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Also available as In-house Course

at Discounted Price!
PC15

01

Plant Maintenance & Reliability Program Optimization


Provides deep understanding into development and implementation of Reliability Programs in Process,
Manufacturing, Petrochemical and Power Plants

13-15 Apr
Kuala Lumpur

4-6 May

Penang

11-13 May
Johor Bahru

Nadeem has more than two decades of diverse professional engineering experience in various industrial
sectors viz. Aviation, Power Plants and Petrochemicals. Key specialties include consulting, training and
development as a Mechanical Power Engineer in:
Process, Power Generation Plants & Aviation
- Life cycle Asset Management
- RCM based Maintenance & Reliability Program development and implementation
- Reliability Analysis & Risk Based Studies
- Remaining Life Assessment Studies, Evaluation, Extension Recommendations
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 / Functional Reliability & Specific Equipment Plans
Plant, Equipment Failure Analysis, RBD Modeling, FMECA, RCM Program Implementation
Focused Lean Six Sigma Certifications for Maintenance and Reliability Professionals
Well versed with RCM Tools & Softwares Weibull 6++, Minitab and Statistica

ABOUT THE

TRAINER

S. Nadeem Ahmed

MSc Engg (Power Plants)


Six Sigma MBB, USA

Course Description
The course covers in detail 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 programwith additional emphasis on Plantperformance,reliability and 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 coursewill also provide an insight into such understandings.
Within 3 days you will be provided with guidance for the implementation of an optimized Maintenance Program with focus on 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 of maintenance work-scopes from Thermal, Combined Cycle and process / Petrochemical plants on plant systems,
components and BOPwill complement this course.

Who Should Attend

Learning Objectives

Maintenance Management
-Managers
-Engineers
-Chief Engineers
-Vice Presidents
Maintenance Staff
Maintenance Planning Managers
Maintenance Program Engineers
Reliability Engineers and Managers
Finance and Procurement Managers

After completing this course, participants will be able to understand / conduct:


A-Z of equipment, Basic Classifications.
API, ANSI & ASME standards for Equipment
Advance Maintenance Management in Process Chain
Eliminate unplanned downtime, Improvement in maintenance program
Latest innovations in RCA and CM for rotating equipment
Implement Solutions that reduce the cost per hour of operation
Increasing daily revenue for Plant reducing OPEX
Optimize performance and efficiency by adopting updates in condition monitoring
Effective reliability program to optimize the performance of Equipment
Reliability Program design, Implementation and control for Plant Equipment
Practical Case studies to Evaluate and adopt solutions in industries
Appropriate Analytical tools for maintenance decision making

Course Benefits

Training Methodology

Improved job performance, Decision making capabilities


Understanding the Design Concepts of Plant Equipment
Equipment Performance Evaluation throughout life Cycle
Understanding Life Extension Evaluation and Recommendations
Understanding Equipment Key performance Indicators
Reliability Program Implementation for Plant Equipment
Operational Cost Monitoring
Understanding operation, and maintenance requirements
Equipment Repair vs. Replacement decision
Technology transfer between participants
Lean Six Sigma Green belt tools

This training will be facilitated using modern techniques through highly


interactive sessions. The Analysis tools application to maintenance,
reliability and failure analysis of Critical Equipment will be exercised with
mini workshop during the sessions. Participants will exercise analysis
software with their own plant data. Repair vs. replacement decisions on
critical equipment will be exercised during web sessions and through
assignments. Development and implementation of reliability and
maintenance program with practical calculations will be delivered during the
training.

For more info, please write to us at: marketing@biztreeventures.com or visit www.biztreeventures.com

Also available as In-house Course


at Discounted Price!

