An Approach To Reliability

As part of the ongoing development of ADGAS workforce, a7 days training workshop on Machinery Maintenance Best Practices was delivered from 21st to 27th Sept 2011 by Forsthoffer Associates Inc. USA jointly with Dresser Rand Middle East. It was the first of its kind to be delivered in DAS Island for18 maintenance personnel. Success of the workshop was a result of close cooperation and coordination of Mr. Fahim Ud Din Dy. VP, General Technical Services Team and ADGAS Training Center under the leadership of Moosa Al Murawwi (ML&D) & Mr. Gavin Harrison (TTTL). ADGAS management is well aware about the factors responsible for machinery down time and its effect on the reliability and profitability of the system. It is one of the key objectives of ADGAS to keep equipment operating at peak reliability and company functioning more profitably through reduced maintenance costs and increased productivity and capacity. A company might have technicians with vast experience and variety of exposures, but unless best practices are made a day to day habit the expected results can never be reached. Effective maintenance is not magic, nor is it dependent on exotic technologies or expensive instruments or systems. Instead, it is dependent on doing simple, basic tasks that will result in reliable plant systems. Preventive & Predictive Maintenance are the most important routine functions that maintenance personnel can accomplish. The two main elements of fixed interval preventive maintenance are procedure and discipline. Procedure means that the correct tasks are done, the right lubricants applied, and consumables replaced at the best interval. Discipline requires that all the tasks are planned and controlled so that everything is done when it should be done. Both these areas deserve attention.
OBJECTIVES OF THE WORKSHOP

The workshop was a joint approach by Forsthoffer Associates (FAI) and Dresser Rand (DR) companies with the following objectives. To optimize plant personnel awareness of:

Machinery function Design Assembly/disassembly Tolerances for optimum machinery safety and reliability

COURSE INSTRUCTORS

The workshop was carried out with the support of Adgas Training center, two Trainers from Adgas Training Center Mr.Peter Arokiadoss and Mr. Abdul Sami Abdul Latif were scheduled to assist the class room and hands on training sessions. On behalf of FAI & DR following three Instructors took the lead. Mr. Budimil Klen ADGAS mechanical trainer provided behind the screen support. (1) WILLIAM (BILL) E. FORSTHOFFER, Has experience of world famous companies like De-Laval Turbine company, Mobil research & development corporation (MRDC), many assignments in world class companies of Saudi Arabia. Bill has demonstrated great achievements in design, maintenance solutions and reliability optimization of rotating equipment during his global career. He finally found his own company called Forsthoffer Associates with the companys objective The optimization of rotating equipment safety through understanding and vendor-user communication. (2) MICHAEL FORSTHOFFER A RIT mechanical Engineering graduate, has been working with rotating equipment since 1998.he has worked on FAIs assignments for Corpus Christi refinery Texas, Saudi Aramco, Alberta Envirofuels, Methanex Canada, Dresser rand, Dakota gassification, John Crane. (3) NABIL AL ATASSI Has over 35 years of oil & gas experience as mechanical engineer initially in Syria then worked for ADCO Abu Dhabi UAE. His assignments include Maintenance, troubleshooting and overhaul of a wide range of rotating and static equipment. He is presently working as Training manager for Dresser Rand and is responsible for providing training in Middle East and North Africa. WORKSHOP The first day of the 7 day workshop was devoted to discussion and review of the critical machinery related best practice Dos and Dontss. It had been a fruitful session that involved the participation of the working & learning technicians. The first day really opened the minds and made the technicians realize the importance of simple practices that results in great outputs. Participants were divided into four groups and throughout the seven days sessions the four groups performed hands on tasks and discussions. Important sessions had been on Bare shaft measurements and checks, Bearing Installations best practices, Oil

condition monitoring, Steam Turbine carbon seal installation, Compressor disassembly safety & emergency procedures. Major part of the workshop was Dresser Rand compressor strip down, inspection/measurements and Reassembly. The course was well appreciated by the participants as something very useful and relevant. The standards and recommendations mentioned in the manuals were meticulously adhered to so that the maintenance practice carried out in ADGAS results in reduced machinery down time and less shutdowns & trips. The workshop concluded in presence of Mr. Jose Manrique (Maintenance Manager) and Mr. Gavin Harrison (Technical training team leader) who reiterated the importance of the best practices which lead to higher reliability, efficiency and profitability. They congratulated and awarded certificates to the participants.

(Written by Abdul Sami Abdul Latif & Peter Arokiadoss, the photographs may be selected based on the space arrangement in the magazine)