Plant & Equipment Failure Root Cause Analysis

13 - 17 May 2013, Kuala Lumpur 19 - 23 May 2013, Abu Dhabi

About The Trainer

Mr. S.Nadeem Ahmed has 20 years plus of diverse engineering experience in Industrial sectors as a Mechanical Engineer with Manufacturing and Engineering MRO Industry. For the past 15 years, he has worked with PK Engineering MRO facility on Maintenance Repair, Overhaul, Testing and Evaluation of Turbo Machinery including Aero and Aero derivative Gas Turbine Power Plants and has diversified experience on General Electric, Rolls Royce and Pratt & Whitney Machines. As an international conference speaker & trainer globally addressing Gas Turbine Power Plants, Rotating equipment, Reliability engineering & lean Six Sigma topics, he has also trained numerous professionals in the same area within and outside his organization. Nadeem has also provisioned Process companies (Power Generation, Oil and Gas etc) on Effective Reliability Improvement Programs, Maintenance Management Strategies, Lean Maintenance and Six Sigma Process Improvement Strategies integrating the same with reliability solutions. He holds a Masters in Mechanical Engineering with Major in Thermal Power Systems Engineering, is a Certified Six Sigma Master Black Belt from USA & is well versed with the Quality, Six Sigma and Power Plant Equipment Reliability Analysis Softwares.

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.

TEL: +65 6376 3129 FAX: +65 6271 9029 EMAIL: SUE@TUN.SG ONLINE: WWW.TUN.SG

Plant & Equipment Failure Root Cause Analysis

13 - 17 May 2013, Kuala Lumpur 19 - 23 May 2013, Abu Dhabi

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 unscheduled events / failures 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 failure analysis, and aligning maintenance strategies and reliability program to control the same ensuring performance factors, efficiency and uptime. The maintenance strategies and philosophies if not effectively controlled may result in failures which are difficult to control as such there is a strong need in plant environment to perform a thorough failure analysis through an established system . This course is designed to understand the concepts of Failure modes and analysis associated with plant critical as well as non critical equipments with redefining the existing Maintenance and reliability programs for the mitigation of same in future. In depth understanding of various types of failures associated with equipment, their associated cost , and advanced analysis tools in software will be supported by case studies . The economic and safety aspects as per RCM philosophy will supplement the course. The comprehensive failure case studies for various equipment from Process and power generation viz Gas turbines, compressors , pumps , heat exchangers , HRSGs . Steam turbines, Fans , Conveyors etc will be discussed in detail . Advanced failure analysis tools and techniques as applied in Industrial Plants will be given a thorough insight. Performance parameters and associated variations due impending failure for various equipment and their interpretation will be addressed in detail.

Benefits & Learning Objectives

Understanding Industrial Plant Equipment Basic Classifications. Functional criticality Performance and functions degradation API , ANSI & ASME standards for Equipment Maintenance program efficiency and effectiveness Equipment Failure Modes and Consequences Understanding failure Analysis, tools and techniques. Detailed understanding of FMEA , ANOVA , RCM Advanced Data Analysis as applied to plant Equipment . Latest innovations in FRCA and CM for rotating equipment . Developing Specific equipment plans in view of failure history . Implement Solutions such as FRACAS and reduction in Main Cost. Increasing daily revenue for Plant reducing failures . Optimize performance and efficiency by learning from condition monitoring Integrating the reliability program, maintenance Program and failure analysis of equipment .

Practical Case studies to Evaluate and adopt solutions in industries Appropriate Analytical tools for maintenance decision making

Who Should Attend

Maintenance Management Managers Engineers Chief Engineers Vice Presidents Maintenance Staff Maintenance Planning Managers Maintenance Program Engineers Reliability Engineers / Managers Reliability Engineers Finance and procurement people

Training Methodology
The training will be facilitated using modern techniques . Supported by case studies from real plant environment , Videos . The failure Analysis tools application to various types of Industrial Equipment will be exercised with mini workshop within the sessions . The audience are requested to bring their laptops to exercise failure analysis software with their own plant data .

