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RELIABILITY ENGINEERING

FOR PROCESS & POWER GENERATION PLANTS


RCM BASED MAINTENANCE RELIABILITY PROGRAM UNDERSTANDING,
DEVELOPMENT & IMPLEMENTATION.
COURSE DURATION: 5 DAYS
Comprehensive Practical Course on Reliability Engineering with RCM Program Development,
Implementation and Optimization in Process and Power Plants with Customer Specific
Equipment Reliability Considerations for GTs, STs, HRSG, Boilers, Generators, Transformers,
Fired Heaters, Heat Exchangers, Pumps, Compressors, Motors, Piping, Instrumentation and
Control Systems, BOPs.

KEY FOCUS :
Maintenance Cost Reduction with Risk Based
Maintenance
Optimizing PM / PDM / Corrective Maintenance
Ratios
Reliability Tools and Applications
Guide Lines for Practical RCM
Development and Implementation

Program

Performance and Functional Based Maintenance


& Reliability Programs

Remaining Life Assessment and Evaluations


Major Checks, Critical Equipment Assessments
and Recommendations
Customized
HRSGs

Model

specific

Gas

turbines,

Heat
Exc ha ng e r s ,
Bo il e r s ,
P um p s ,
Compressors, Motors, Steam Turbine, Control
Systems, MOVs, Auxiliaries etc.
Discussions LTSA Reviews and Subcontract
Repair Analysis.

REACH US Today for Greater Safety, Quality, Reliability, Productivity, Profitability


HRD Approved Class A Training Provider (since Year 2002). Registered with Ministry of Finance

Reliability Engineering For Process & Power Generations Plants

COURSE DESCRIPTION
Process and Power Plants reliable operations and Maintenance are
paramount to overall effectiveness of plant business 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,
Pumps, compressors, Motors, 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 and Power Plant Operating Performance and Functional
parameters, Plant Reliability considerations, and Reliability Tools as
part of RCM Program development and implementations, Criticalities
and Failure modes, consequences and mitigation characteristics.

WHO SHOULD ATTEND?

The program is specifically designed for New,


Medium Aged, and Aged Process & Power Plants.

Process and Power Plant


Maintenance Management

It 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

Managers
Engineers
Chief Engineers
Vice Presidents

Condition Monitoring data and further corrections in Maintenance

Maintenance Staff

Program, introduction of RBIs (Risk Based inspections) for the

Maintenance Planning
Managers

optimization of Process Plant Maintenance schedule.


Process and Power Plant Bad Actors management programs
with emphasis on Trips, Performance variations, Production
Load

cycling

its

effects,

Turnaround

Work-Scopes

Optimization techniques will supplement the course with


Practical exercises.

Maintenance Program
Engineers

Reliability Engineers /
Managers

Finance and Procurement


Managers

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
and Power Plant objectives will be discussed in depth.
The Asset management model as applied to Plant equipment as part
of RCM strategies will be discussed in detail with reference to PAS55 / ISO 55000 recommendations.

www.facebook.com/IDCTrainingHouse
www.idc-training.com
info@idc-training.com
+603-8061 5126 / 8061 8720
No.7, Unit 8, Jalan Industri PBP 3, Taman Industri Pusat Bandar Puchong, 47100 Puchong, Selangor, Malaysia.

Reliability Engineering For Process & Power Generations Plants

COURSE BENEFITS
Understanding Performance and Functions GAPs in a Plants
Understanding the Design Concepts of Plants
Plant Major Checks,
Equipment Plans

Rotor,

Boiler

Assessments,

Critical

Equipment performance Evaluation throughout life Cycle


Understanding Life Extension Evaluation and Recommendations
Understanding
Indicators

Equipment

Key

Maintenance

performance

Plants Bad Actors Management, Analysis


RCM based Reliability Program Development and Implementation
Guidelines
Issues in Implementing RCM in a Process and Power Plant
Operational Cost Monitoring and Analysis
Understanding Operation, and Maintenance requirements
Criticality Analysis, RBD Modelling
Systems & Equipment Repair vs. Replacement decision
Improved job performance, Decision making capabilities
Technology transfer between participants

