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Optimising Equipment Maintenance &  Replacement Decisions

An Intensive 5 - Day Training Course

Optimising Equipment Maintenance &
Replacement Decisions

Current View: In-Person format Go to Online format

Scheduled Dates

Date: Location: Fee: Enrollment:
10 - 14 Oct 2021 Dubai - UAE $4,950
27 - 31 Dec 2021 London - UK $5,950
09 - 13 May 2022 London - UK $5,950
09 - 13 Oct 2022 Dubai - UAE $4,950
26 - 30 Dec 2022 London - UK $5,950

*Exclusive of VAT

Why Choose this Training Course?

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 PetroKnowledge 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:

  • Main types of equipment failure mechanisms
  • Maintenance methodologies and economic aspects
  • Spare parts handling and storage modeling
  • Risk assessment and management
  • Equipment inspection and fitness for service analysis

What are the Goals?

By the end of this training course, the participants will be able to:

  • Identify equipment failures, and the impact on plant reliability
  • Understand the cost-effectiveness of Preventive/Predictive Maintenance program
  • Apply techniques of optimisation of various maintenance activities
  • Define criteria for work-crew size, spare parts and equipment replacement
  • Make the important decision on the basis of the cost and benefit analysis
  • Incorporate safety objectives to the equipment repair or replacement optimisation

Who is this Training Course for?

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

  • Operation, technical production & service professionals
  • Technical professionals responsible for maintenance and repair of equipment
  • Professionals involved in inspection and reliability
  • Technical professionals dealing with risk assessment and integrity analysis
  • Technicians dealing with regulating and metering and other measurements

How will this Training Course be Presented?

This PetroKnowledge course will be conducted along workshop principles with formal lectures and interactive examples, which will result in the active participation of all delegates in discussions and teamwork of problem solving. There will be several class-workshops during which case studies and real life problems will be solved in team work. This will provide understanding of the problems and illustrate the efficient application of modern maintenance optimisation technologies. There will be ample opportunities for active, open discussions and sharing professional experiences on various industrial applications. All course materials will be provided.

Daily Agenda

Day One: Physical Asset Management & Failure Analysis

  • Physical Asset Management
  • Maintenance Management: Preventive / Predictive Approach
  • Nature and Modes of Equipment Failure
  • Failure Modes & Effect Analysis (FMEA)
  • Analysis of Component Failure data using the Weibull Distribution
  • Censored Data, the 3-Parameter Weibull, and the Kolmogorov-Smirnov Test

Day Two: Preventive Maintenance & Spare Parts Replacements

  • Reliability and Availability Concept: MTBF & MTTR
  • Reliability Improvement through Reduction of Downtime
  • Maintenance Performance Quantification
  • Preventive Maintenance & Spare Part Handling
  • Spare Parts Provisioning: Prediction Models and Techniques
  • Management of Change: In-Kind Spare Parts

Day Three: Equipment Inspection & Fitness for Service

  • Condition Monitoring & Inspection
  • Risk Based Inspection (RBI)
  • Risk Matrix: Management and Mitigation Measures
  • Reliability Improvement through Inspection
  • Inspection Scope & Frequency
  • Fitness for Service Analysis (FFS)

Day Four: Economics of Maintenance, Repair & Replacement

  • Management of Maintenance Resources
  • Effective Use of CMMS
  • Maintenance Organization Analysis : Crew size
  • Equipment Repair or Replacement Decision
  • Economic Aspect of Maintenance Outsourcing: Subcontract
  • Economic Aspect of Equipment Replacement

Day Five: Total Productive Maintenance & Safety

  • Capital Investment in Equipment and Maintenance: ROI
  • Total Productive Maintenance
  • Safety in Maintenance Work
  • KPI and OEE: Leading and Lagging Indicators
  • Summary and Conclusions