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Reliability Improvement Program for Industrial Power Generation

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Save time and money for this course to be conducted in-house at your own convenience. Kindly contact us @ +65 9467 0076 or simin@tun.sg for more information. www.tun.sg EARLY BIRD SPECIALS! Register & pay by 31 December 2011 to SAVE up to SGD500! Reliability Improvement Program and Maintenance Cost Optimization for Process & Power generation Plants This Course emphasizes in detail on the background of Plant Maintenance / reliability Program as part of the Plant asset management and will specifically emphasize on issues related to development, implementation and control of maintenance program with additional emphasis on Plant performance, reliability, Remaining life assessment and Maintenance cost analysis. Asset Management Concept as applied to Plant environment, its systems, structure and components will be discussed in detail. Maintenance strategy and various concepts may reduce cost, but all must be integrated to ensure high reliability levels. Continued compliance with the plant regulatory requirements, while fulfilling the challenges of cost reductions and effective maintenance programs, is of paramount importance. OEMs and Operators should be on the same level of understanding. This course will also provide an insight into such understandings. Within a 5-days period you will be provided with guidance for the implementation of an optimized Maintenance Program and will focus on the monitoring task and the relevance of the efficiency of the Maintenance Program, in order to fulfill the operational requirements and to avoid unnecessary maintenance cost. Case studies with practical examples from Thermal , Combined Cycle and process plants will complement this course . Continuing safe operations is to be delivered by the plant Manufacturer for the establishment of an approved Plant maintenance program and must contain the necessary details, including frequencies, of all maintenance required to be carried out for a safe and economical Plant operation. Implementation of such maintenance program requires the preparation and planning of the maintenance tasks. These tasks are normally based upon the Maintenance Review Board Report and the Manufacturer’s Maintenance Planning Recommendation as detailed in the Maintenance Planning Document (MPD). In order to establish an operator’s maintenance programme, the tasks and periods (interval/ frequencies) at which each part of the plant , system ,components , accessories, equipment, instruments, electrical and communication apparatus, and associated systems and installations should be inspected. Such implementation includes the periods at which items as appropriate should be checked, cleaned, lubricated, replenished, adjusted and tested as well. 12-17 February 2012 Kuala Lumpur Malaysia
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Page 1: Reliability Improvement Program for Industrial Power Generation

Save time and money for this course to be conducted in-house at your own convenience. Kindly contact us @ +65 9467 0076 or [email protected] for more information. www.tun.sg

Early Bird

SpEcialS!

Register & pay by 31 December 2011

to SAVE up to SGD500! Reliability Improvement Program and Maintenance Cost Optimizationfor Process & Power generation Plants

This Course emphasizes in detail on the background of Plant Maintenance / reliability Program as part of the Plant asset management and will specifically emphasize on issues related to development, implementation and control of maintenance program with additional emphasis on Plant performance, reliability, Remaining life assessment and Maintenance cost analysis. Asset Management Concept as applied to Plant environment, its systems, structure and components will be discussed in detail. Maintenance strategy and various concepts may reduce cost, but all must be integrated to ensure high reliability levels. Continued compliance with the plant regulatory requirements, while fulfilling the challenges of cost reductions and effective maintenance programs, is of paramount importance. OEMs and Operators should be on the same level of understanding. This course will also provide an insight into such understandings.

Within a 5-days period you will be provided with guidance for the implementation of an optimized Maintenance Program and will focus on the monitoring task and the relevance of the efficiency of the Maintenance Program, in order to fulfill the operational requirements and to avoid unnecessary maintenance cost. Case studies with practical examples from Thermal , Combined Cycle and process plants will complement this course .

Continuing safe operations is to be delivered by the plant Manufacturer for the establishment of an approved Plant maintenance program and must contain the necessary details, including frequencies, of all maintenance required to be carried out for a safe and economical Plant operation. Implementation of such maintenance program requires the preparation and planning of the maintenance tasks. These tasks are normally based upon the Maintenance Review Board Report and the Manufacturer’s Maintenance Planning Recommendation as detailed in the Maintenance Planning Document (MPD). In order to establish an operator’s maintenance programme, the tasks and periods (interval/ frequencies) at which each part of the plant , system ,components , accessories, equipment, instruments, electrical and communication apparatus, and associated systems and installations should be inspected. Such implementation includes the periods at which items as appropriate should be checked, cleaned, lubricated, replenished, adjusted and tested as well.

