process-reliability-engineeringadvancedBersertifikat
Petrochemical O&M Academy
Dari Pemahaman Proses hingga Asset Performance
7 days durasi
in-house / public-batch / hybrid
Yang Akan Anda Pelajari
- ✓Membangun peta O&M lifecycle sebuah aset petrochemical dari commissioning hingga decommissioning.
- ✓Membaca dan menggunakan P&ID secara operasional untuk tracing, isolasi, dan troubleshooting.
- ✓Menyusun strategi maintenance berbasis criticality dan risk untuk peralatan kritis.
- ✓Menghitung dan menginterpretasikan indikator reliability: MTBF, MTTR, dan Availability.
- ✓Melakukan Root Cause Analysis untuk menghilangkan kegagalan berulang (bad actor elimination).
- ✓Merancang program integrity management dan risk-based inspection untuk peralatan statis.
- ✓Menyusun rencana turnaround lengkap, termasuk scope, critical path, dan strategi isolasi.
- ✓Membangun dashboard KPI O&M yang menghubungkan reliability, maintenance, operasi, integrity, dan turnaround.
- ✓Menyusun business case asset performance untuk dipresentasikan kepada manajemen plant.
Untuk Siapa Program Ini
Process EngineerOperations EngineerMaintenance EngineerReliability EngineerInstrument EngineerMechanical EngineerSupervisor dan Superintendent Operasi/MaintenancePlant Manager
Prasyarat
- • Memahami dasar P&ID dan diagram proses (BFD/PFD) disarankan namun tidak wajib.
- • Pengalaman kerja minimal 1 tahun di lingkungan operasi, maintenance, atau engineering plant.
Silabus Lengkap
01Modul 1 — O&M Strategy & Petrochemical Asset Lifecycle+
- –Operation vs Maintenance vs Reliability
- –O&M vs Asset Management vs Production Management
- –Siklus hidup aset petrochemical: Concept → FEED → Construction → Commissioning → Operation → Turnaround → Decommissioning
- –O&M sebagai Lifecycle Engineering
- –Asset Performance Framework
- –Hierarki tujuan O&M: Safety → Reliability → Availability → Production → Cost → Asset Value
02Modul 2 — Petrochemical Process & Operating Philosophy+
- –Alur proses petrochemical tipikal: feed preparation hingga export
- –Process Criticality dan Operating Envelope
- –Normal Operating Window dan Process Constraints
- –Production Bottleneck dan Process Upset
- –Production Loss Mechanism
03Modul 3 — Operations Excellence+
- –Normal Operation, Start-up, Shutdown, Emergency Shutdown
- –Operator Rounds dan Alarm Management
- –Operating Discipline dan Operating Procedures
- –Shift Handover
- –Troubleshooting Philosophy
04Modul 4 — P&ID for O&M+
- –Membaca P&ID dari perspektif O&M
- –Equipment Boundary dan Normal Flow Path
- –Isolation Philosophy: Block Valve, DBB, Drain & Vent, Bypass
- –Control Loop, Interlock, ESD, Cause & Effect
- –P&ID-Based Troubleshooting
05Modul 5 — Maintenance Strategy+
- –Reactive, Corrective, Preventive, Predictive Maintenance
- –Condition-Based dan Proactive Maintenance
- –Risk-Based Maintenance
- –Maintenance Strategy Selection dan PM Optimization
06Modul 6 — Asset Criticality & Maintenance Prioritization+
- –Production, Safety, Environmental, dan Quality Criticality
- –Failure Consequence dan Probability of Failure
- –Criticality Matrix dan Critical Equipment Register
07Modul 7 — Reliability Engineering+
- –Availability, Maintainability, MTBF, MTTR, Failure Rate
- –Bathtub Curve dan Failure Distribution
- –Reliability Block Diagram, Series vs Parallel System
