FE061: Mechanical Integrity, Safety & Reliability

Transcription

1 FE061: Mechanical Integrity, Safety & Reliability FE061 Rev.001 CMCT COURSE OUTLINE Page 1 of 5

2 Training Description: This intensive course explains how to establish a program for maintaining the integrity of critical process equipment to improve reliability and satisfy government regulations. Participants will learn how to satisfy regulatory requirements and improve reliability by establishing management systems, procedures and training programs for mechanical integrity (MI). This course Includes instruction on management systems for MI, determining what equipment to include, identifying applicable codes and standards, deciding what repairs and preventive maintenance should be performed, developing procedures, establishing requirements for training MI personnel, how to handle equipment deficiencies, and what types of quality assurance should be performed to ensure equipment is properly fabricated and installed and spare parts and materials are suitable for their intended application. This course prepares each participant to evaluate their existing practices versus recognized codes and standards and then to efficiently improve or develop and implement their mechanical integrity (MI) program. Topics also include how to merge your MI program with a reliability program as well as to describes computerized maintenance management systems and their selection. Training Objective: By the end of the training, participants will be able to: Develop and implement a mechanical integrity, safety and reliability program for critical process equipment, while satisfying government requirements Up-to-date MI strategies and techniques for effectively building and implementing a comprehensive MI program that addresses process safety management requirements and/or reliability and other concerns as defined through company, industry, and regulatory requirements Learn how to develop, implement, and maintain an efficient MI program. Through thorough, step by step instruction the experienced instructor guide participants through building their own MI program regardless of the age, size, or complexity of the facility How to expand this program to encompass reliability and quality goals How to define and assign roles and responsibilities How to integrate your new or revised MI program with existing MI activities Develop an inspection and testing plan using your own equipment list or generic examples Quality assurance methods for identifying and resolving equipment deficiencies How to develop maintenance procedures and training programs for maintenance personnel Training Designed for: This course is intended for Designated employees responsible for designing, developing, and implementing a PSM based MI program, Engineers Mechanical & Plant, Managers Plant Managers, Maintenance, and Productions, PSM Manager or Coordinators, Operations and maintenance managers, engineers, and other staff responsible for mechanical integrity. FE061 Rev.001 CMCT COURSE OUTLINE Page 2 of 5

3 Training Program: DAY ONE: PRE-TEST Overview of Mechanical Integrity Regulatory Requirements for Mechanical Integrity Learning objectives and goals for mechanical integrity (MI) Motivations for mechanical integrity o Regulations, standards, and interpretations o Relationship to Reliability programs o Safety and Reliability Designing a mechanical integrity program Minimal MI program only for compliance? Fully integrated reliability program? Something in-between? Workshop: Deciding in detail what you need your MI program to address (this sets the basis for later workshops and discussion) Developing a mechanical integrity program Equipment identification and related issues o List of critical equipment o Types of MI activities (reactive, proactive, preventive, predictive) o Choosing the right task type and choosing the specific task o Determining the right frequency for the task (condition or time dependent) o Workshop: Starting the development of an inspection, test, and preventive maintenance (ITPM) plan Developing a mechanical integrity program (continued) Personnel focus o Procedures o Training o Safety o Workshop: Completing the development of an IPTM plan by identifying written procedures and training needs for your mechanical integrity program DAY TWO: Developing a mechanical integrity program (continued) Management systems required and related issues o Quality assurance o Equipment deficiency resolution o Root cause analysis o Management of change o Workshop: Identifying gaps in your quality assurance plan and identifying additional needs for procedures and training FE061 Rev.001 CMCT COURSE OUTLINE Page 3 of 5

4 Implementing/Maintaining a mechanical integrity program Review of detailed checklist for implementing an MI/safety/reliability system Documenting and managing data/results, computer systems and other equipment files Workshop: Customizing the detailed implementation checklist to your specific needs (optional) Roles and Responsibilities for MI Workshop: Identifying roles and responsibilities for your MI program Key performance indicators for MI and continual improvement of a mechanical integrity program DAY THREE: Mechanical Integrity Management Systems Equipment Covered Codes, Standards and Practices Maintenance Tasks Procedures Training and Qualification of Personnel DAY FOUR & FIVE: Preventive Maintenance Tasks Preventive Maintenance Frequencies Corrosion and Non-Destructive Testing Handling Equipment Deficiencies Quality Assurance Computerized Maintenance Management Systems Course Conclusion POST-TEST and EVALUATION Training Requirement: Hand s on practical sessions, equipment and software will be applied during the course if required and as per the client s request. Training Methodology: This interactive training course includes the following training methodologies as a percentage of the total tuition hours:- 30% Lectures, Concepts, Role Play 30% Workshops & Work Presentations, Techniques 20% Based on Case Studies & Practical Exercises 20% Videos, Software & General Discussions Pre and Post Test FE061 Rev.001 CMCT COURSE OUTLINE Page 4 of 5

5 Training Certificate(s): Internationally recognized certificate(s) will be issued to each participant who completed the course. Training Fees: As per the course location - This rate includes participant s manual, hand-outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day. Training Timings: Daily Timings: 07:45-08:00 Morning Coffee / Tea 08:00-10:00 First Session 10:00-10:20 Recess (Coffee/Tea/Snacks) 10:20-12:20 Second Session 12:20-13:30 Recess (Prayer Break & Lunch) 13:30-15:00 Last Session For training registrations or in-house enquiries, please contact: Aisha Relativo: aisha@cmc-me.com Tel.: or Mob.: Training & Career Development Department FE061 Rev.001 CMCT COURSE OUTLINE Page 5 of 5