom
24hr Content
Registration deadline: 15 July 2024
Custom Scheduling
Andy Mellor
INCO3601


Format: Instructor-led


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To register multiple team-members at once, use the link below.

Need a dedicated version of this program for your team? Please contact us.

Course Objective

Participants will gain an understanding of key concepts pertaining to Condition Monitoring and Condition Based Maintenance, including Vibration Monitoring, Thermography, Ultrasound and Oil Analysis.

Private course for team

Custom scheduling

Industry Expert

On-site or virtual

1-year access

to course material

PDH Hours qualified course

Read more here

About the course


   In-Company

   Live sessions

   24hr Content

   Custom

  English

   INCO3601

Condition Based Maintenance is an increasingly used strategy for maintaining industrial assets, offering significant cost benefits when compared to time-based preventative maintenance and run-to-failure strategies. 

To maximise these cost benefits a structured approach is required, and this course provides a tried and tested process which is applicable to any industry, providing maintenance managers, engineers, and planners with the conceptual and practical knowledge to implement successful Condition Monitoring and Condition Based Maintenance programmes.

The course covers important topics such as, when to apply Condition Based Maintenance, how often to monitor assets, how to choose between different data collection methods, including online / cloud based monitoring, the role and limitations of AI approaches, the requirement for consistency in data collection, how to set alarm and limit values, the importance of failure / root-cause analysis to secure feedback and create opportunities for continuous improvement of asset reliability and reductions in maintenance cost. 

Optional modules cover a variety of condition monitoring technologies. Participants can select a mixture of these that are appropriate to their assets.

The course consists of 24hr of live sessions, split across multiple sessions, with the instructor. All training content is provided through your EngineeringTrainer account.

After the course you maintain 1-year unlimited access to the course, including any new course material. This allows you to perform modules again should you need to refresh your knowledge.

 

Questions?  Contact us

  hello@engineeringtrainer.com

    +31 (0)85 058 0051
         Monday - Friday, 9am - 6pm CEST








Meet your instructor


Instructor Andy Mellor 

Managing Director


Machinery Troubleshooting, Condition Monitoring, Maintenance Management Consultancy, In-Situ balancing, Industrial Reliability Improvement.


 PMAR logo

Program & Details


  1. The Purpose of Maintenance

  2. What constitutes a failure?

  3. Maintenance strategies

    1. Run to failure

    2. Time / usage based

    3. Condition based

    4. Failure finding

    5. Design-out

  1. Prerequisites for Condition-Based Maintenance

  2. The P-F interval concept and its relationship with criticality

  3. Trendability

  4. Condition Monitoring vs Condition Inspection.

  1. Availability, Reliability, Mean Time to Failure

  2. Burn-in, random and wear out failure distributions. Weibull Analysis

  3. Physical Failure Mechanisms

  4. The relationship between installation quality, loading roughness, physical failure mechanisms and the P-F Interval

  5. Continuous Improvement

  1. Criticality Analysis & prioritisation

  2. Technical analysis, FMESA

  3. Set-up

  4. Routine Monitoring – Data collection

  5. Routine Monitoring – Screening, Diagnosis, Prognosis

  6. Feedback loops, long term and short term

  7. Review

  1. A look at the hype and reality of claimed cost savings

  2. A robust process to calculate cost savings

  3. Practices that secure a sound return on investment

  4. Making the case for investment in Condition Based Maintenance

  1. The benefits of Planned Maintenance

  2. The relationship between P-F intervals and Planning horizons

  1. What is Competence?

  2. Inhouse Monitoring

  3. Outsourced Monitoring

  4. Mixed Approach

  5. Online Monitoring

  6. The use and current status of AI in screening and analysis

Using CM technologies for:     

    1. Early Life Management     

    2. Mid-Life Management     

    3. Obsolescence / End of Life Management

  1. Different approaches to RCFA

  2. Cause and Effect

  3. Necessary and Sufficient Causes

  4. Using Condition Monitoring information in RCFA

  5. Change / Difference Analysis

  6. Convergent vs Divergent thinking and the need for both

  7. When to stop

  8. Devising and implementing solutions

Technology-Specific Modules - Pick A and 2 others for course of 24hr Content

How to structure information in the workplace so inspections are easily carried out and the results of inspections are actionable.

