Beruflich Dokumente
Kultur Dokumente
12
Course Description
Reliable operations and maintenance are paramount to overall effectiveness of Process Plant objectives, ensuring minimum downtimes and
maintenance cost optimization. The variety of Equipment such as Gas Turbines, HRSGs, Boilers, Steam Turbines, Generators, heat Exchangers,
Fired Heaters brings certain complexities when identifying problems and conducting the specific maintenance requirements. This 5-day
program is designed to assist the Maintenance management, technicians and engineers in identifying the various Process Plant Operating
Performance and Functional parameters, Process Plant Reliability considerations, and Realiability Tools as part of RCM Program development
and implementations, Criticalities and Failure modes, consequences and mitigation characteristics.
The program is specifically designed for New, Medium Aged and Aged Process Plants and will help participants in developing a Proactive
Maintenance and Reliability program with embedded RCM methodology & implementation for the whole Plant with emphasis on Specific
Equipment plans. Participants will also be provided understanding of Preventive and Predictive Maintenance programs with analysis of
Condition Monitoring data and further corrections in Maintenance Program, introduction of RBIs (Risk Based inspections) for the optimization of
Process Plant Maintenance schedule.
Process Plant Bad actors management programs with emphasis on Trips, Performance variations, Load cycling and its effects, Turnaround
Work-scopes Optimization techniques will supplement the course with Practical exercises.
A thorough insight into the Current Practices GAPS and resolution, Maintenance cost and life cycle analysis will supplement the course.
Remaining Life Assessments, Evaluations and Recommendations and Equipment Repair and Replacement decisions as part of Process plant
objectives will be discussed in depth.
The Asset management model as applied to Plant equipment as part of RCM strategies will also be discussed in detail with reference to
PAS-55 / ISO 55000 recommendations.
Course Benefits
Learning Objectives
After completing this course, participants will be able to understand / conduct:
A-Z of a Plant
Plant Equipment Basic Classifications
Plant Performance and Functional Standards
Advance Maintenance Management in Plant
Eliminate unplanned down time, Improvement In maintenance program
Latest innovations in RCM, FRCA and CM for Modern Plants
Reliability Tools Understanding and Applications
RCM Implementation strategies and Issues resolutions for success
Implement Solutions that reduce the cost per hour of operation
Increasing daily revenue for Process Plant
Optimize performance and efficiency by adopting updates in condition monitoring
Effective reliability program to optimize the performance of the Equipment
RCM based Reliability Program design, Implementation and control for whole plant
Practical Case studies to Evaluate and adopt solutions in Process Plants
Appropriate Analytical tools for maintenance decision making
Training Methodology
The comprehensive training will be facilitated using modern techniques, supported by case studies from real plant environment and
videos. The Analysis tools application to maintenance, reliability and failure analysis will be exercised with mini workshop within the
sessions. Participants are requested to bring their laptops to exercise analysis software with their own plant compressor data. Repair vs.
replacement decisions on specific equipment will also be exercised during training.
Course Agenda
DAY
01
02
Data Sources, Run length data, Run meters, DCS, Operating logs
CMMS, failure data, Notification Text, Operators and Maintainers as sources
Publicly available sources, Performance Standards
Errors in data sources, Independent & Identical conditions
Defining Critical Systems / Equipments / Components.
GTs, Boilers, HRSGs, Generators, Steam Turbines, Heat Exchangers, Fired Heaters, Miscellaneous Systems
Identifying Functions of Critical Systems / Equipment / Components
Criticality Analysis, Review of Plant, FMECA
Performance Vs Functional Reliability
Calculating Reliability, Availability & Maintainability (RAMs Practical Exercises)
Understanding MTBF. MTTR, MTTF, MODT and Weibull Analysis & Shape Factors
Statistical Distribution Fitting to Plant / Equipment Data
Statistical Reliability Program, Understanding Reliability Alert levels (Green, Amber, Red)
Practical Exercises on Process Plant Equipment
4
DAY
03
DAY
04
DAY
05