Module 16 – Maintenance & Reliability Basics

Objective:
By the end of this module, a trainee will be able to:

1. Understand the importance of maintenance in petrochemical plants.

2. Differentiate between preventive, predictive, and corrective maintenance.

3. Recognize common equipment types and their maintenance requirements.

4. Understand the operator’s role in reliability and maintenance.

5. Apply basic troubleshooting and reporting to support plant uptime.

16.1 – Introduction to Maintenance & Reliability

Definition:

• Maintenance = activities to keep equipment in safe, efficient, and reliable condition.

• Reliability = the ability of equipment to perform its intended function without failure.

Importance:

• Prevents unplanned downtime and safety incidents.

• Reduces repair costs and production losses.

• Supports overall plant efficiency and product quality.

Operator Role:

• Monitor equipment health daily.

• Perform minor maintenance tasks per SOP.

• Report anomalies for timely intervention.

Analogy:

• Maintenance = “regular oil change and tire check for a car to prevent breakdown.”

• Reliability = “a car starting every day without fail.”

16.2 – Types of Maintenance

• Preventive Maintenance (PM)

Scheduled maintenance to prevent failures (lubrication, filter change, inspection)

Perform routine checks, fill logs, replace minor components

• Predictive Maintenance (PdM)

Uses data and monitoring to predict failures (vibration, temperature, oil analysis)

Report abnormal readings, assist maintenance team with inspections

• Corrective Maintenance (CM)

Repairs after failure occurs

Notify maintenance, follow safety procedures, isolate equipment if needed

• Reliability-Centered Maintenance (RCM)

Combines PM, PdM, and CM to optimize uptime

Understand equipment criticality, follow SOPs, monitor trends

Operator Tips:

• Follow maintenance schedules strictly.

• Log daily equipment observations.

• Communicate potential issues to maintenance team proactively.

16.3 – Common Equipment & Basic Maintenance

• Pumps

Function: Move liquids

Check vibration, pressure, seal leakage, lubrication, strainer cleaning

• Compressors

Function: Move gases

Monitor temperature, vibration, oil level, filters

• Heat Exchangers

Function: Transfer heat

Check fouling, pressure drop, leaks, cleaning schedule

• Valves

Function: Regulate flow

Check for leaks, operation smoothness, lubrication

• Reactors

Function: Chemical conversion

Monitor pressure, temperature, safety interlocks

• Storage Tanks

Function: Contain feed/products

Inspect level, corrosion, vents, and leaks

• Piping & Strainers

Function: Transport fluids

Inspect for leaks, clean strainers, check insulation

Operator Tips:

• Observe abnormal noises, vibration, or temperature trends.

• Ensure routine lubrication and cleaning per SOP.

• Never attempt major repairs; report to maintenance.

Analogy:

• Equipment = “machines in a factory; operators are caretakers preventing breakdowns.”

16.4 – Equipment Reliability Concepts

Key Principles:

1. MTBF (Mean Time Between Failures): how long equipment operates before failure.

2. MTTR (Mean Time To Repair): how long it takes to restore equipment.

3. Criticality: equipment that affects safety, production, or quality requires special attention.

Operator Role:

• Help maintain high MTBF by proper operation.

• Reduce MTTR by early detection and reporting.

• Follow SOPs for critical equipment operations.

16.5 – Operator Role in Maintenance & Reliability

1. Daily Rounds: observe pumps, compressors, reactors, valves, and utilities.

2. Log Data: temperatures, pressures, flow rates, alarms, vibrations.

3. Preventive Tasks: strainer cleaning, minor lubrication, visual inspections.

4. Report & Communicate: abnormalities, unusual trends, alarms to maintenance and control room.

5. Participate in Shutdowns/Turnarounds: assist maintenance in safe operations.

Analogy:

• Operator = “caretaker who notices early signs of wear in a machine before it breaks.”

16.6 – Troubleshooting & Maintenance Interaction

• Operators are first responders for abnormal equipment behavior.

• Observation + basic corrective action = prevents minor issues from becoming major failures.

• Collaboration with maintenance ensures:

  • Correct diagnosis

  • Safe repairs

  • Minimal downtime

16.7 – Quiz / Knowledge Check

1. What is the difference between preventive and predictive maintenance?

2. Name three pieces of equipment and basic operator maintenance tasks.

3. What does MTBF stand for and why is it important?

4. What is the operator’s role in equipment reliability?

5. Give an analogy for maintenance in everyday life.

6. How should an operator respond to abnormal equipment observations?

16.8 – Media Sites Integration

• Videos:

  • Daily operator rounds and equipment inspection

  • Conceptual preventive maintenance demonstration

  • Example of strainer cleaning and minor lubrication

• Diagrams / Infographics:

  • Equipment maintenance points diagram

  • MTBF/MTTR reliability curve

  • Operator maintenance checklist

• PDF Downloads:

  • Daily operator inspection checklist

  • Maintenance reporting template

  • Conceptual preventive maintenance guide

• Interactive:

  • Embedded quizzes

  • Scenario exercises: detect abnormal equipment trend and suggest preventive action

16.9 – Summary & Key Takeaways

1. Maintenance ensures equipment reliability, safety, and production continuity.

2. Operators perform observations, minor maintenance, and reporting to support plant reliability.

3. Types of maintenance: preventive, predictive, corrective, and RCM.

4. Understanding criticality and MTBF/MTTR helps prioritize actions.

5. Collaboration between operators and maintenance prevents unplanned downtime and improves safety.