LEARNING OBJECTIVES
After completing this course, participants will be able to understand:
A-Z of a Process and Power 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
success

Issues resolutions for

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 and Power Plants

Appropriate Analytical tools for maintenance decision making

www.facebook.com/IDCTrainingHouse
www.idc-training.com
info@idc-training.com
+603-8061 5126 / 8061 8720
No.7, Unit 8, Jalan Industri PBP 3, Taman Industri Pusat Bandar Puchong, 47100 Puchong, Selangor, Malaysia.

Reliability Engineering For Process & Power Generations Plants

COURSE OUTLINE
DAY 1
Plant RCM Approach & Data Requirements

Understanding Process and Power Plant Types and Designs


Performance and Functional Variations on Process and Power
Plant 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

Data Sources, Run length data, Run meters, DCS, operating


logs

CMMS, failure data, Notification Text, Operators and


Maintainers as sources

Publicly available sources, OREDA, IEEE


Errors in data sources, Independent & Identical conditions
Defining Critical Systems / Equipment / Components
GTs, Boilers, HRSGs, Generators, Steam Turbines, HEs, Fired
Heaters, Misc. 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

www.facebook.com/IDCTrainingHouse
www.idc-training.com
info@idc-training.com
+603-8061 5126 / 8061 8720
No.7, Unit 8, Jalan Industri PBP 3, Taman Industri Pusat Bandar Puchong, 47100 Puchong, Selangor, Malaysia.

Reliability Engineering For Process & Power Generations Plants

DAY 2
Plant Life Cycle and Failure Analysis (Performance and
Functional Based)

Understanding Bath Tub Curve


Statistical Distribution Fitting to Plant / Equipment Data
Statistical Reliability Program, Understanding Reliability Alert
levels (Green, Amber, Red)

Practical Exercises on Process Plant Equipment


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 3
Maintenance and Reliability Program Development &
Optimization

Auditing the Existing Preventive Maintenance Program and


Reliability Program

Developing a Reliability Block Diagram (RBD Modelling)


Critical Performance and Condition Monitoring TAGs
identification for Process Plant Equipment

Understanding Existing Maintenance and Reliability Programs


PM vs PDM vs RTF strategies
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

www.facebook.com/IDCTrainingHouse
www.idc-training.com
info@idc-training.com
+603-8061 5126 / 8061 8720
No.7, Unit 8, Jalan Industri PBP 3, Taman Industri Pusat Bandar Puchong, 47100 Puchong, Selangor, Malaysia.

Reliability Engineering For Process & Power Generations Plants

DAY 4 & 5
RCM program Development & Roll Out, Software
Requirements, LTSA

Mechanical, Electrical, Instrumentation and Condition Monitoring


PM Task Analysis

Effective use of Maintenance Historical Data Base, OREDA


Use of Software in RCM Analysis
RCM Equipment Specific Case Studies (Mini Workshops)
Redefining maintenance task in Maintenance strategy for GAPs
elimination

Reliability Improvement in Systems / Equipment / 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 Agreement) Review
Conclusions
TRAINING METHODOLOGY
The training will be facilitated using modern techniques, supported
by case studies from real Process and Power Plant environment and
videos. The

Analysis tools application to

plant 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 data. Repair vs.
replacement decisions on specific equipment will be exercised during
the course.

www.facebook.com/IDCTrainingHouse
www.idc-training.com
info@idc-training.com
+603-8061 5126 / 8061 8720
No.7, Unit 8, Jalan Industri PBP 3, Taman Industri Pusat Bandar Puchong, 47100 Puchong, Selangor, Malaysia.

