Optimizing Equipment Maintenance & Replacement Decisions

Introduction:

Major world companies from the process and petrochemical industry have developed their maintenance practices based on the optimization of the 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 optimization 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 the reliability of the equipment in operation, the 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. The 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 optimization including equipment replacement. Various optimization techniques will be presented and the optimization criteria explained

Targeted Groups:

• Operation, technical production & service professionals
• Technical professionals responsible for the 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

Course Objectives:

At the end of this 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 optimization of various maintenance activities
• Define criteria for work-crew size, spare parts and equipment replacement
• Make an important decision based on the cost and benefit analysis
• Incorporate safety objectives to the equipment repair or replacement optimization

Targeted Competencies:

• 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

Course Content:
Unit 1: 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

Unit 2: 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

Unit 3: 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)

Unit 4: 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

Unit 5: 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