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Reliability Improvement Program and Maintenance Cost Optimization

for Process & Power generation Plants
12-17 February 2012 Kuala Lumpur Malaysia

Ea r ter Sp ly &p E to c B SA ay b ia ir d VE y 3 up 1 D lS to ec ! S e

GD mb 50 er 0! 20 1

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 Manufacturers Maintenance Planning Recommendation as detailed in the Maintenance Planning Document (MPD). In order to establish an operators 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.

Save time and money for this course to be conducted in-house at your own convenience. Kindly contact us @

+65 94670076 or simin@tun.sg for more information.

www.tun.sg

Reliability Improvement Program and Maintenance Cost Optimization for Process & Power generation Plants
12-17 February 2012 Kuala Lumpur Malaysia

Benefits Of Attending This Course About The Trainer

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. 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. Plant Life cycle Understanding Plant Maintenance program development Plant reliability Program Implementation and control Maintenance Cost control & Optimization Lean maintenance methodologies Maintenance & reliability Data Analysis tools and techniques. Remaining life Assessment

Who Should Attend

Maintenance Management o Managers o Engineers o Chief Engineers o Vice Presidents Maintenance Staff Maintenance Planning Managers Maintenance Program Engineers Reliability Engineers / Managers

About the orgAnizer

T.U.N International was formed with the objective of truly understanding the needs of each individual organizations 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. Our vision is to be the No. 1 preferred training provider for all corporate companies by providing an innovative approach to your training requirements. We facilitate a training solution that is not only cost effective, but tailored to yield maximum benefits. 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 Solutions Save 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: linda@tun.sg

Save time and money for this course to be conducted in-house at your own convenience. Kindly contact us @

+65 82531407 or amutha@tun.sg for more information.

www.tun.sg

Reliability Improvement Program and Maintenance Cost Optimization for Process & Power generation Plants
12-17 February 2012 Kuala Lumpur Malaysia

Course Outline

This 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.

Day 1
Understanding Plant Environment
Process, Plant and People Manpower, Measurement, Materials, Methods Role of a Plant in Business Objective. Mission, Vision and values. Corporate Business Plans and impact on Plant Environment

Risk Analysis and Life extension evaluation and recommendations ~ Process, Power Generation Plants ~ Examples, GTs, Steam turbines, Boilers, Generators, BOP ~ Complete Risk Report example, criticality Analysis

Day 3
Failure Considerations and Analysis
Definitions, Philosophy, Fail Safe Design Concept System Configuration and Redundancy Non Redundant / Redundant Single Path, Parallel, Multiple Path System Life Cycle Process, Classification of Failures MSG, MSG-2 and MSG-3 Maintenance Process and Decision Logic RCM Reliability Centered maintenance program in Plants Failure Effect Categorization / criticality Time-to-Failure, Failure scenarios

Understanding Plant Environment

Process, Plant and People Manpower, Measurement, Materials, Methods Role of a Plant in Business Objective. Mission, Vision and values. Corporate Business Plans and impact on Plant Environment

Plant design Objective / Procurement / EPC Issues

Design requirements for a Plant Process Plants Power Generation Plants ~ 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

Scheduled / Unscheduled Maintenance Task / Function Codes Logistics and Man hour planning aspects Maintenance Task Packaging ~ Turn around Checks ~ Equalized Programs ~ Phased Programs Maintenance Task Cards, Computerized Maintenance Management Systems Maintenance Program Implementation and Development ~ Staggered Implementation Plan ~ Service Experience ~ Periodic Review ~ Inspection Interval Escalations ~ Successive reviews and amendments Lean Maintenance Concepts and integration with existing programs. Efficiency & Effectiveness of maintenance Program Inventory Monitoring to Support Maintenance Program

Plant Maintenance and Performance Data Collection

Day 5
Maintenance Cost
Direct and Indirect Cost Associated with Plant Maintenance Cost Baselines Maintenance Contracts Cost Aspects Maintenance Cost Reporting, Data Analysis Cost Benefit Model, Change Proposals Cost Analysis

