process-reliability-engineeringadvancedCertified
Petrochemical O&M Academy
From Process Understanding to Asset Performance
7 days duration
in-house / public-batch / hybrid
What You'll Learn
- ✓Build an O&M lifecycle map for a petrochemical asset from commissioning to decommissioning.
- ✓Read and use P&ID operationally for tracing, isolation, and troubleshooting.
- ✓Develop criticality- and risk-based maintenance strategies for critical equipment.
- ✓Calculate and interpret reliability indicators: MTBF, MTTR, and Availability.
- ✓Conduct Root Cause Analysis to eliminate recurring failures (bad actor elimination).
- ✓Design an integrity management and risk-based inspection program for static equipment.
- ✓Develop a complete turnaround plan, including scope, critical path, and isolation strategy.
- ✓Build an O&M KPI dashboard connecting reliability, maintenance, operations, integrity, and turnaround.
- ✓Develop an asset performance business case to present to plant management.
Who This Is For
Process EngineerOperations EngineerMaintenance EngineerReliability EngineerInstrument EngineerMechanical EngineerOperations/Maintenance Supervisor and SuperintendentPlant Manager
Prerequisites
- • Basic understanding of P&ID and process diagrams (BFD/PFD) recommended but not required.
- • Minimum 1 year of work experience in a plant operations, maintenance, or engineering environment.
Full Syllabus
01Module 1 — O&M Strategy & Petrochemical Asset Lifecycle+
- –Operation vs Maintenance vs Reliability
- –O&M vs Asset Management vs Production Management
- –Petrochemical asset lifecycle: Concept → FEED → Construction → Commissioning → Operation → Turnaround → Decommissioning
- –O&M as Lifecycle Engineering
- –Asset Performance Framework
- –O&M objective hierarchy: Safety → Reliability → Availability → Production → Cost → Asset Value
02Module 2 — Petrochemical Process & Operating Philosophy+
- –Typical petrochemical process flow: feed preparation through export
- –Process Criticality and Operating Envelope
- –Normal Operating Window and Process Constraints
- –Production Bottleneck and Process Upset
- –Production Loss Mechanism
03Module 3 — Operations Excellence+
- –Normal Operation, Start-up, Shutdown, Emergency Shutdown
- –Operator Rounds and Alarm Management
- –Operating Discipline and Operating Procedures
- –Shift Handover
- –Troubleshooting Philosophy
04Module 4 — P&ID for O&M+
- –Reading P&ID from an O&M perspective
- –Equipment Boundary and Normal Flow Path
- –Isolation Philosophy: Block Valve, DBB, Drain & Vent, Bypass
- –Control Loop, Interlock, ESD, Cause & Effect
- –P&ID-Based Troubleshooting
05Module 5 — Maintenance Strategy+
- –Reactive, Corrective, Preventive, Predictive Maintenance
- –Condition-Based and Proactive Maintenance
- –Risk-Based Maintenance
- –Maintenance Strategy Selection and PM Optimization
06Module 6 — Asset Criticality & Maintenance Prioritization+
- –Production, Safety, Environmental, and Quality Criticality
- –Failure Consequence and Probability of Failure
- –Criticality Matrix and Critical Equipment Register
07Module 7 — Reliability Engineering+
- –Availability, Maintainability, MTBF, MTTR, Failure Rate
- –Bathtub Curve and Failure Distribution
- –Reliability Block Diagram, Series vs Parallel System
- –Reliability-Centered Thinking
08Module 8 — Failure Mode, RCA & Bad Actor Elimination+
- –Failure Mode vs Failure Mechanism, Symptom vs Root Cause
- –Pareto Analysis, 5 Why, Fishbone
- –Fault Tree Analysis, FMEA, RCFA
- –Bad Actor Management and Recurring Failure
09Module 9 — Rotating Equipment Reliability+
- –Pumps: cavitation, seal failure, bearing, alignment, vibration
- –Compressors: surge, vibration, bearing, seal, performance degradation
- –Turbomachinery and condition monitoring
10Module 10 — Static Equipment & Mechanical Integrity+
- –Pressure Vessel, Heat Exchanger, Reactor, Column, Furnace, Storage Tank, Piping
- –Corrosion, Erosion, Cracking, Wall Thickness
- –Inspection and Fitness for Service
11Module 11 — Inspection, Corrosion & RBI+
- –Inspection Philosophy and Planning
- –Corrosion Mechanisms, CUI, Erosion, Dead Leg
- –NDT: UT, RT, PT, MT, VT
- –Risk-Based Inspection and Inspection Interval
12Module 12 — Instrumentation & Control Maintenance+
- –Instrument Criticality, Sensor Failure, Transmitter, Control Valve
- –Calibration and Instrument Air
- –Interlock, SIS, ESD, Proof Testing
13Module 13 — Process Safety in O&M+
- –Process Safety vs Personal Safety, Major Accident Hazard
- –HAZOP and LOPA
- –Safety Barrier, SIS/SIL, PSV, ESD, Flare
- –Barrier Health
14Module 14 — Safe Work, Isolation & PTW+
- –Permit to Work and LOTO
- –Mechanical, Electrical, and Process Isolation
- –Gas Testing, Confined Space, Hot Work, SIMOPS
15Module 15 — Maintenance Work Management+
- –Notification, Work Request, Work Order
- –Planning, Scheduling, Backlog
- –Job Plan, Work Pack, Close-out, Lessons Learned
16Module 16 — CMMS / EAM & Digital O&M+
- –Asset Hierarchy, Functional Location, Equipment Master
- –Maintenance Plan, Work Order, Failure Coding
- –Digital Twin, IIoT, Predictive Analytics
17Module 17 — Turnaround & Shutdown Management+
- –Turnaround Strategy and Scope Development
- –Worklist, Critical Path, Long Lead Items, Spare Readiness
- –Isolation, SIMOPS, Inspection, Maintenance during the window
- –Mechanical Completion, Reinstatement, Start-up, Post-Turnaround Review
18Module 18 — Production & Energy Optimization+
- –Production Availability, Bottleneck, Debottlenecking
- –Energy KPI: steam, cooling water, fuel gas, electricity
- –Compressor and Pump Efficiency, Energy Intensity
19Module 19 — MOC, Management System & O&M Governance+
- –Management of Change and Temporary Modification
- –Documentation Control and As-Built
- –Competency, Audit, KPI Governance, Lifecycle Cost
20Module 20 — O&M KPI & Executive Dashboard+
- –Reliability KPI: MTBF, MTTR, Availability, Failure Rate
- –Maintenance KPI: PM Compliance, Schedule Compliance, Backlog
- –Operations, Integrity, and Turnaround KPI
21Module 21 — Asset Performance Management+
- –Asset Performance, Asset Health, Asset Criticality
- –CAPEX vs OPEX and Maintenance Optimization
- –Framework: Asset Condition → Risk → Reliability → Availability → Production → Revenue → Asset Value
22Module 22 — Integrated Petrochemical O&M Simulation+
- –Virtual plant dataset: BFD, PFD, P&ID, Equipment/Maintenance History, DCS Trend, Production Data
- –Simulation flow: P&ID Tracing → RCA → Reliability Analysis → Maintenance Strategy → Business Case
23Module 23 — Executive Capstone+
- –Cross-functional group work: Operations, Maintenance, Reliability, Integrity, HSE, Management
- –Developing an O&M Strategy, 12-month Roadmap, and Business Case
- –Board / Plant Manager presentation before a panel