Course Overview:
This course focuses on identifying, analyzing, and preventing failures in process equipment to enhance operational safety, reliability, and efficiency. It equips participants with practical strategies for failure analysis, condition monitoring, and the implementation of preventive maintenance and reliability programs in industrial settings.
Course Objectives:
By the end of this course, participants will be able to:
- Understand common causes and mechanisms of process equipment failures
- Apply failure analysis techniques to identify root causes
- Implement effective preventive and predictive maintenance strategies
- Utilize condition monitoring tools to detect early signs of failure
- Improve equipment reliability through design, operation, and maintenance best practices
- Ensure compliance with relevant safety and industry standards
Who Should Attend:
- Maintenance and reliability engineers
- Process and plant engineers
- Operations and production supervisors
- Asset integrity and HSE professionals
- Technical staff involved in equipment inspection, monitoring, or maintenance
Course Outline:
Overview of Process Equipment Failures
- Types of process equipment and typical failure scenarios
- The cost and impact of equipment failures
- Failure statistics and trends in industry
Failure Modes and Mechanisms
- Mechanical, thermal, and chemical failure types
- Fatigue, corrosion, erosion, wear, and creep
- Human error and operational factors
Failure Analysis Techniques
- Root Cause Failure Analysis (RCFA)
- Fault Tree Analysis (FTA) and Failure Modes and Effects Analysis (FMEA)
- Data collection, inspection, and reporting tools
Preventive and Predictive Maintenance Approaches
- Preventive maintenance planning and scheduling
- Condition-based maintenance (CBM) and predictive analytics
- Key performance indicators (KPIs) for maintenance effectiveness
Condition Monitoring Tools and Techniques
- Vibration analysis, thermography, ultrasonic testing, and oil analysis
- Monitoring and interpreting equipment health data
- Early warning systems and decision-making support
Improving Equipment Reliability
- Design improvements and operational controls
- Reliability-centered maintenance (RCM) practices
- Spare parts management and maintenance documentation
Safety, Compliance, and Best Practices
- Compliance with API, ASME, and ISO standards
- Integration with process safety and risk management systems
- Case studies of notable equipment failures and lessons learned