COURSE OVERVIEW:

The reliability and availability of process plant equipment are directly dependent on the quality and frequency of maintenance activities. This course provides a technical examination of the maintenance strategies required to preserve the integrity of both rotating and static equipment in refinery and petrochemical environments. Participants will explore the transition from reactive "breakdown" maintenance to proactive Predictive and Reliability-Centered Maintenance (RCM) approaches to minimize unscheduled downtime.

The scope of this training involves a detailed analysis of the primary equipment found in process plants, including pumps, compressors, heat exchangers, pressure vessels, and piping systems. Attendees will learn about modern condition monitoring techniques such as vibration analysis, thermography, and oil analysis to detect early signs of mechanical degradation. The course emphasizes the importance of proper lubrication, alignment, and seal management as the foundational pillars of rotating equipment longevity.

Coverage includes the planning and execution of maintenance during both routine operations and major turnarounds. Participants will examine the regulatory requirements for pressure vessel inspection (API 510/570) and the procedures for safe equipment isolation and blinding. By integrating mechanical engineering principles with maintenance management software (CMMS), this course equips maintenance professionals with the skills to optimize asset lifecycles, reduce repair costs, and ensure the safe, continuous operation of the production facility.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Differentiate between Preventive, Predictive and Corrective maintenance.

2.  Implement Reliability-Centered Maintenance (RCM) principles for critical assets.

3.  Interpret vibration analysis reports to diagnose rotating equipment faults.

4.  Execute precision alignment and balancing of pumps and motors.

5.  Manage mechanical seal selection and maintenance for leak-free operation.

6.  Plan and supervise the cleaning and retubing of heat exchangers.

7.  Utilize non-destructive testing (NDT) for pressure vessel inspection.

8.  Perform Root Cause Failure Analysis (RCFA) for repeating equipment failures.

9.  Manage lubrication programs and oil analysis for rotating machinery.

10.  Execute safe blinding, isolation and nitrogen purging for maintenance entry.

11.  Utilize Computerized Maintenance Management Systems (CMMS) for task tracking.

12.  Oversee the maintenance and calibration of control valves and actuators.

13.  Formulate a cost-effective maintenance budget and spare parts inventory.

TARGET AUDIENCE:

Maintenance Engineers, Mechanical Technicians, Plant Operators, Reliability Specialists, and Turnaround Planners.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.