COURSE OVERVIEW:

Preventive Maintenance (PM) is the foundation of mechanical reliability in the complex environment of a process plant. This course provides a technical roadmap for developing and implementing effective PM strategies that minimize unplanned downtime and extend the service life of rotating and static assets. Participants will explore the logic of time-based and usage-based maintenance, learning how to structure tasks that address specific failure modes of pumps, compressors, heat exchangers, and conveyors.

The course emphasizes a data-driven approach to PM, moving away from "generic" schedules toward customized programs based on asset criticality and operating conditions. The scope includes a detailed look at the core activities of a PM program: lubrication, cleaning, adjustment, and minor component replacement. Participants will analyze how to use Computerized Maintenance Management Systems (CMMS) to track work orders, manage spare parts, and evaluate the effectiveness of the PM program through Key Performance Indicators (KPIs).

Coverage also includes the human and organizational factors necessary for PM success, such as the development of clear Standard Operating Procedures (SOPs) and the training of the maintenance workforce. Attendants will explore the transition from simple PM to "Condition-Directed" maintenance, integrating basic inspection techniques into the routine. By the end of this course, participants will be equipped to design a PM strategy that balances the cost of maintenance with the risk of failure, ensuring the continuous and efficient operation of the plant’s mechanical infrastructure.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Define the role of Preventive Maintenance within the broader Asset Management framework.

2.  Conduct a criticality assessment to prioritize mechanical equipment for PM.

3.  Develop detailed PM checklists for pumps, compressors, and gearboxes.

4.  Determine the optimal frequency of PM tasks based on manufacturer data and plant history.

5.  Manage the lubrication requirements for a wide range of mechanical assets.

6.  Utilize a CMMS to schedule, track, and analyze maintenance activities.

7.  Identify the signs of "Over-Maintenance" and its impact on reliability and cost.

8.  Execute basic condition-monitoring tasks during routine PM inspections.

9.  Write clear and effective Standard Operating Procedures (SOPs) for PM tasks.

10.  Manage spare parts inventory to support the preventive maintenance schedule.

11.  Analyze PM compliance and effectiveness using Mean Time Between Failures (MTBF).

12.  Integrate safety and environmental checks into the mechanical PM program.

13.  Lead a team toward the successful execution of a plant-wide PM strategy.

TARGET AUDIENCE:

Maintenance Engineers, Plant Supervisors, Reliability Technicians, and Operations Personnel responsible for the upkeep of mechanical equipment in process industries.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.