Course Objectives:

1. Introduction to Process Plant Equipment:
• Define key types of equipment used in process plants, such as pumps, compressors, valves, heat exchangers, and pressure vessels.
• Understand the role of each piece of equipment within the overall process plant operation.
2. Basic Principles of Equipment Maintenance:
• Learn the fundamental principles of equipment maintenance, including preventive, predictive, and corrective maintenance.
• Identify the benefits of proactive maintenance in reducing downtime, increasing reliability, and extending equipment life.
3. Maintenance Strategies and Techniques:
• Explore different maintenance strategies such as Total Productive Maintenance (TPM), Reliability-Centered Maintenance (RCM), and Condition-Based Monitoring (CBM).
• Understand how to choose and implement the appropriate strategy for different types of equipment.
4. Maintenance Planning and Scheduling:
• Learn how to develop a maintenance plan that includes routine checks, inspections, and equipment servicing.
• Understand the importance of effective scheduling and resource allocation to avoid unplanned downtime and optimize plant operations.
5. Troubleshooting and Diagnostics:
• Develop the skills to diagnose common issues in process plant equipment through inspection, performance analysis, and root cause analysis.
• Identify the steps to take when equipment fails or is operating inefficiently.
6. Spare Parts Management and Inventory Control:
• Understand how to manage spare parts inventory and ensure the availability of critical parts for quick repairs.
• Learn the importance of inventory control and how to optimize spare parts ordering and storage to reduce costs.
7. Safety and Compliance in Maintenance:
• Understand the safety protocols and best practices to be followed during maintenance activities.
• Recognize the importance of compliance with safety standards, environmental regulations, and industry guidelines (such as ISO and OSHA).
8. Equipment Lifecycle Management:
• Learn about the equipment lifecycle, from installation to decommissioning.
• Understand the concepts of asset management, including assessing equipment condition and determining the appropriate time for replacement or upgrades.
9. Use of Maintenance Software and Technology:
• Introduce the use of Computerized Maintenance Management Systems (CMMS) for tracking and managing maintenance tasks, equipment performance, and repair history.
• Explore the role of digital technologies, like IoT and predictive analytics, in modern maintenance practices.
10. Maintenance Performance Metrics and KPIs:
• Learn how to establish and track key performance indicators (KPIs) for equipment performance and maintenance efficiency.
• Understand metrics such as Mean Time Between Failure (MTBF), Mean Time to Repair (MTTR), and Overall Equipment Efficiency (OEE).
11. Cost Management in Maintenance:
• Learn how to analyze and control maintenance costs, including the cost of downtime, labor, materials, and equipment replacement.
• Explore strategies for cost-effective maintenance and how to align maintenance budgets with operational goals.
12. Environmental Considerations and Sustainability:
• Understand the environmental impact of process plant operations and maintenance activities.
• Learn strategies for implementing sustainable practices, including energy efficiency and waste reduction in maintenance processes.
13. Case Studies and Best Practices:
• Analyze real-world case studies to identify best practices in the maintenance of process plant equipment.
• Learn from industry leaders about challenges, solutions, and innovations in plant maintenance.