TRAINERS PROFILE

S. NADEEM AHMED
Nadeem has a diverse professional engineering experience
of more than 25 years in various industrial sectors
including Aviation, Power Plants and Petrochemicals. His
Key Specialties in Consulting, Training & Development as a

POWER PLANT
PROJECTS

Mechanical Power Engineer includes:

Power Plant Lumut, Risk Based


Assessment and Remaining Life

Process, Power Generation Plants & Aviation

Study evaluation and

Life Cycle Asset Management Strategies


Asset Management Standards Implementations
RCM based Maintenance & Reliability Program development

Recommendation

Hunts Town 225 MW Combined


Cycle Power Plant Ireland, Risk

and implementation.

Reliability Analysis & Risk Based Studies


Remaining Life Assessment Studies, Evaluation, Extension

Based Assessment and Remaining


Life Study evaluation and

Recommendations

Recommendation

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
Reliability & Specific Equipment Plans

Malakoff 1400 MW Combined Cycle

Functional

Reliability Performance and


Improvement Program
Development and Implementation
in Power Plants

Plant , Equipment Failure Analysis , RBD Modeling , FMECA ,


RCM Program Implementation
RAM / RCM Study for Plants, Units, Systems
Focused Lean Six Sigma Certifications for Maintenance and
Reliability Professionals
Well versed with RCM Tools & Softwares Weibull 6++, Minitab
and Statistica

www.facebook.com/IDCTrainingHouse
www.idc-training.com
info@idc-training.com
+603-8061 5126 / 8061 8720
No.7, Unit 8, Jalan Industri PBP 3, Taman Industri Pusat Bandar Puchong, 47100 Puchong, Selangor, Malaysia.

TRAINERS PROFILE

S. NADEEM AHMED
TECHNICAL EXPERIENCES

PARTIAL CLIENTELE

CONSULTANCIES PARTICIPATED AS PROJECT

(FOR IN-HOUSE
CONSULTANCY / TRAINING)

Combined Cycle Power Plant Risk Assessment Evaluation,


Remaining Life Study and Life Extension Recommendations

Abu Dhabi Company for Onshore


Oil Operations (ADCO)

LTSA Evaluation for Combined Cycle and Thermal Power


Plants

Abu Dhabi Marine Operating


Company, ADMA-OPCO

Alstom GT13E2, Mitsubishi MHI 7001, Siemens V93.4, GE


Frame Machines including Frame 7, 9

Abu Dhabi National Oil Company


(ADNOC) - GASCO

Maintenance and Reliability Program Development and


Optimization

SCECO Kingdom of Saudi Arabia

Malakoff Power Plant

Power Plant Maintenance, Performance and Life Cycle


Management

ARAMCO KSA
SABIC KSA

Plant Critical Equipment Maintenance, Reliability and


Replacement Decisions

Petro Vietnam

Gas Turbine, Design, Upgrades, Operation and Maintenance

Riyadh Cement KSA

Gulf Drilling Company

Risk Assessment for Gas turbines in CCGTPPs

Qatar Gas

Overhaul Scope Optimization for Gas Turbines in CCGTPPs

Iraqi Petroleum

Power Plant RCM program development Implementation

KESC Karachi Electric Supply


Corporation

YTL Power Corp

Hunts Town Power Plants Ireland

Shell Philippines

www.facebook.com/IDCTrainingHouse
www.idc-training.com
info@idc-training.com
+603-8061 5126 / 8061 8720
No.7, Unit 8, Jalan Industri PBP 3, Taman Industri Pusat Bandar Puchong, 47100 Puchong, Selangor, Malaysia.

REGISTRATION FORM

RELIABILITY ENGINEERING FOR PROCESS & POWER


GENERATION PLANTS
DATE: 25-29 JUL 2016
TIME: 8:30AM5:30PM

VENUE: IDC Training House, No. 7, Unit 8, Jalan Industri PBP 3,


Taman Industri Pusat Bandar Puchong, 47100 Puchong, Selangor, Malaysia.

