MP.

12

Reliability Engineering for Process Plants

RCM Based Maintenance & Reliability Program Understanding, Development & Implementation

About the Trainer

S. Nadeem Ahmed
MSc Engg (Power Plants)
Six Sigma MBB, USA
More than two decades of diverse professional engineering experience in various
industrial sectors viz. Aviation, Power Plants and Petrochemicals. Key specialties
include consulting, training and development as a Mechanical Power Engineer in:
Process, Power Generation Plants & Aviation
- Life cycle Asset Management
- RCM based Maintenance & Reliability Program development and implementation
- Reliability Analysis & Risk Based Studies
- Remaining Life Assessment Studies, Evaluation, Extension Recommendations
Work-scope Optimization on Aero and Aero derivative Power Plant Turbo machinery
Maintenance Repair & Overhaul
Thermal and CCPP Power Generation Performance Evaluation
Critical / Rotating Equipment Performance / Functional Reliability & Specific Equipment Plans
Plant, Equipment Failure Analysis, RBD Modeling, FMECA, RCM Program Implementation
Focused Lean Six Sigma Certifications for Maintenance and Reliability Professionals
Well versed with RCM Tools & Softwares Weibull 6++, Minitab and Statistica

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Course Description
Reliable operations and maintenance are paramount to overall effectiveness of Process Plant objectives, ensuring minimum downtimes and
maintenance cost optimization. The variety of Equipment such as Gas Turbines, HRSGs, Boilers, Steam Turbines, Generators, heat Exchangers,
Fired Heaters brings certain complexities when identifying problems and conducting the specific maintenance requirements. This 5-day
program is designed to assist the Maintenance management, technicians and engineers in identifying the various Process Plant Operating
Performance and Functional parameters, Process Plant Reliability considerations, and Realiability Tools as part of RCM Program development
and implementations, Criticalities and Failure modes, consequences and mitigation characteristics.
The program is specifically designed for New, Medium Aged and Aged Process Plants and will help participants in developing a Proactive
Maintenance and Reliability program with embedded RCM methodology & implementation for the whole Plant with emphasis on Specific
Equipment plans. Participants will also be provided understanding of Preventive and Predictive Maintenance programs with analysis of
Condition Monitoring data and further corrections in Maintenance Program, introduction of RBIs (Risk Based inspections) for the optimization of
Process Plant Maintenance schedule.
Process Plant Bad actors management programs with emphasis on Trips, Performance variations, Load cycling and its effects, Turnaround
Work-scopes Optimization techniques will supplement the course with Practical exercises.
A thorough insight into the Current Practices GAPS and resolution, Maintenance cost and life cycle analysis will supplement the course.
Remaining Life Assessments, Evaluations and Recommendations and Equipment Repair and Replacement decisions as part of Process plant
objectives will be discussed in depth.
The Asset management model as applied to Plant equipment as part of RCM strategies will also be discussed in detail with reference to
PAS-55 / ISO 55000 recommendations.

Who Should Attend

Process Plant Maintenance Management
- Managers
- Engineers
- Chief Engineers
- Vice Presidents
Maintenance Sta
Maintenance Planning Managers
Maintenance Program Engineers
Reliability Engineers and Managers
Finance and Procurement Managers

Course Benefits

Understanding Performance and Functions GAPs in a Plant

Understanding the Design Concepts of Plants
Plant Major Checks, Rotor, Boiler Assessments
Equipment performance Evaluation throughout Lifecycle
Understanding Life Extension Evaluation and Recommendations
Understanding Equipment Key Maintenance performance Indicators
Plants Bad Actors Management, Analysis
RCM based Reliability Program Development and Implementation Guidelines
Issues in Implementing RCM in a Process Plant
Operational Cost Monitoring and Analysis
Understanding operation, and Maintenance requirements
Criticality Analysis, RBD Modeling
Systems & Equipment Repair vs. Replacement decision
Improved job performance, Decision making capabilities
Technology transfer between participants

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Learning Objectives
After completing this course, participants will be able to understand / conduct:
A-Z of a Plant
Plant Equipment Basic Classifications
Plant Performance and Functional Standards
Advance Maintenance Management in Plant
Eliminate unplanned down time, Improvement In maintenance program
Latest innovations in RCM, FRCA and CM for Modern Plants
Reliability Tools Understanding and Applications
RCM Implementation strategies and Issues resolutions for success
Implement Solutions that reduce the cost per hour of operation
Increasing daily revenue for Process Plant
Optimize performance and efficiency by adopting updates in condition monitoring
Effective reliability program to optimize the performance of the Equipment
RCM based Reliability Program design, Implementation and control for whole plant
Practical Case studies to Evaluate and adopt solutions in Process Plants
Appropriate Analytical tools for maintenance decision making

Training Methodology
The comprehensive training will be facilitated using modern techniques, supported by case studies from real plant environment and
videos. The Analysis tools application to maintenance, reliability and failure analysis will be exercised with mini workshop within the
sessions. Participants are requested to bring their laptops to exercise analysis software with their own plant compressor data. Repair vs.
replacement decisions on specific equipment will also be exercised during training.