12-17 February 2012Kuala Lumpur Malaysia

Page 2: Reliability Improvement Program for Industrial Power Generation

Save time and money for this course to be conducted in-house at your own convenience. Kindly contact us @ +65 8253 1407 or [email protected] for more information. www.tun.sg

S. Nadeem Ahmed has more than Twenty 20 years of industrial experience with career as a Mechanical Engineer with Manufacturing and Engineering MRO Industry. He in experienced in Maintenance Repair, Overhaul, Testing and Evaluation of Turbo Machinery including Aero and Aero derivative Gas Turbine Power Plants . Have worked with various concerns on life extension and evaluation of 1400 MW+, combined cycle power plants and 1600MW+, Thermal Power Plants .

As an expert in Lean Six Sigma, Maintenance programs and Reliability Programs has Provisioned various companies (Power Generation, Oil and Gas, aviation etc) on Effective Reliability Improvement Programs, Maintenance Management Strategies and Programs optimization, Lean Maintenance and Six Sigma Process Improvement Strategies integrating the same with reliability solutions.

As a Global Event Trainer has Trained Number of professionals in Reliability programs, GT Power Plants, Thermal Power Plants, Rotating equipment, Maintenance Management, lean Six Sigma within and outside organization.

He is Masters in Mechanical Engineering with Major in Thermal Power Systems Engineering and Six Sigma Master Black Belt.

Benefits Of Attending This Course During this course the audience will have a deep practical insight into the Plant Maintenance program and optimization of same with effective cost control for the same as this program is executed at floor level. Will acquire a thorough knowledge of all the maintenance documents, Analysis tools and advanced plant life cycle concepts. The reliability requirements in plant environment are getting vide importance and this course will give audience a thorough understanding of Plant Reliability Program with RCM methodologies and practically implementing the same. The course is designed to train the professionals / Plant People on tools and techniques with practical case studies and mini workshops.

• PlantLifecycleUnderstanding• PlantMaintenanceprogramdevelopment• PlantreliabilityProgramImplementationandcontrol• MaintenanceCostcontrol&Optimization• Leanmaintenancemethodologies• Maintenance&reliabilityDataAnalysistoolsandtechniques.• RemaininglifeAssessment

T.U.N International was formed with the objective of truly understanding the needs of each individual organization’s training requirements. Our strength lies in our ability to listen to our clients, understand their unique business issues and assisting them to deliver the appropriate training solution based on the business challenges in the current market situation.

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We deeply value our working relationship with our clients and constantly dedicate ourselves to exceed your expectations of us. Besides customizing in-house training solutions for corporate companies, we also offer public courses and conferences in various industries.

T.U.N In-house Training SolutionsSave up to 40% when you use T.U.N In house Training Solutions to customize in-house training programmes for your organization. Tailor-made training courses, at a venue of your choice and a time convenient to you and at a fraction of the cost. For more information on T.U.N In-house Training Solutions, please contact Ms. Linda Teo at +65 6376 3178 or email: [email protected]

About the orgAnizer

Reliability Improvement Program and Maintenance Cost Optimization for

Process & Power generation Plants12-17 February 2012 • Kuala Lumpur Malaysia

About The Trainer

Who Should Attend • MaintenanceManagement o Managers o Engineers o Chief Engineers o Vice Presidents• MaintenanceStaff• MaintenancePlanningManagers• MaintenanceProgramEngineers• ReliabilityEngineers/Managers

Page 3: Reliability Improvement Program for Industrial Power Generation

Save time and money for this course to be conducted in-house at your own convenience. Kindly contact us @ +65 8253 1407 or [email protected] for more information. www.tun.sg

Day 1Understanding Plant Environment• Process,PlantandPeople• Manpower,Measurement,Materials,Methods• RoleofaPlantinBusinessObjective.• Mission,Visionandvalues.• CorporateBusinessPlansandimpactonPlant

Environment

Understanding Plant Environment• Process,PlantandPeople• Manpower,Measurement,Materials,Methods• RoleofaPlantinBusinessObjective.• Mission,Visionandvalues.• CorporateBusinessPlansandimpactonPlant

Environment

Plant design Objective / Procurement / EPC Issues• DesignrequirementsforaPlant• ProcessPlantsPowerGenerationPlants ~ Thermal Power Plants ~ Combined cycle power plants ~ Boilers, Gas turbines, HRSG, Steam Turbine

and Generators ~ Design trends (Typical machines OEM examples) ~ Critical Plant Equipment, Rotary Kilns, Furnaces

etc ~ Commissioning Phase ~ EPC Issues, Deviation from design ~ OEMs perspective / Owner

Day 2Introduction to Plant Maintenance • MaintenanceOrganizationandexposition• MaintenancePhilosophies/Strategies• AssociatedMaintenanceprocedure• AssetManagementConcept• PAS55-1/PAS55-2understanding• ContentsoftheMaintenanceProgram• TypesofMaintenanceStrategies ~ Gas Turbines, HRSG, Boilers, Steam Turbines,