- –Reliability-Centered Thinking
08Modul 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 dan Recurring Failure
09Modul 9 — Rotating Equipment Reliability+
- –Pumps: cavitation, seal failure, bearing, alignment, vibration
- –Compressors: surge, vibration, bearing, seal, performance degradation
- –Turbomachinery dan condition monitoring
10Modul 10 — Static Equipment & Mechanical Integrity+
- –Pressure Vessel, Heat Exchanger, Reactor, Column, Furnace, Storage Tank, Piping
- –Corrosion, Erosion, Cracking, Wall Thickness
- –Inspection dan Fitness for Service
11Modul 11 — Inspection, Corrosion & RBI+
- –Inspection Philosophy dan Planning
- –Corrosion Mechanisms, CUI, Erosion, Dead Leg
- –NDT: UT, RT, PT, MT, VT
- –Risk-Based Inspection dan Inspection Interval
12Modul 12 — Instrumentation & Control Maintenance+
- –Instrument Criticality, Sensor Failure, Transmitter, Control Valve
- –Calibration dan Instrument Air
- –Interlock, SIS, ESD, Proof Testing
13Modul 13 — Process Safety in O&M+
- –Process Safety vs Personal Safety, Major Accident Hazard
- –HAZOP dan LOPA
- –Safety Barrier, SIS/SIL, PSV, ESD, Flare
- –Barrier Health
14Modul 14 — Safe Work, Isolation & PTW+
- –Permit to Work dan LOTO
- –Mechanical, Electrical, dan Process Isolation
- –Gas Testing, Confined Space, Hot Work, SIMOPS
15Modul 15 — Maintenance Work Management+
- –Notification, Work Request, Work Order
- –Planning, Scheduling, Backlog
- –Job Plan, Work Pack, Close-out, Lessons Learned
16Modul 16 — CMMS / EAM & Digital O&M+
- –Asset Hierarchy, Functional Location, Equipment Master
- –Maintenance Plan, Work Order, Failure Coding
- –Digital Twin, IIoT, Predictive Analytics
17Modul 17 — Turnaround & Shutdown Management+
- –Turnaround Strategy dan Scope Development
- –Worklist, Critical Path, Long Lead Items, Spare Readiness
- –Isolation, SIMOPS, Inspection, Maintenance selama window
- –Mechanical Completion, Reinstatement, Start-up, Post-Turnaround Review
18Modul 18 — Production & Energy Optimization+
- –Production Availability, Bottleneck, Debottlenecking
- –Energy KPI: steam, cooling water, fuel gas, electricity
- –Compressor dan Pump Efficiency, Energy Intensity
19Modul 19 — MOC, Management System & O&M Governance+
- –Management of Change dan Temporary Modification
- –Documentation Control dan As-Built
- –Competency, Audit, KPI Governance, Lifecycle Cost
20Modul 20 — O&M KPI & Executive Dashboard+
- –Reliability KPI: MTBF, MTTR, Availability, Failure Rate
- –Maintenance KPI: PM Compliance, Schedule Compliance, Backlog
- –Operations, Integrity, dan Turnaround KPI
21Modul 21 — Asset Performance Management+
- –Asset Performance, Asset Health, Asset Criticality
- –CAPEX vs OPEX dan Maintenance Optimization
- –Framework: Asset Condition → Risk → Reliability → Availability → Production → Revenue → Asset Value
22Modul 22 — Integrated Petrochemical O&M Simulation+
- –Virtual plant dataset: BFD, PFD, P&ID, Equipment/Maintenance History, DCS Trend, Production Data
- –Alur simulasi: P&ID Tracing → RCA → Reliability Analysis → Maintenance Strategy → Business Case
23Modul 23 — Executive Capstone+
- –Kerja kelompok lintas fungsi: Operations, Maintenance, Reliability, Integrity, HSE, Management
- –Penyusunan O&M Strategy, Roadmap 12 bulan, dan Business Case
- –Board / Plant Manager Presentation di depan panel