Plant Integrity Management – Plant Defect Assessment & Risk-Based Inspection
Plant Integrity Management by Defect Assessment / Serviceability and Risk-Based Inspection & Maintenance
1. Introduction to Plant Integrity.
2. Improving plant integrity
o Hardware options – standby technique
o Improved / high-efficiency Components
o Reliability of system / subsystem / components.
o Plant Integrity and Productivity / Line of balance
3. Overall Equipment Effectiveness concept
o Developing historical OEE models / Example
o Predicting equipment failure from OEE model
o Improving OEE
4. Life cycle assessment of Equipment/components.
o Parameters for enhancing life cycle of plant and machinery and productivity
o Operation severity impact – high temperature/pressure operation / cyclic operation – examples
o Shut down / startup procedures - impact on equipment life cycle
o Standard operating procedures.
5. Defects identification from
o Equipment performance parameters
o Failure rates/maintenance history
o Corrosion / erosion / wear out of components / sections
6. Continuum Damage mechanics
o Damage mechanics
o Behavioral pattern of equipment
o Analysis of equipment behavior.
o Developing damage models and damage prediction
7. Equipment fractures
o Fracture theory
o Material influences
o Elastic/ plastic fracture mechanics models
o Fully plastic and creep fracture mechanics concepts.
8. Defect Assessment Procedures
o Standard methods
o Visual / non-destructive tests / microanalysis
o Selection of materials of construction from historical fatigue, and creep-fatigue analysis
9. Creep, Fatigue, and Crack Growth
o Basics of Creep / Fatigue in equipment
o High-temperature cracks / Stress corrosion cracking
o Thermally induced cracks
o The behavior of a cracked / defective components
o Reliability of cracked reactors – case studies Reformer
o Thermally induced cracking in a reactor – case study – coker unit reactor
o Reliability Assessment using quantitative methods.
o Inspection for Serviceability
10. Equipment maintenance / replacement decisions.
o Operation/maintenance‘ failure data analysis.
o Fitness for service using KPIs
o Under rating service parameters.
o Case studies/examples.
11. Summing up
Learning objectives :
This program covers the basics of
Risk-based Inspection & Maintenance
Preventive and Predictive Maintenance
Evaluation of failure rates / Risk Priority Number concept
Fault tree analysis and
- Application of these concepts in actual operation and maintenance practices for achieving an Integrated Plant Management System.
This program is intended for all operations/ maintenance/production planning/inspection and safety and project personnel from petroleum, petrochemical, fertilizer, power plants and equipment intensive industries.
The specific advantage of this training program is the hands-on training with group exercises and case studies. After participation in this program shall be able to assess the reliability/risk of their industries and carry out predictive maintenance of their plant, which could save substantial maintenance costs and avert costly equipment failures.