Generators ~ Critical process equipment, furnaces, distillation

towers etc. ~MiscRotating&StaticEquipment/structures

(BOP)

Plant Life Cycle Understanding• UnderstandingPlantLife(Design)vsActualUseful

life • EffectofPlantMaintenancestrategyonlife• Understandingcriticalityofprocess/equipment

Reliability Improvement Program and Maintenance Cost Optimization for

Process & Power generation Plants12-17 February 2012 • Kuala Lumpur Malaysia

Course OutlineThis course outlines the background of Plant maintenance / reliability program optimization and will specifically emphasize on the cost monitoring and method and steps required for the determination and implementation of the same. Plant asset management strategies will also be discussed in detail.

• RiskAnalysisandLifeextensionevaluationandrecommendations

~ Process, Power Generation Plants ~ Examples, GTs, Steam turbines, Boilers,

Generators, BOP ~ Complete Risk Report example, criticality

Analysis

Day 3Failure Considerations and Analysis• Definitions,Philosophy,FailSafeDesignConcept• SystemConfigurationandRedundancy• NonRedundant/RedundantSinglePath,Parallel,

Multiple Path System• LifeCycleProcess,ClassificationofFailures• MSG,MSG-2andMSG-3MaintenanceProcess

and Decision Logic• RCMReliabilityCenteredmaintenanceprogramin

Plants • FailureEffectCategorization/criticality• Time-to-Failure,Failurescenario’s

Plant Maintenance and Performance Data Collection • PrimesourcesofInformation,TypesofData&

Collection System• ProcessFlowDiagram,ReportsandRepeaters• ComponentRemovalsandFailures,TripsonPlant.• ServiceDifficulty/OccurrenceReport,Structural

Irregularity Report• AnalysisTechniques,SixSigmaTools,Distribution

Fitting for Data• DataDisplayandReporting• PlantPerformanceReport,StatisticsSummary• Statistics,Variations,CriticalFailureReport

Day 4Reliability Programs• ReliabilityAnalysis• UnderstandingaReliabilityProgramImplementation • CostvsROIonreliabilityprogram• PerformanceMeasurementandParameters• MonthlyPlantReliabilityReport ~ Plant, Systems, components, structures, Critical

systems . ~ Critical systems and rotating equipment.• ReliabilityBasedInspections.• MRB,RCBandRRBfunctioning(baselines)• ImplementingRCBrecommendations.

Maintenance Program Implementation• Documents(OEM,MPD,Operatorspecific

Maintenance program, Modification)• PlantOperator’sMaintenanceProgram,General

Requirements

• Scheduled/UnscheduledMaintenance• Task/FunctionCodes• LogisticsandManhourplanningaspects• MaintenanceTaskPackaging ~ Turn around Checks ~ Equalized Programs ~ Phased Programs• MaintenanceTaskCards,Computerized

Maintenance Management Systems• MaintenanceProgramImplementationand

Development ~ Staggered Implementation Plan ~ Service Experience ~ Periodic Review ~ Inspection Interval Escalations ~ Successive reviews and amendments • LeanMaintenanceConceptsandintegrationwith

existing programs.• Efficiency&EffectivenessofmaintenanceProgram• InventoryMonitoringtoSupportMaintenance

Program

Day 5Maintenance Cost• DirectandIndirectCostAssociatedwithPlant• MaintenanceCostBaselines• MaintenanceContracts–CostAspects• MaintenanceCostReporting,DataAnalysis• CostBenefitModel,ChangeProposals• CostAnalysis

Maintenance Organization Exposition • Documents/manuals• OverallExpositionmanual• Engineeringproceduresmanual• Associatemaintenanceprocedures• ReliabilityReports

Plant life extension and Evaluation • DevelopingabaselinestudylevelforPlant• RemainingLifeAssessment• Currentreliabilitylevels/Lastshutdown/

turnaround reports • LifeEvaluationquestionnaire.• Riskassessmentofsystems/components• Recommendationsforlifeextensions,work-scopes• Investmentsintoplantassets.• Casestudy1400MWplantlifeextension.

Case Studies • ReliabilityImprovementProgram(Example)• MaintenancePlanning(CaseStudy/workshop)• MaintenanceCostAnalysis(Workshop)

Page 4: Reliability Improvement Program for Industrial Power Generation

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Reliability impRovement pRogRam and maintenance coSt optimization foR pRoceSS & poweR geneRation plantS 12Th -17Th FebRUaRy 2012KUala lUmpUR malaySIa

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