  1. What is vibration?

  2. How is it quantified?

  3. Vibration analysers and measurement equipment

  4. How do vibration sensors work?

  5. The influence of sensor mounting on measurement accuracy

  6. Vibration signal processing

  7. Vibration data plots

  8. The relationship between machinery faults and vibration signatures

  9. Where to measure vibration?

  10. Vibration standards and setting limits

  11. Case histories

  1. Oil viscosity and its measurement

  2. The make-up of lubricating and hydraulic oils

  3. Elemental spectral analysis of oil

  4. Oil oxidation and test to detect and quantify oxidation

  5. The role of bases in engine oils

  6. The effect of water and particulate contamination on the life of lubricated components

  7. Tests to detect water and particulates

  8.  The relationship between metallic wear and particle concentrations

  9. Tests to detect ferrous wear

  10. Oil sampling – how to get a representative sample safely, without introducing contamination

  11. Sampling frequencies

  12. Visual inspection whilst sampling

  13. Interpreting lab reports

  14. Contamination control in lubrication

  1. What is Infra-Red radiation? (IR)

  2. IR cameras vs IR thermometers

  3. How IR cameras Work

  4. Camera palettes and image presentation features

  5. Selecting the camera range

  6. The importance of focussing on measurement accuracy

  7. Distance, image resolution and temperature accuracy

  8. Emissivity and reflectivity in theory and practice

  9. Reflected Ambient Temperature

  10. Applications – Mechanical, Building, Process, Electrical

  11. Safety considerations

  12. Qualitative vs Quantitative thermography

  13. Limits and standards for electrical IR

  1. Introduction

  2. AC motor construction

  3. Making motor signature measurements

  4. Rotor bar fault detection

  5. Eccentricity detection

  6. Mechanical fault detection

  1. What are acoustic emission (AE) and ultrasound (Us)?

  2. Processes that generate AE and Us

  3. Features of AE and Us instrumentation

  4. Applications with case histories:

    1. Compressed Air Leak detection

    2. Steam Trap monitoring

    3. Bearing monitoring

    4. Slow-speed machinery

    5. Electrical discharges

Results

After this course, you...  

  • be able to identify where Condition Based Maintenance can be successfully applied and where it cannot.

  • be able to identify relevant technologies for a given asset.

  • be able to identify a suitable monitoring / inspection interval for a given technology / asset.

  • be able to manage the implementation of Condition Based Maintenance using the Pragmatic process.

  • understand how to leverage Condition Monitoring / Condition Based Maintenance to drive improvements in Asset reliability and availability, reduced maintenance costs, and improved labour utilisation.  

Who should attend this course

This course is aimed at anyone who will be involved in applying or using Condition Monitoring or Condition Based Maintenance including: 

  • New CM practitioners, 

  • Maintenance engineers and managers, 

  • Reliability engineers and technicians, 

  • Engineers responsible for interpreting and acting on CM reports, 

  • Production supervisors who want to understand how asset condition impacts production plans. 

Prerequisites:

  • Some familiarity with the management of maintenance in an Industrial, Utilities, or Building Management setting is useful.

Level: Intermediate


Live sessions

This course consists of instructor-led group sessions, these group sessions can be Virtual or Onsite. During these sessions participants can ask questions to the instructor which are discussed, as well as questions submitted beforehand in the learning portal.

After each live session used slides and exercise documents are made available to participants on the learning portal.

Please note that for privacy reasons no recordings of the live sessions are made or provided.

You receive 1-year unlimited access to the course. This allows you to watch content again if this is beneficial for your daily work activities.

Live sessions

This course consists of instructor-led group sessions, these group sessions can be either virtual or on-site. During these sessions participants can ask questions to the instructor which are discussed, as well as questions submitted beforehand in the learning portal.

After each live session used slides and exercise documents are made available to participants on the learning portal. You receive 1-year unlimited access to this material in the learning portal.

Please note that for privacy reasons no recordings of the live sessions are made or provided.

A personal digital certificate will be made available to each participant upon full attendance.


Example Certificate:


FAQ

This course consists of instructor-led live sessions which consist of presentations, demonstrations and discussions of questions. During each live session participants can ask questions to the instructor (through chat or microphone) which will be answered.

Please note that for privacy reasons no recordings of the live sessions are made or provided.

The training material used in the live sessions, for example the slides or exercises, will be available in the EngineeringTrainer portal for a year after the date of the training allowing you to refresh your knowledge or review material if needed. 

No, course content is not available for download.

The training material used in the sessions, for example the slides or exercises, will be available in the EngineeringTrainer portal for a year after the date of the training allowing you to refresh your knowledge or review material if needed. 

Please note that for privacy reasons no recordings of the live sessions are made or provided. 

Yes, interactive Q&A sessions are part of the live sessions in this course and allow you to interact with the instructor and ask questions.

To respect the privacy of the participants the live sessions will not be recorded, and as such the live sessions cannot be played back. Therefore it is important for all participants to block the time slots of the live sessions in their calendars and be present. 

No software licenses are provided as part of this course. 

Yes, this course qualifies for PDH hours as per the NCEES CPC Guidelines.

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Luuk Hennen    
Product specialist

  hello@engineeringtrainer.com

   +31 (0)85 058 0051
        Monday - Friday, 9am-6pm CEST 

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