Course Overview

Operator Asset Care is an essential part of the ‘world class’ approach to maximize the effectiveness of operational assets and processes within companies. It not only addresses maintenance but all aspects of the operation of manufacturing facilities and at its very heart lies in the motivation and enhancement of company personnel.Operator Asset Care (OAC) are activities that involve operators maintaining certain aspects of their own equipment, independent of the maintenance department. The activities include daily inspections, lubrication, parts replacement, detections of abnormalities and precision checks.The goal of OCA is to prevent equipment deterioration, restoring equipment to its ideal state and reporting abnormalities to the maintenance department It is an approach that enables traditional maintenance practices to change from re-active to proactive by sharing responsibility for machinery condition, performance and maintenance.The goal of this course is to place powerful and proven improvement tools in the hands of your entire workforce.

Course Objectives

Attendees will gain an understanding of:

• The roles of operators in improving reliable care of tools; equipment and machinery to improve asset operation
• Making the maintenance of machinery condition everyone’s responsibility; not only an artisans
• The importance and difference between “age related” and “random” failures and be prepared to correctly identify and manage both
• Using techniques such as audible, tactile and visual inspection and easy to use checklists
• The causes and “why’s” of asset failure and how breakdown can be avoided in the first place
• The importance of bearing, seal, lubrication failure and the degradation of overall machine life.

Operators will learn the following skills for independent equipment maintenance:

• How to keep equipment running smoothly?
• How to inspect for problems during regular cleaning
• How to contain debris that can shorten equipment life?
• How to manage equipment lubrication effectively?
• How to use activity boards and meetings?
• How to use Standard Operating Procedures and one-point lessons to promote effective equipment maintenance.

Course Contents

Module (01) Oil & Gas principles & Asset Care Programs

• Introduction to oil & gas.
• Process components
• Process Diagram Fundamentals
• BFD (Block Flow Diagram)
• PFD (Process Flow Diagram)
• Utility flow Diagrams
• P&ID (Piping and instrumentation diagram)
• How to Read P&ID
• Line list & PDS (Process Data Sheet)
• Basic Plot / Block Plan.
• Utilities consumption & calculation.
• Develop utility summary & energy efficient consumption.
• Operator Care Programs.
• Operator rounds & operator basic care process & best practices.
• Equipment maintenance basic care strategy.

 Module (02) Static Equipment Basic Care (Valves)

• Static Equipment used in oil & gas.
• Types of manual valves.
• Ball Valves
• Plug Valves
• Needle valves
• Globe valves
• Gate Valves
• Relief Valves
• Valves asset basic care best practices.
• Control system basics
• Hazardous area classification fundamentals.
• Process Safety Management system
• Case example or case study.

 Module (03) Static equipment Basic care (Separators & Storage Tanks)

• Separation equipment selection.
• Separation equipment design.
• Separation Equipment application.
• Separators selection & maintenance.
• Separators asset basic care best practices.
• Verification of operator Separators rounds & Control system.
• Best practices of Static
• Case Study
• Storage tanks Basic Care Sheets & templates
• Questions

• Storage tanks selection
• Storage tanks application
• Storage tanks calculation fundamentals.

• Bund wall capacity calculation.
• distance to process facility calculations.
• Numbers of tanks in one Dike.
• Tank shell calculations.

• Heat Exchangers Operations & Maintenance.
• Heat Exchangers asset care programs

 Module (04) Rotating & Electrical equipment Basic

• Pumps Operations & maintenance.
• Fan Motors Operations.
• Introduction to Relief
• Relief & Safety valves theory of operation
• Relief & pressure safety valve sizing
• Flare purge gas calculations
• Flare system radiation zone calculation.
• Flare Knock out drum sizing application.

 Module (05) Equipment Troubleshooting Fundamentals

• Difference between Troubleshooting, Optimization & debottlenecking.
• Tools Supporting Operations Management.
• Troubleshooting techniques.
• Best practices of troubleshooting.
• Operations Integration.
• Case Study – Oil plant vulnerability troubleshooting.
• Case Study – Fractionation Plant problem troubleshooting.

 Module (06) Becoming Equipment Conscious Operators

• Goal of Operator Asset Care
• The Roles of Production and Maintenance in Autonomous Maintenance
• 5S in Operator Asset Care
• What is Equipment Conscious Operators?
• Ability to discover abnormalities
• Ability to correct abnormalities
• Ability to set optimal equipment conditions
• Ability to maintain optimal equipment conditions
• 4 Skills in becoming Equipment Conscious Operators
• Skill Level 1: Recognizing
• Deterioration & Improving Equipment to Prevent It
• Skill Level 2: Understanding
• Equipment Structure & Function
• Skill Level 3: Understanding the
• Causes of Quality Defects
• Skill Level 4: Performing Routine
• Repairs
• The 16 Major losses that disrupt equipment The Role of Operator in Workplace Safety

 Module (07) Cleaning Is Inspection

• What is cleaning?
• Why Initial cleaning is at the heart of OAC Identify 7 types of irregularities
• Remove all unnecessary objects
• Find sources of contamination and Quality defects
• The target “maintenance cleaning time

 Module (08) Inspection

• What are the principles of equipment
• The basic causes of failure
• What is a problem and how to look for it Using 5 senses
• Using Inspection Checklists (examples for Hydraulic Unit & Drive System)
• Tagging when you find a Problem Countermeasures for the source of problems

 Module (09) Using Localized Containment

• What is Accelerated Deterioration? Purpose of containment
• Problems associated with Large Enclosures Localized containment
• Types and examples of containment guards Continually improving containment

 Module (10) Effective Equipment Lubrication Why do we need to Lubricate?

• Types and Grouping of Lubricants
• Adding right Lubricant at the right time and right amount
• Operator lubrication responsibilities & Tips Daily Lubrication Checks
• Setting & Easing Lubrication Standards Visual Management of Lubricants Consolidate lubricants to reduce the amount of stock
• How lubricants should be stored and FIFO usage

 Practical’s: Some hard copy templates available. Short RCA presentations by delegates.Check Sheet, Pareto Graph, Fishbone, 5W2H, 5WHYSummative Assessment