Optimising Equipment Maintenance & Replacement Decisions

Ø INTRODUCTION

  Major world companies from the process and petrochemical industry have developed their maintenance practices based on the optimisation of predictive maintenance management system. This approach works well for both stationary and rotating equipment and includes continuous condition monitoring and the detailed inspection of vital elements of the equipment. The optimisation of the maintenance activities includes the spare parts handling, the selection of the right size and skill of maintenance crew with consideration of potential outsourcing i.e. subcontracting. Based on the collected data on reliability of the equipment in operation, Maintenance department can complete the Fitness for Service analysis based on which the decision can be made about 3Rs: Run, Repair or Replace, for the particular component of the equipment. Final decision regarding equipment replacement depends very much on the economic and safety aspect that must be taken into consideration.

This training course is intended to introduce the participant to the process of making decisions regarding equipment maintenance optimisation including equipment replacement. Various optimisation techniques will be presented and the optimisation criteria explained. This IACT course will also include several workshops with case studies and real world problems to be solved. This will enable all participants to actively take part in the team work and classroom discussions.

The training course will feature:

l  Main types of equipment failure mechanisms

l  Maintenance methodologies and economic aspects

l  Spare parts handling and storage modeling

l  Risk assessment and management

l  Equipment inspection and fitness for service analysis

Ø Objectives

 At this program's conclusion, participants should be able to: 

l  Identify equipment failures, and the impact on plant reliability

l  Understand the cost-effectiveness of Preventive/Predictive Maintenance program

l  Apply techniques of optimisation of various maintenance activities

l  Define criteria for work-crew size, spare parts and equipment replacement

l  Make the important decision on the basis of the cost and benefit analysis

l  Incorporate safety objectives to the equipment repair or replacement optimisation 

Ø TRAINING METHODOLOGY

This training course will combine presentations with instructor-guided interactive discussions between participants relating to their individual workplace. Practical exercises, video material and case studies aiming at stimulating these discussions and providing maximum benefit to the participants will support the training.

This interactive training course includes the following training methodologies as a percentage of the total tuition hours:

l  30% Lectures, Concepts, Role Play

l  30% Workshops & Work Presentations, Techniques

l  20% Based on Case Studies & Practical Exercises

l  20% Videos, Software & General Discussions

Pre and Post Test

Ø WHO SHOULD ATTEND?

This training course is suitable to a wide range of professionals but will greatly benefit:

l  Operation, technical production & service professionals

l  Technical professionals responsible for maintenance and repair of equipment

l  Professionals involved in inspection and reliability

l  Technical professionals dealing with risk assessment and integrity analysis

l  Technicians dealing with regulating and metering and other measurements 

                                                                               Outline

Day 1

Physical Asset Management & Failure Analysis

Competency Description: Familiarization with asset management and types of failures

l  Types of maintenance systems

l  Modes of failures

l  Weibull distribution

l  Physical Asset Management

l  Maintenance Management: Preventive / Predictive Approach

l  Nature and Modes of Equipment Failure

l  Failure Modes & Effect Analysis (FMEA)

l  Analysis of Component Failure data using the Weibull Distribution

l  Censored Data, the 3-Parameter Weibull, and the Kolmogorov-Smirnov Test

Day  2

 Preventive Maintenance & Spare Parts Replacements

Competency Description: Ability to select spare parts replacement options

l  Concept of Reliability & Availability

l  Methods of spare part replacement

l  Handling Not-In-Kind spare parts

l  Reliability and Availability Concept: MTBF & MTTR

l  Reliability Improvement through Reduction of Downtime

l  Maintenance Performance Quantification

l  Preventive Maintenance & Spare Part Handling

l  Spare Parts Provisioning: Prediction Models and Techniques

l  Management of Change: In-Kind Spare Parts 

Day 3

Equipment Inspection & Fitness for Service

Competency Description: Understanding the calculation of fitness for service and remaining life of equipment

l  Risk based inspection

l  Risk management

l  Fitness for service

l  Condition Monitoring & Inspection

l  Risk Based Inspection (RBI)

l  Risk Matrix: Management and Mitigation Measures

l  Reliability Improvement through Inspection

l  Inspection Scope & Frequency

l  Fitness for Service Analysis (FFS) 

Day 4

 Economics of Maintenance, Repair & Replacement

Competency Description: Familiarization with economic aspects of maintenance

l  Use of CMMS

l  Optimisation of maintenance

l  Economic impact of equipment replacement

l  Management of Maintenance Resources

l  Effective Use of CMMS

l  Maintenance Organization Analysis : Crew size

l  Equipment Repair or Replacement Decision

l  Economic Aspect of Maintenance Outsourcing: Subcontract

l  Economic Aspect of Equipment Replacement 

Day 5

  Total Productive Maintenance & Safety

Competency Description: Recognizing safety in connection with total productive maintenance 

l  Return of investment ROI

l  Concept of total productive maintenance

l  KPI indicators

l  Capital Investment in Equipment and Maintenance: ROI

l  Total Productive Maintenance

l  Safety in Maintenance Work

l  KPI and OEE: Leading and Lagging Indicators

l  Summary and Conclusions