Course Agenda
DAY

01

Understanding Process Plant Types and Designs

Performance and Functional Variations on PP Equipment.
Understanding Reliability in Industrial Plant Environment
Plant Reliability Roadmap
Types of Reliabilities, Functional, Performance, Process etc.
Understanding Layers of Protection in Plants, SIL
Mechanical, Electrical & Instrumentation Systems Reliability
Understanding RCM Program and Its Historical Development
Complete Understanding of Maintenance Strategies and Philosophies
DAY

02

Data Sources, Run length data, Run meters, DCS, Operating logs
CMMS, failure data, Notification Text, Operators and Maintainers as sources
Publicly available sources, Performance Standards
Errors in data sources, Independent & Identical conditions
Defining Critical Systems / Equipments / Components.
GTs, Boilers, HRSGs, Generators, Steam Turbines, Heat Exchangers, Fired Heaters, Miscellaneous Systems
Identifying Functions of Critical Systems / Equipment / Components
Criticality Analysis, Review of Plant, FMECA
Performance Vs Functional Reliability
Calculating Reliability, Availability & Maintainability (RAMs Practical Exercises)
Understanding MTBF. MTTR, MTTF, MODT and Weibull Analysis & Shape Factors
Statistical Distribution Fitting to Plant / Equipment Data
Statistical Reliability Program, Understanding Reliability Alert levels (Green, Amber, Red)
Practical Exercises on Process Plant Equipment

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4
DAY

03

Identifying Functional and Performance Failures / Failure Modes, Consequences

29 Steps RCM Process for a Failure Mode
Reviewing the FRCA Studies in Process Plants
Using Cause Mapping, FTA, ETA in Reliability Studies
Identifying Critical TAGS on Process Plant
Maintenance Costing, CAPEX and OPEX vs. LTSAs
Understanding Mitigations like Additional PM Tasks and RBIs
Inventory levels variation with Plant Reliability

DAY

04

Auditing the Existing Preventive Maintenance Program and Reliability Program

Developing a Reliability Block Diagram (RBD Modelling)
Critical Performance and Condition Monitoring TAGs identification for PP Equipment
Understanding Existing Maintenance and Reliability Programs
Developing of Maintenance and Reliability (KPIs) and GAPs Measurement
Weibull Analysis, Analyzing MTBF, MTTR, MTTF for PP Systems/ Equipment
RAM / RBD Model Parameters Evaluation
Understanding Existing SAP History and Review for GAPs

DAY

05

Mechanical, Electrical, Instrumentation and Condition Monitoring PM Task Analysis

Effective use of Maintenance Historical Database
Use of Software in RCM Analysis
RCM Equipment Specific Case Studies (Mini Workshops)
Redefining Maintenance Tasks in Maintenance Strategy
Reliability Improvement in Systems / Equipments / Components
Making RCM a Success Plant Wide, Developing a Culture
Plant Performance, Functional and Financial Gains through RCM
Extending RCM study into RLA study for Plant Systems/ Equipment/ Components
Additional Specific recommendations for Quality and Condition Monitoring for Reliability Success in Plants
Subcontract Repair reliability Vs OEM Repair Reliability
LTSAs (Long Term Services Agreements) Review
Course closure

About BizTree Ventures

BizTree is a Malaysia based company responsible for promoting quality learning in technical and commercial areas, in accordance with international practices. BizTree is dedicated to the
development of professionals in operations, engineering and commercial disciplines through a comprehensive portfolio of technical and management training programs. BizTree oers training
programs as webinars, in-house and public courses, as well as seminars and conferences, for such varied sectors as Aviation, Oil & Gas, Manufacturing, Process and Power Generation.
Formed by professionals with successful track record in related sectors, BizTree has association with internationally recognized and experienced trainers and aspires to become a solutions provider
of choice for all industries globally. BizTree desires to empower you, as our business partners, with in-depth analysis, critical thinking and practical knowledge covering current trends and ideas
supported by world-class trainers who would bring real-life experience to the learning environment.
BizTree Ventures Sdn Bhd | NW-3A-30, Cova Square, Jalan Tecknologi, Kota Damansara, 47810 Kuala Lumpur, Malaysia | Cell: +6012 427 5260 | Email: marketing@biztreeventures.com

For more info, please write to us at: marketing@biztreeventures.com or visit www.biztreeventures.com