#1620 - An Introduction to Overall Plant Maintenance
In today's environment, process plants are interested in increasing
profitability by improving reliability and achieving maintenance excellence.
To attain these ends, new approaches and tools are being used. The
purpose of this course is to provide an overview of overall plant
maintenance and turnaround practices that have proven to be effective in
increasing plant reliability in a safe and cost effective manner.
Who Should Attend
Supervisors and Managers assigned responsibility for maintenance and
turnaround planning, cost, and unit reliability. Participants should
have an understanding of their plant's current practices, performance, and
opportunities for improvement.
This course is divided into two main sections as described below.
Day 1 - Maintenance Practices for Improved Performance
This session introduces a model for achieving excellence in maintenance
with a review of each model component. Such areas as overall
philosophy, risk-based decision-making, and work scope justification will
be discussed. Metrics will be introduced for stewarding performance
and activities needed for continuous improvement.
- Maintenance Management Model: A model for
conducting plant maintenance will be presented. The model is based
on a proven model that has been successfully used to achieve maintenance
excellence. This module establishes the basis for the subsequent
modules that will explain the various model elements in more detail.
- Maintenance Objective Setting: This module
will present the various business plans needed for an effective
maintenance organization, including examples.
- Work Selection: Procedures for screening work
requests and how work should be prioritized will be discussed.
Risk-based decision-making will be included, integrating different risk
matrices. Also, cost benefit analysis will be reviewed and how it
can be used to prioritize work.
- Work Planning and Scheduling: The roles and
responsibilities of planners and schedulers are presented, plus the
procedures for performing both activities. The discussion will
include the staffing and criteria for effective planning and what should
be included in an effective work plan. Also included will be some
metrics for assessing planning.
- Work Execution: Different contracting
approaches are presented along with the objectives of work execution.
An example roles and responsibilities list for supervisors is included.
- Stewardship: This section covers the
activities normally employed to ensure maintenance objectives are
achieved. Performance metrics are also reviewed with target values
for business, system, and functional indicators.
- Continuous R&M Improvement: Activities to
improve reliability performance are reviewed, including several
techniques for performing failure analysis. When to do and when
not to do a failure analysis is discussed.
Day 2 - Introduction to Turnaround Best Practices
This session will introduce proven practices that have been
successfully applied in several key turnaround areas. The practices
for any one area are a composite of practices that have been successfully
used by several refineries and are not those of one individual refinery.
- Turnaround Management and Philosophy: This
module will review management's responsibility in ensuring that a
turnaround is successful. To be effective, Management must
establish a Basic Philosophy, Management Principles, and the Overall
Objectives for the turnaround. In addition, Management should
form a Turnaround Management Committee to guide and support the
- Milestone Plan: The Milestone Plan provides
an overview of strategic activities in the turnaround and is a key
document in communicating planning progress. The elements
included in a Milestone Plan will be presented and examples of a plan
will be provided.
- Work Scope: Work scope is the process of
identifying mechanical, process, engineering, and project work that is
required to be performed during the turnaround in order to achieve the
business objectives. The selection process for identifying work
will be discussed, including a risk assessment procedure.
- Cost Management: Cost management is a key
activity to ensure a successful turnaround. The purpose of this
section is to outline procedures for developing the turnaround budget
and for stewarding against the budget.
- Turnaround Planning: Effective planning is
one of the critical factors for a successful turnaround. This
module will review the key elements of effective turnaround planning,
what defines a good work plan, and staffing for doing the planning.
- Contracting: The purpose of this section is
to outline the procedures for developing contracts for the turnaround.
The items discussed are what are included in a contracting strategy,
and the different types of contracts that can be used.
- Execution: The purpose of this section is
to outline the procedures for executing a safe and effective
turnaround, including supervisor responsibilities and pre-execution
Course Duration - 2 days