27th 28th April 2014, Inter Continental Hotel. Abu Dhabi.

UAE

RCM based Critical Equipment Maintenance Optimization

Leading-edge practices for operating a state-of-the-art maintenance facility

Key Learning Objectives

1. A-Z of equipment, Basic Classifications. 2. API , ANSI & ASME standards for Equipment 3. Advance Maintenance Management in Process Chain. 4. Eliminate unplanned down time, Improvement In maintenance program. 5. Latest innovations in RCA and CM for rotating equipment. 6. Implement Solutions that reduce the cost per hour of operation 7. Increasing daily revenue for Plant 8. Optimize performance and efficiency by adopting updates in condition monitoring 9. Effective reliability program to optimize the performance of Equipment

Course Overview
Process and Power Plant Equipments play a major role in managing processes across the plant .The Equipment is very expensive to maintain and as such un-schedule events associated with equipment can have high impact on direct and indirect operating cost of plant. This course is designed for professionals to have an insight into equipment maintenance strategies and reliability program, its implementation, control, performance factors, efficiency and uptime with replacement or repair decisions optimization. Maintenance program for equipment whether static or rotating is a proactive and live document and as such need constant review in the light of OEM maintenance planning document and implementation of the same at Operations level .The course is aimed at learning the Maintenance management of equipment with proactive strategy and especial emphasis on Reliability centered maintenance program and its cost effectiveness. The asset management model as applied to various equipments will be discussed in detail with reference to PAS-55 recommendations and ISO 55000 (under development).

Training Methodology
The training will be facilitated using modern techniques & Supported by case studies from real plant environment, Videos. The Analysis tools application to maintenance, reliability and failure analysis will be exercised with mini workshop within the sessions. The audiences are requested to bring their laptops to exercise analysis softwares with their own plant data. Repair vs. replacement decisions on specific equipment will be exercised within sessions.

Benefits of attending the course

Improved job performance, Decision making capabilities. Understanding the Design Concepts of Plant Equipment Equipment performance Evaluation throughout life Cycle Understanding Life Extension Evaluation and Recommendations Understanding Equipment Key performance Indicators Maintenance Reliability Program Implementation for Plant Equipment Operational Cost Monitoring Understanding operation, and maintenance requirements Equipment Repair vs Replacement decision Technology transfer between participants

What Attendees are saying?

1. This course gave me ideas I can implement immediately and gain immediate results. 2. The best seminar I have ever attended! 3. The instructor displayed a sound proficiency in the subject matter and was able to teach it effectively. 4. Your upbeat teaching style kept our whole class on their toes. Definitely recommend this seminar to any company looking to get a handle on their Maintenance.

Be proactive. Join us for two days of best-in-class, cross-industry case studies including:
1. The comprehensive case studies for various equipment form Process and power generation will supplement this course. 2. Advanced failure analysis tools (six sigma) and techniques as applied in Industrial Plants will be given a thorough insight. 3. Performance calculations for various equipment and interpretation of parameters will be addressed in detail.

Lean Six Sigma Tools and Applications

For Registration:
Tel: +60 3 20274751 Fax: +60 3 7865 1533 Email:waseem@mawaevents.com web: www.mawaevents.com

Course Contents
Day 1
Overview of Plant Equipment Types of Equipment Static vs Rotating Special purpose Equipment Plant systems , components Compressors , Gas Turbines ,Fans Motors , Heat Exchangers , Boilers , HRSG Generators etc Application of Equipment and their part in your process chain Importance of Equipment as an Asset in Plant Videos Design, Operation and Total Cost Optimization Plant as an Asset , Key Asset Management Strategies Basic design of equipment static and Rotating Structure and operation of critical equipment Equipment Condition Monitoring Techniques Test & Inspection ,Inspection Data Gathering Vibration Analysis ,Thermal techniques Oil Analysis , Wear Debris Detection Online Monitoring of CBM data Performance Monitoring and Analysis Other methods & Latest Developments Example , Advanced Gas turbine Technology Example , HRSG Heat recovery steam generator Plant Equipment issues Balancing Issues for Rotating Equipment Lubrication Selection Vibration Issues in Rotating Equipment Equipment Fatigue and Failure Modes Causes of Fatigue and failures Aerofoil / Impeller failures in Turbo Machinery Failure Videos Root Cause Failure Analysis Process , Failure Reporting Cause behind the cause Reliability improvement Program for Plant Equipment Use of Six Sigma tools and Methodologies Equipment Maintenance KPIs /Overhauling Work-Scopes Cost per hour of Operation Restoration Work scoping Minimum Cost Mid and Final Overhaul MTBO , MTBUR , MTTF Considerations Lean Maintenance concepts Reliability, Availability, Maintainability, and Safety Impact of special and common cause variation on RAMS Work-Scope example of Gas turbine in LNG Applications Special Applications Reliability Consideration LNG Trains Power Generation Plants Oil Platforms Petrochemicals / refineries Process Plants , Cement , Fertilizer Rotating Equipment Reliability Programs in Applications More Performance & Failure Videos Gas Turbines , Contained / Un-Contained Pumps , Compressors , Fans & Wind Mills Aviation Disasters due Rotating equipment Insurance issues

