Optimizing Rotating Equipment with Continuous Reliability Improvement (CRI)

Introduction:

Studies conducted on oil refineries worldwide reveal that maintenance and inspection services for rotating equipment account for over twenty percent of total repair and inspection costs. Given that rotating equipment is often crucial to process operations and production, breakdowns can lead to significant downtime costs.

The Rotating Equipment and Continuous Reliability Improvement (CRI) program aims to provide participants with a comprehensive understanding of how to employ predictive and preventive maintenance strategies, along with effective failure monitoring, to enhance the reliability and performance of rotating equipment.

Objectives:

By the end of the Rotating Equipment and Continuous Reliability Improvement (CRI) course, participants will be able to:

• Utilize the proven methodologies and templates introduced in the course.
• Focus on key aspects of reliability.
• Understand the nature of failures and their impact on rotating equipment performance.
• Make informed maintenance decisions for critical equipment.
• Reduce the impact of unplanned plant outages.
• Empower their teams to maximize efficiency.

Training Methodology:

• Workshops
• Case Studies
• Scenario-Based Exercises
• Group Work
• Expert Talks

Course Outline:

Unit 1: Linking Reliability with Competitive Advantage and Ways to Make It Work for Your Organization

• The concept of reliability.
• Probability of events occurring.
• Methods for assessing reliability.
• The value of reliability in business.
• Current performance evaluation.
• Strategic decision-making for reliability.

Unit 2: Using Reliability Modeling to Establish Inherent Reliability

• Essential elements of reliability models.
• Classic reliability models.
• Risk-based models.
• Markov chains.
• Monte Carlo simulations.

Unit 3: Understanding the Nature of Failures to Make the Best Response

• Causes of failure.
• Types of failures.
• Common failure patterns.
• Failure analysis techniques.
• Methods for failure pattern analysis.
• Preventive activities to address failures.

Unit 4: Optimizing Failure Management to Ensure Cost-Effective Maintenance

• Risk and criticality assessment.
• Equipment operational capacity.
• Analyzing modes of failure and consequences.
• Impact of failures.
• Selecting appropriate maintenance activities.
• Developing optimal maintenance plans.

Unit 5: Setting Up a Continuous Reliability Improvement Process to Improve Performance

• Measuring the improvement ratio against the cost of improvement.
• Securing top management commitment.
• Defining project scope.
• Technical components of the project plan.
• Social factors in project planning.
• Anticipated results and outcomes.