M406 – Predictive Maintenance

M406 – Predictive Maintenance


A predictive maintenance program is essentially an extension of the preventive maintenance program commonly found on most industrial sites and is based on the actual condition of the component.  The program employs monitoring and includes trending of component operating conditions.  In this fashion, a failure of the component can be predicted and averted by performance of minor maintenance at a convenient time, such as during scheduled shutdowns.

Predictive maintenance programs require a significant amount of analytical ability.  Since this is the case the program is not suitable for all types of plant equipment.  The equipment failure modes for those components in the program must be evaluated and the failure indicators periodically trended.  To perform these parts of the program requires considerable skill and knowledge, along with specialized equipment.  With this in mind we need to analyze the elements of a predictive maintenance program.

  • Keep operating equipment running
  • Reduce forced outage occurrences

Predictive maintenance programs go a long way in reducing forced outages and in this course you will learn:

  • Predictive maintenance techniques
  • Plant equipment selection
  • Selection of monitoring techniques and monitoring equipment
  • Frequency of monitoring
  • Trend analysis of monitoring data

As management, you are not only required to manage the day-to-day maintenance activities, but also must maintain records, trend problem areas, and find the causes of recurring problems in your facility.  I this course we will deal with the reduction of ‘unplanned’ or ‘in-service-failure’ of key equipment through the use of Predictive Maintenance Programs and Condition Monitoring.  We will also look at the trending of certain monitoring areas on equipment that cannot be spared (critical equipment).


At the completion of this course the participant will be able to:

  1. State the elements which make up a predictive maintenance program.
  2. Describe the factors which to into selection of equipment to be covered in a predictive maintenance program.
  3. Describe the function of a predictive maintenance program.
  4. Describe the philosophy used to develop a predictive maintenance program.
  5. Discuss how goals for the predictive maintenance program are developed.
  6. State and describe the different type of predictive program organizations.
  7. Describe the advantages / disadvantages of the different types of organizations.
  8. List the requirements for organizing each different type of program.
  9. Describe the requirements and criteria for selecting the various personnel positions with the predictive maintenance program.
  10. Lit the steps involved in performing a detailed personnel needs analysis.
  11. State the theory of an oil analysis-monitoring program.
  12. Discuss the requirements for an oil analysis.
  13. Explain the terminology used in vibration analysis.
  14. Describe the common causes of vibration.
  15. State the theories and applications for acoustic leak monitoring.
  16. State the theories and applications for ultrasonic transducer systems.
  17. State the theories and applications for thermography.

Topical Outline

  1. Introduction
  2. Elements of a Predictive Maintenance Program: Selection process, preparation process, and performance review.
  3. Establishing the Predictive Maintenance Program: Program justification, financial benefits
  4. Program Types: Centralized program, independent program
  5. Personnel Requirements: Selection criteria, attitude, leadership, compatibility, technical requirements, program manager, support engineer, support technician, maintenance engineer, maintenance supervisor, I&C technician, instrucotr, needs analysis training.
  6. Budget Estimates: Budget plan, equipment costs, personnel costs, training costs, transportion, instrumentation costs, miscellaneous costs.
  7. Mechanical Anaysis Techniques: Vibration monitoring, oil analysis, infrared thermography, ultra sound
  8. Course conclusion and discussion

What you will receive:

  • 1 copy of HPC Technical Services' textbook, Predictive Maintenance
  • A "Certificate of Completion" with 1.3 CEUs.

Course dates / location / fee

See www.hpcnet.com for detail on the course dates / locations / and registration fees.  Course is typically 2-days in length, including recommended exam.

HPC’s 3-4-2 policy applies:  Sign up 3 for the same course/date, pay in advance, and pay for only 2 (the 3rd participant is free)!

HPC Technical Services reserves the right to cancel any course/seminar within 10-working days of the scheduled date.  Fees are 100% refunded or credited to another Seminar (clients' choice) if HPC should cancel any Seminar.  HPC is not responsible for non-refundable airline tickets or other travel expenses under any circumstance.

This 2-day class is preceded by, in the same week, a 2-day class on Root Cause Failure Analysis: M405.  Enroll for both courses and receive a discounted price.

Frequently asked questions

  • Will HPC Technical Services bring this course to our location for our personnel only? YES, call or e-mail Steven Parker, stparker@hpcnet.com for a price quotation.
  • Will HPC Technical Services customize the presentation at our site to suit our particular needs?
  • Is HPC Technical Services' textbook available for purchase as a reference document? Coming Soon
  • What is the cost for HPC Technical Service to deliver this course at our location? Well, of course that can vary, but generally speaking, if you're planning on having 6+ attend, when considering your T&L; it is to your advantage to perform the course at your plant (office).  You gain from the customization and price.
  • Can HPC Technical Services provide "Technical Assistance" in conducting functional checkouts or troubleshooting problems? Yes we can.  Call or contact Stephen Parker, stparker@hpcnet.com for our rate sheets and any further information required.