Learning Objectives

Upon successful completion of this course, participants will be able to:

1. Fundamentals of Equipment Component Repair and Replacement

• Understand the importance of repair feasibility assessments in plant maintenance.
• Identify common failure modes and degradation mechanisms in industrial components.
• Differentiate between repairable and non-repairable components.

2. Inspection and Failure Analysis Techniques

• Conduct visual, mechanical, and non-destructive testing (NDT) for component integrity assessment.
• Use vibration analysis, ultrasonic testing, and thermal imaging for diagnostics.
• Interpret wear patterns, corrosion effects, and fatigue failures.

3. Cost-Benefit Analysis: Repair vs. Replacement Decision

• Evaluate repair costs, downtime impact, and replacement lead times.
• Implement total cost of ownership (TCO) and lifecycle cost analysis (LCA).
• Assess criticality of equipment and risk of recurring failures.

4. Repair Techniques for Common Plant Components

• Learn welding, machining, reconditioning, and surface treatment techniques.
• Understand coating, hardfacing, and metal spraying for wear protection.
• Apply reverse engineering and 3D printing for component restoration.

5. Preventive and Predictive Maintenance Strategies

• Implement condition-based monitoring (CBM) and predictive maintenance (PdM) approaches.
• Optimize lubrication, alignment, and calibration for prolonged component life.
• Develop proactive maintenance schedules to minimize repair needs.

6. Quality Control and Reliability Engineering in Repairs

• Establish quality assurance protocols for repaired components.
• Use statistical reliability analysis and failure mode and effects analysis (FMEA).
• Ensure compliance with safety and industry repair standards (ISO, API, ASME).

7. Decision-Making Framework for Repair Feasibility

• Develop standardized procedures for repair vs. replacement evaluation.
• Integrate historical maintenance data, spare parts availability, and vendor support.
• Implement digital tools for predictive maintenance and asset lifecycle management.

8. Case Studies and Practical Applications

• Analyze real-world scenarios of component repair feasibility assessments.
• Participate in hands-on failure analysis and repair decision exercises.
• Develop a customized repair feasibility assessment framework for plant operations.

Target Audience

• Maintenance engineers and plant technicians
• Reliability and asset management professionals
• Operations and production managers
• Mechanical and electrical engineers in plant maintenance
• Quality control and safety officers