PARTICIPANT DETAILS1
Full Name (as per IC/Passport):
________________________________________
Email:
________________________________________
Job Title:
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FEE (Please tick your preferred option)


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Mobile No.:
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[ ] Self Sponsored
[ ] Sponsored by Company

PARTICIPANT DETAILS2
Full Name (as per IC/Passport):
________________________________________
Email:
________________________________________
Job Title:
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Salutation:
______________________
Mobile No.:
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[ ] Self Sponsored
[ ] Sponsored by Company

PARTICIPANT DETAILS3
Full Name (as per IC/Passport):
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Email:
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NORMAL FEE

SAVE MORE
with Group Rate!
(3 Pax or More)

[ ] RM 5,900 / USD 2,000


per pax

Prices include lunches, refreshments, and


course materials

Course fee is subject to 6% Goods and


Services Tax (GST) according to the Malaysian
Government law.
AUTHORIZATION

Salutation:
______________________
Mobile No.:
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[ ] Self Sponsored
[ ] Sponsored by Company

[ ] RM 6,200 / USD 2,100


per pax

*Compulsory if sponsored by company

Signatory must be authorized to sign on behalf


Name
: _____________________________
Job Title : _____________________________
Signature : _____________________________
Date
: _____________________________
Company Stamp:

INVOICE DETAILS
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* This registration is invalid without signature & company stamp.

FINANCE DEPARTMENT CONTACT DETAILS

DISCLAIMER

Name : ________________________________ Direct Line:


Email
: ________________________________ ______________________
Job Title : ________________________________

1) IDC Training House Sdn Bhd reserves the


right to cancel or make alternative
arrangements to the course content, date,
trainer, venue & course fee if the needs arise
due to unforeseen circumstances.
2) Fee does not include any taxes (withholding
or otherwise). In case of any taxes applicable,
the client has to ensure that the taxes are
paid on top of the investment fee paid for the
course. Compliance with the local tax laws is
the responsibility of the client.

METHOD OF PAYMENT (Please tick your preferred option)


[ ] BY CASH
* 50% down payment is required in order to secure the seat.
[ ] BY CREDIT CARD
* 50% down payment is required in order to secure the seat.
* Visa/Master card only. 2% surcharge based on total invoice value.
[ ] BY CHEQUE
* Made payable to IDC Training House Sdn Bhd.
* Cheque payment will only be accepted if received NOT LESS than 7
working days before training date. Full prepayment via cheque will only
be acknowledged upon clearance by the bank.
[ ] BY BANK TRANSFER
* Seat is confirmed only upon payment received with remittance slip
(quoted with invoice number).
* All bank charges to be borne by payer. Please ensure that IDC Training
House Sdn Bhd receives the full invoiced amount.
CURRENCY

BANK ACCOUNT DETAILS


Account holder: IDC TRAINING HOUSE SDN BHD

[ ] MYR
(Malaysian Ringgit)

Bank
: Ambank (M) Berhad
Account No : 091-201-200378-6
Swift No
: ARBK MYKLXXX

[ ] USD
(United States
Dollar)

Bank
: OCBC Bank (M) Berhad
Account No : 786-113201-4
Swift No
: OCBCMYKLXXX

To REGISTER, please EMAIL this form to info@idc-training.com


or FAX to +603-80687720
For more INFO, please call +603-8061 5126 / 8061 8720

REGISTRATION & CANCELLATION POLICY


1) Seat is confirmed only upon receiving
Registration Form with Proof of Payment.
Verbal or written request to reserve seat will
not be entertained.
2) Any cancellation/amendment must be
received in writing. Otherwise, full course fee
will be charged accordingly. Verbal notice
alone will not be entertained.
3) For any cancellation received in writing less
than seven (7) working days prior to the
course date, or no-show, client is liable to pay
the full course fee and NO REFUND will be
granted. Replacement of delegate to same
training session is allowed at no extra charges.
4) For any cancellation received in writing NOT
less than seven (7) working days prior to the
course date, full refund will be granted, with
less RM 150 administrative fee and any
related bank or credit card charges.
5) For any postponement received in writing less
than seven (7) working days of the training
course, client is liable to pay 50% of course
fee as a penalty on late notice.

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