Compressors , Gas Turbines ,Fans Motors , Heat Exchangers , Boilers , HRSG Generators , fans , Structures etc Application of Equipment and their part in your process chain Importance of Equipment as an Asset in Plant Design for Performance and Zero breakdown Videos

Day 1
Overview of Process Plants Types of Plants Process , Power Generation , Manufacturing Asset Management Special Facilities , LNGs Plant Economics a basic Insight Role of Equipment in Process Chain How plant equipment fail Videos Overview of Plant Equipment Types of Equipment Static vs Rotating Special purpose Equipment Plant systems , components

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 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 Maintenance Planning & Scheduling for plant Equipment Maintenance Supervision / Skill Enhancement Working with external vendors versus self-maintenance Types of Maintenance and its Implications on equipment Failures. Unscheduled Events and Non Routine Maintenance ( failures)

TEL: +65 6376 3129 FAX: +65 6271 9029 EMAIL: SUE@TUN.SG ONLINE: WWW.TUN.SG

Plant & Equipment Failure Root Cause Analysis

Day 2
Plant Equipment Integrity Management Statutory, Safety, Operating and Maintenance Standards API , ASME and ANSI standards for plant equipment Documentation and Record Keeping requirements Auditing and Analysis of operating management systems Equipment Condition Monitoring for understanding failures 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 Root Cause Failure Analysis Introductory Concepts Root cause failure analysis philosophy The four-step problem solving approach The importance of a priori failure cause identification Pareto analysis Identifying potential root causes Why analysis Blending root cause analysis approaches Pareto analysis Fault tree analysis (FTA) Event and causal factor analysis (ECFA) Barrier analysis Management oversight and risk tree analysis (MORT) Change analysis , Critical incident technique (CIT) The 5-Whys technique Fault tree analysis introduction FMEA ( failure modes and Effects by Analysis ) Systematic Approach FRACAS

Day 4

13 - 17 May 2013, Kuala Lumpur 19 - 23 May 2013, Abu Dhabi

Reliability Programs The RCM Process and Method Forecasting and predicting the failures RCM Programs and Gains Reliability Program elements , Implementation and Control RCM Exercises , 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. Effectivity of Maintenance Program & Reduction In failures Documents ( OEM , MPD , Operator specific Maintenance program, Modification) Plant Operators Maintenance Program , General Requirements 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 Equipment maintenance Program Inventory Monitoring to Support Equipment Maintenance Program

Day 3
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 Integrating Equipment Maintenance KPIs and Equipment Failures Modes 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 of Failure Analysis Tools Discussions. 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

Day 5
Equipment Maintenance work scopes & Implications on Failure Modes 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 Setting RBIs for failure prediction and Trends Economic life of Capital equipment / failure Implications EPC issues Operation and Maintenance economics Direct and Indirect Cost Associated with Plant Maintenance Cost Baselines Maintenance Contracts Cost Aspects Maintenance Cost Reporting Failure Costs Trends in Life Cycle of Plant Life extension and evaluation for plant The Risk equation and decisions Repair vs Replace ,Lease vs Buy-in LTSAs and Failure Warranties / Insurances Conclusion

TEL: +65 6376 3129 FAX: +65 6271 9029 EMAIL: SUE@TUN.SG ONLINE: WWW.TUN.SG

Plant & Equipment Failure Root Cause Analysis

13 - 17 May 2013, Kuala Lumpur 19 - 23 May 2013, Abu Dhabi 4 EASY WAYS TO REGISTER Phone : +65 6376 3129 Fax : +65 6271 9029

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Yes! I/We Will attend Plant & Equipment Failure Root cause Analysis on o 13 - 17 May 2013, Kuala Lumpur o 19 - 23 May 2013, Abu Dhabi I would like to purchase the course documentation at SGD 500 per set. Delegate 1 Mr/Ms/Mrs: ________________ Name:_____________________ Job Title:___________________ Tel: _______________________ Email:_____________________ Delegate 3 Mr/Ms/Mrs: ________________ Name:_____________________ Job Title:___________________ Tel: _______________________ Email:_____________________ Delegate 2 Mr/Ms/Mrs: ________________ Name:_____________________ Job Title:___________________ Tel: _______________________ Email:_____________________ Delegate 4 Mr/Ms/Mrs: ________________ Name:_____________________ Job Title:___________________ Tel: _______________________ Email:_____________________

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FEE PER DELEGATE EARLY BIRD
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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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STANDARD RATE

Plant & Equipment Failure Root cause Analysis o 13 - 17 May 2013, Kuala Lumpur o 19 - 23 May 2013, Abu Dhabi

SGD 5,099
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SGD 5,499

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TEL: +65 6376 3129 FAX: +65 6271 9029 EMAIL: SUE@TUN.SG ONLINE: WWW.TUN.SG