The foundation of plant integrity lies in ensuring that assets are properly designed, operated, and maintained according to specific requirements. The profitability of plants is heavily influenced by the efficiency of their preventive maintenance strategy. Throughout their service life, assets face deterioration mechanisms and potential damage. To ensure reliable performance, availability, and safety at a reasonable cost, it’s essential to understand the risks posed by these deterioration mechanisms and their effects. This understanding allows for the identification of the most effective maintenance tasks tailored to current conditions. The process involves recognizing the deterioration mechanisms, determining failure rates, establishing risk criteria, and defining the frequency, scope, and methods of maintenance.
Historically, maintenance strategies have been based on experience and reactive approaches to failures. These strategies often fail to fully account for the risks of failure or the degradation mechanisms that affect assets during operation. As a result, some organizations may fail to perform the appropriate maintenance actions at the right intervals, leading to asset failures, while others may overspend, wasting resources or even inducing failures due to excessive maintenance.
This intensive 2-day Energy training course introduces the Risk-Based Maintenance (RBM) methodology, which helps assess the likelihood and risk of asset failures. RBM allows organizations to prioritize assets for maintenance, optimize maintenance techniques, schedules, and resource allocation, and develop long-term maintenance plans. It integrates with existing methodologies such as Failure Mode Effect & Criticality Analysis (FMECA), Risk-Based Inspection (RBI), and Potential Failure Analysis (PFA), resulting in improved safety, lower risks of failure, fewer unexpected shutdowns, and reduced operational costs. This makes maintenance a more valuable asset to the organization.
Participants will learn how to apply a systematic and integrated approach involving various disciplines that affect plant integrity. The course will also present case studies from RBM projects in the industry, examining both successes and challenges to extract valuable lessons.
This Risk-Based Maintenance Workshop training course will cover:
- The application of the RBM methodology to develop an effective maintenance strategy
- Understanding and implementing risk and risk-based thinking in maintenance practices
- Analyzing the probability of failure and its impact on system risk
- Selecting the right maintenance tasks and predictive technologies
- Integrating RBM with methodologies like FMECA, RBI, PFA, and the maintenance workflow
- Using cost-benefit analysis and decision-support tools to improve maintenance effectiveness
- Measuring performance with Key Performance Indicators (KPIs)
Upon completing the Risk-Based Maintenance Workshop training course, delegates will:
- Gain an understanding of the principles and real-world application of a Risk-Based Maintenance (RBM) program
- Learn how RBM can enhance maintenance effectiveness and overall performance
- Understand how RBM integrates with workflow management and other established methodologies
- Receive practical advice on applying RBM for optimal outcomes
- Develop a tangible action plan for implementing RBM within their responsibilities, aligning it with Asset Management strategies and establishing measurement criteria for results.
This Risk Based Maintenance Workshop training course will utilize a variety of proven learning techniques to ensure maximum understanding, comprehension and retention of the information presented. It is composed in such a way that it can be held for all professionals involved in managing or implementing Risk Based Maintenance processes. It is conducted along workshop principles with formal lectures and interactive exercises. Relevant case studies illustrate the application of each subject in an operations environment and each learning point will be re-enforced with practical exercises. There will be many opportunities for discussion and sharing experiences.
This Energy training course is directed towards Maintenance & Reliability Engineers, Maintenance and Engineering Professionals and Maintenance and Production Heads, who wish to update themselves on Risk Based Maintenance, maintenance reference plans, judge its suitability for their needs, and learn how to implement it for the benefit of their organizations.
Overview of the RBM methodology
- The business impact of maintenance
- Asset Management as a framework to realise value from assets
- Cost-benefit decisions: the right amount of maintenance
- The maintenance reference plan
- Deterioration of assets – basic failure behaviour of assets and systems
- Understanding risk: a key driver for preventive maintenance
- The seven steps of Risk Based Maintenance: integration of Failure Mode Effect & Criticality Analysis (FMECA)
- Failure patterns & Weibull distribution
- Determine maintenance tasks and frequencies
Implementation aspects
- Using Decision Support Tools to optimize maintenance tasks & frequencies
- Alternative tasks for specific equipment
- inspection & testing
- condition monitoring
- Implementing Predictive Maintenance technologies
- Implementation aspects and integration with maintenance workflow management and other methodologies like Risk Based Inspection (API 580) and Potential Failure Analysis (PFA)
- Monitoring performance
- Action plan to implement RBM