• Explain the strategy for plant and utility maintenance

This course studies the different utility requirements for a process plant and the maintenance efforts undertaken in the plant to support plant productivity. Plant utilities are discussed along with their generation and effective utilization. The main utilities required for the process in the plant are water, steam, air & refrigerants. Steam & non-steam heating media are important for the conversion of raw materials to products in reactors & to increase temperatures in chemical processes. Cooling is important to maintain the temperature in the process. Compressed air, process air are used in the process & instrument air is used in pneumatic devices & controls. While plant maintenance discusses the strategy for maintaining equipment in the plant, planning and scheduling maintenance of equipment in the plant, maintainability and reliability.To train students to integrate theoretical knowledge with real-world utility and plant maintenance problems that occur, students are given group assignments in the form of case studies, in this case the case of providing utility facilities and plant maintenance in certain types of industries. It is expected that by focusing on a case intensively and in detail, ELECTIVE COURSE students can be trained to think critically, creatively, and innovatively, and have the intellectual ability to solve problems at the individual and group levels. In addition, to broaden students’ perspectives on process support facilities and maintenance programs in certain industries, students conduct a factory visit to one of the factories in the Jabodetabek area to see firsthand and listen to explanations from practitioners in the factory. Thus, students can contribute to providing alternative solutions to various problems that arise in society, the nation and the state.

• Introduction to Plant Maintenance Strategy

  • Overview of plant maintenance and its importance in industrial operations
  • Objectives of maintenance: ensuring safety, reliability, and cost-effectiveness

• Maintenance Programs

  • Types of maintenance strategies:
    • Preventive Maintenance: Scheduled inspections and servicing to prevent failures
    • Predictive Maintenance: Using condition monitoring to predict and prevent breakdowns
    • Corrective Maintenance: Repairs after failure to restore functionality
    • Proactive Maintenance: Root cause analysis to eliminate issues before they occur
  • Designing and implementing effective maintenance programs

• Maintainability

  • Principles of maintainability in plant equipment and systems
  • Factors affecting maintainability: design, accessibility, and standardization
  • Strategies for improving maintainability in industrial processes

• Reliability

  • Understanding reliability concepts: Mean Time Between Failures (MTBF), Mean Time to Repair (MTTR)
  • Techniques for improving equipment reliability: redundancy, quality control, and robust design
  • Reliability-centered maintenance (RCM): balancing reliability and cost-effectiveness

• Planning and Scheduling

  • Importance of maintenance planning and scheduling in plant operations
  • Steps in planning maintenance activities: identifying tasks, resources, and timelines
  • Scheduling tools and techniques: Gantt charts, Critical Path Method (CPM), and software tools
  • Monitoring and adjusting maintenance schedules for optimal efficiency

1. Dhillon, B. S., Engineering Maintenance: A Modern Approach, CRC Press, 2002.
2. Higgins, L. R., Mobley, R. K., & Smith, R., Maintenance Engineering Handbook, McGraw-Hill, 2002.
3. Sanders, R. E., Chemical Process Safety, Elsevier, 2005.
4. Palmer, D., Maintenance Planning and Scheduling Handbook, McGraw-Hill, 1999.