Maintenance Issues for Equipment (General) Life Cycle / Bath Tub Curve Optimizing Operation over Lifetime Optimizing Reliability of plant Equipment Life cycle operating cost ,Cost impact calculations Maintenance Cost Key Performance Indicators Key maintenance issues with plant equipment Maintenance Management o Maintenance Planning & Scheduling for plant Equipment o Maintenance Supervision / Skill Enhancement o Working with external vendors versus self-maintenance o Types of Maintenance and its Implications Plant Equipment Integrity Management Statutory, Safety, Operating and Maintenance Standards API , ASME and ANSI standards for plant equipment Documentation and Record Keeping requirements

Course Contents
Day 2: Reliability Program for Plant Equipment Reliability Programs The RCM Process and Method Forecasting and predicting the failures o RCM Programs and Gains o Reliability Program elements , Implementation and Control o RCM Exercises ,Reliability Analysis o Understanding a Reliability Program Implementation o Cost vs ROI on reliability program Day o 1 Performance Measurement and Parameters Overview of Plant o Monthly PlantEquipment Reliability Report Plant, Systems, components, Types of Equipment structures, Critical systems. Staticand vs Rotating Criticalsystems rotating Special purpose Day 2 equipment. o Reliability Based Inspections. o MRB , RCB and RRB functioning ( base Reliability lines )Program for Plant Equipment o Implementing RCB recommendations. Reliability Programs The Program RCM Process and Method Maintenance Implementation Documents ( OEM , MPD , Operator specific Maintenance program, Modification) o Plant Operators Maintenance Program , General Requirements o Scheduled/Unscheduled Maintenance o Task / Function Codes ,Logistics and Man hour planning aspects o Maintenance Task Packaging Turn around Checks , Equalized Programs ,Phased Programs o Maintenance Task Cards , Computerized Maintenance Management Systems o Maintenance Program Implementation and Development Staggered Implementation Plan Service Experience, Periodic Review Inspection Interval Escalations Successive reviews and Course approach: amendments o o o o Lean Maintenance Concepts and integration with existing programs. Efficiency & Effectiveness of Equipment maintenance Program Inventory Monitoring to Support Equipment Maintenance Program

Equipment Maintenance work scopes o o Work-scope planning guides ( OEMs) Work-scope Examples Gas Turbines , HRSG ,Steam Turbines , Generators , general Equipment Understanding work-scope cost HARD / SOFT time threshold for Rotating Equipment

o o

Economic life of Capital equipment o o EPC issues Operation and Maintenance economics Direct and Indirect Cost Associated with Plant Maintenance Cost Baselines Maintenance Contracts Cost Aspects Maintenance Cost Reporting Life cycle cost analysis Life extension and evaluation for plant Repair vs Replace ,Lease vs Buy-in LTSAs

o o o o o o

Selection of Plant Equipment Process Considerations Maintenance consideration , Cost ASME . ANSI , API Codes Long and Short term Agreements Maintenance Service Offerings Best Mix of Qualities Conclusions Q/A

This course aims to provide audiences with

A clear methodology applicable to all relevant organisations Industry standard terminology and content Methodology and tools that is consistent with the entire business case

Consultant Profile:
SYED NADEEM AHMED 22 years of diverse engineering experience in Industrial sectors. For the past 17 years working with PIA Engineering MRO facility on Maintenance Repair & Overhaul of Turbo Machinery. Diversified Experience on GE, Rolls Royce and Pratt & Whitney Gas turbine Engines. Present assignments include the Reliability Program Implementation, review and control for Maintenance Program. He is Six Sigma Master Black Belt from FBE LLC USA. Well versed with Reliability Analysis Tools, RCFA, RCM and Reliability Analysis Software weibull 6+, Minitab R15 Six Sigma Analysis software. Hands on experiences Certification Class I Approval 2.4A14 for CFM56-3B2 Gas Turbine PP. GEs GE90-94B, GE90-115B and CF6-80C2A8 Engines FAM Power Plant Engineering from General Electric ,

Productivity is never an accident. It is always the result of a commitment to excellence, intelligent planning , and focused effort . Paul J. Meyer
For Information / Registration
Waseem Shahzad Director Sales & Marketing MAWA EVENTS SDN BHD Trusted in delivering Excellence Tel: +60 3 20274751 Fax: +60 3 7865 1533 Web: www.mawaevents.com Email:waseem@mawaevents.com