Day 2
Introduction to Plant Maintenance
Maintenance Organization and exposition Maintenance Philosophies / Strategies Associated Maintenance procedure Asset Management Concept PAS55-1 / PAS55-2 understanding Contents of the Maintenance Program Types of Maintenance Strategies ~ Gas Turbines, HRSG, Boilers, Steam Turbines, Generators ~ Critical process equipment, furnaces, distillation towers etc. ~ Misc Rotating & Static Equipment / structures (BOP)

Prime sources of Information, Types of Data & Collection System Process Flow Diagram, Reports and Repeaters Component Removals and Failures, Trips on Plant. Service Difficulty / Occurrence Report, Structural Irregularity Report Analysis Techniques, Six Sigma Tools, Distribution Fitting for Data Data Display and Reporting Plant Performance Report, Statistics Summary Statistics, Variations , Critical Failure Report

Maintenance Organization Exposition

Documents / manuals Overall Exposition manual Engineering procedures manual Associate maintenance procedures Reliability Reports

Day 4
Reliability Programs
Reliability Analysis Understanding a Reliability Program Implementation Cost vs ROI on reliability program Performance Measurement and Parameters Monthly Plant Reliability Report ~ Plant, Systems, components, structures, Critical systems . ~ Critical systems and rotating equipment. Reliability Based Inspections. MRB, RCB and RRB functioning (base lines) Implementing RCB recommendations .

Plant life extension and Evaluation

Plant Life Cycle Understanding

Developing a base line study level for Plant Remaining Life Assessment Current reliability levels / Last shutdown / turnaround reports Life Evaluation questionnaire. Risk assessment of systems / components Recommendations for life extensions, work-scopes Investments into plant assets. Case study 1400 MW plant life extension .

Understanding Plant Life (Design) vs Actual Useful life Effect of Plant Maintenance strategy on life Understanding criticality of process / equipment

Case Studies

Maintenance Program Implementation

Documents (OEM, MPD, Operator specific Maintenance program, Modification) Plant Operators Maintenance Program, General Requirements

Reliability Improvement Program (Example) Maintenance Planning (Case Study / workshop) Maintenance Cost Analysis (Workshop)

Save time and money for this course to be conducted in-house at your own convenience. Kindly contact us @

+65 82531407 or amutha@tun.sg for more information.

www.tun.sg

T.U.N International 16 Jalan Kilang Timor, Redhill Forum, #03-07 Singapore 159308 Tel: 65 6376 3175 Fax: 65 6271 9029

Reliability impRovement pRogRam and maintenance coSt optimization foR pRoceSS & poweR geneRation plantS
12Th -17Th FebRUaRy 2012 KUala lUmpUR malaySIa
EvEnt CodE: REIPM12
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Cheque/Bank Draft made payable To: T.U.N INTeRNaTIONal Redhill Forum, 16 Jalan Kilang Timor, #03- 07Singapore 159308 Bank Transfer account Name Bank Name account No Bank No Branch Code Swift Code Bank Address : T.U.N INTeRNaTIONal : OCBC Bank : 569-034796-001 : 7339 569 : OCBCSGSG : 65 Chulia Street, OCBC Centre, Singapore 049513 *Please Quote Ref REIPM12 and Invoice No. Hotel accommodation & travel costs are not included in the registration fee. A reduced corporate room rate has been arranged at the hotel for attendees at this conference. To take advantage of this special rate, please process the hotel room reservation form provided upon confirmation of your attendance.

payment policy

Full payment of course fee to be received by the stipulated date of training, failing which T.U.N INTERNATIONAL will exercise the right to refuse entry to the delegate.

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T.U.N INTERNATIONAL reserves the right to replace or modify the advertised speakers/topics should there be circumstances beyond the control of the organizers before the event. Any changes will be updated on our website as soon as possible.

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