Condition Monitoring and Predictive Maintenance

Programme Summary

Condition monitoring becomes useful when reliable measurements lead to timely maintenance decisions. This programme introduces vibration, thermal, lubricant and performance monitoring methods and their appropriate applications. Participants examine sample datasets, establish meaningful alarm and escalation logic and connect findings to maintenance work orders. The focus is selecting proportionate techniques and recognising when specialist diagnosis is required.

Training Objectives

1 Explain the purpose of condition monitoring; 2 Compare common predictive maintenance techniques; 3 Improve interpretation of trends and exceptions; 4 Connect monitoring findings with maintenance decisions; 5 Build practical monitoring programme governance.

Learning Outcomes

1 Select monitoring methods for equipment faults; 2 Identify measurement quality limitations in datasets; 3 Interpret supplied trends against operating context; 4 Prioritise findings using equipment consequence information; 5 Prepare an actionable condition monitoring report.

Target Audience

Reliability Engineers; Maintenance Engineers; Condition Monitoring Technicians; Maintenance Planners; Asset Engineers.

Target Industries

Manufacturing Plants; Power Generation; Petrochemical Facilities; Water Utilities; Mining Operations; Large Facilities.

Course Contents

• Module 1 Monitoring Programme Purpose: Failure development and warning opportunities; Equipment criticality and monitoring priorities; Costs benefits and decision ownership.
• Module 2 Failure Mode Selection: Functions failures and detectable symptoms; Monitoring suitability and technical limitations; Intrusive versus nonintrusive measurement approaches.
• Module 3 Data Collection Quality: Operating conditions and repeatable measurements; Sensor location and instrument suitability; Data integrity and baseline records.
• Module 4 Vibration Monitoring Fundamentals: Amplitude frequency and trending concepts; Common rotating equipment fault patterns; Limits of introductory vibration interpretation.
• Module 5 Thermal Monitoring Fundamentals: Temperature patterns and heat transfer; Emissivity reflections and environmental effects; Electrical access and inspection boundaries.
• Module 6 Lubricant and Wear Monitoring: Sampling points and contamination controls; Wear particles and oil condition; Interpretation trends and laboratory interfaces.
• Module 7 Ultrasound and Acoustic Methods: Leak bearing and discharge applications; Measurement consistency and noise interference; Screening findings and specialist confirmation.
• Module 8 Process Performance Monitoring: Pressure flow temperature and efficiency; Changes in duty and operating load; Separating process changes from degradation.
• Module 9 Alarm and Escalation Logic: Baselines thresholds and trend changes; Consequence based response priorities; False alarms and missed detections.
• Module 10 Maintenance Decision Integration: Finding severity and remaining uncertainty; Work order creation and planning; Verification after maintenance intervention.
• Module 11 Programme Performance Review: Coverage reliability and monitoring compliance; Avoided failures and evidence limitations; Technique review and continuous improvement.
• Module 12 Monitoring Case Workshop: Selecting techniques for critical equipment; Interpreting supplied condition datasets; Reporting findings and recommended actions.

Assessment

• 60 single best answer questions, including applied scenarios; one mark per question.
• 90 minute invigilated digital examination with identity verification. Approved accessibility adjustments preserve the assessed competence.
• Supplied reference pack permitted; external internet and AI assistance prohibited.
• Individual applied assessment (45 minutes): Select monitoring methods for three assets, interpret supplied trends and issue a condition report with justified priorities and followup actions.
• Assessment criteria: Suitability of selected monitoring techniques; Accuracy and limits of data interpretation; Actionability of maintenance recommendations.
• Pass each component separately: 45/60 written marks (75%) and at least 70% on the applied task.
• Individual results and feedback are provided. One reassessment may follow coaching under the published enrolment terms.

Certification

• Successful learners receive a TQCSI Arabia digital Certificate of Successful Completion.
• The certificate records the learner name, exact programme title, teaching hours, completion date and unique verification reference.
• Verified identity, full attendance and separate written and applied passes are required; all mandatory critical criteria must be met.
• Proposed issue target: within 30 calendar days of approved results and settlement of applicable fees.
• Records assessed introductory condition monitoring skills; it does not confer specialist diagnostic certification or authorise hazardous equipment inspection.
• Attendance confirmation may record completed hours for unsuccessful learners; it does not certify successful completion.

Programme Profile

Number of daysNumber of daysNumber of days

333

Total teaching hoursTotal teaching hoursTotal teaching hours

18 hours; breaks, pre course work and formal final assessments excluded.18 hours; breaks, pre course work and formal final assessments excluded.18 hours; breaks, pre course work and formal final assessments excluded.

Delegates allowedDelegates allowedDelegates allowed

Maximum 16 delegates.Maximum 16 delegates.Maximum 16 delegates.

Training prerequisitesTraining prerequisitesTraining prerequisites

Maintenance or reliability experience and basic mechanical knowledge are required. Advanced vibration analysis, thermographic certification and diagnostic authorisation are outside this introductory course.Maintenance or reliability experience and basic mechanical knowledge are required. Advanced vibration analysis, thermographic certification and diagnostic authorisation are outside this introductory course.Maintenance or reliability experience and basic mechanical knowledge are required. Advanced vibration analysis, thermographic certification and diagnostic authorisation are outside this introductory course.

Pre course assignment and assessmentPre course assignment and assessmentPre course assignment and assessment

Complete a 30 minute diagnostic comparing failure symptoms, equipment criticality and available monitoring data.Complete a 30 minute diagnostic comparing failure symptoms, equipment criticality and available monitoring data.Complete a 30 minute diagnostic comparing failure symptoms, equipment criticality and available monitoring data.

End of course assessmentEnd of course assessmentEnd of course assessment

60 question written exam (90 minutes) and individual applied task (45 minutes).60 question written exam (90 minutes) and individual applied task (45 minutes).60 question written exam (90 minutes) and individual applied task (45 minutes).

Passing criteriaPassing criteriaPassing criteria

75% written and 70% applied, passed separately; full attendance.75% written and 70% applied, passed separately; full attendance.75% written and 70% applied, passed separately; full attendance.