Course Agenda

DAY

01
Understanding Plant Environment
Process, Plant and People
Manpower, Measurement, Materials, Methods
Role of a Plant in Business Objectives
Mission, Vision and values
Corporate Business Plans and Impact on Plant Environment

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.
- Miscellaneous Rotating &Static Equipment / structures (BOP)
DAY

Plant Design Objective / Procurement / EPC Issues


Design requirements for a Plant for Performance / Reliability
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 / Owner perspective

Plant Life Cycle Understanding


Understanding Plant Life (Design) vs. Actual Useful life
Effect of Plant Maintenance Strategy on life
Understanding criticality of process / equipment
Risk Analysis and Life extension evaluation and recommendations
- Process, Power Generation Plants
- Examples of Gas Turbines, Steam turbines, Boilers, Generators, BOP
- Complete Risk Report example, Criticality Analysis

02
Failure Considerations and Analysis
Definitions, Philosophy, Fail Safe Design Concept
System Configuration and Redundancy
Non Redundant / Redundant Single Path, Parallel, Multiple Path Systems
Life Cycle Process, Classification of Failures
MSG, MSG-2 and MSG-3 Maintenance Processand Decision Logic
RCM Reliability Centered maintenance program in Plants
Failure Effect Categorization / criticality
Time-to-Failure, Failure scenarios

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 (Baselines)
Implementing RCB recommendations

Plant Maintenance and Performance Data Collection


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

Plant Maintenance Work-scopes


Work-scope planning guides (OEMs)
Work-scope Examples
- Gas Turbines, HRSG, Steam Turbines, Generators, BOP, Furnaces,
Kilns, Rotating Equipment, Systems viz. fuel, electrical, hydraulic, air etc.
Understanding Work-scope cost
HARD / SOFT time threshold for
- Systems
- Components
- Structure
- BOP including structures

DAY

03
Maintenance Program Implementation

Maintenance Cost

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
- Turnaround 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

Direct and Indirect Cost Associated with Plant


Maintenance Cost Baselines
Maintenance Contracts CostAspects
Maintenance Cost Reporting, Data Analysis
Cost Benefit Model, Change Proposals
Cost Analysis

Plant Life Extension and Evaluation


Developing a Baseline Study Level for Plant
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 of 1400 MW plant life extension / Refinery

Maintenance Organization Exposition

Case Studies, Workshops

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

Reliability Improvement Program (Example)


Maintenance Planning (Case Study / workshop)
Maintenance Cost Analysis (Workshop)

For more info, please write to us at: marketing@biztreeventures.com or visit www.biztreeventures.com

Also available as In-house Course


at Discounted Price!

Venue

Dates

Price

Discounts on Group registration

Kuala Lumpur

13-15 Apr 2015

USD 2,950 per participant

Penang

4-6 May 2015

USD 2,950 per participant

5% for 3 5 participants
7% for 6 8 participants
10% for 9 or more participants

11-13 May 2015

USD 2,950 per participant

Plus, early bird discount!

Johor Bahru

Broad Terms & Conditions


Registration: A business contract will be signed between the
Client and BizTree at least 15 days prior to the course date.
Fees: Course fee is inclusive of trainer related costs, training
material, stationery, IT support, meals and refreshments.
Payment Terms: Fee must be paid in full within 15 days after the
business contract is signed (registration). Payment can be via
either of the two methods mentioned above. BizTree reserves the
right to refuse enrolment/registration of the participants if
payment is not received on time. All payments must be made in
Malaysian Ringgits unless otherwise stated on the business
contract.
Substitutions: BizTree may allow the Client to substitute
participant(s) with same number of other participant(s) at no extra
charge, provided if the Client has paid the course fee in full.
Substitutions must be received in writing by BizTree by mail or
email 5 days prior to the start of course.
Discounts: BizTree at its discretion may offer 'Early Bird
Discount' or Team Discount. In order to be considered for
discounts, the Client must pay the course fee full after signing the
contract (registration) and before the scheduled course date.

Others: While every reasonable effort will be made to adhere to


the advertised package, BizTree reserves the right to change
event dates, sites or location or omit event features, or merge the
event with another event, as it deems necessary without penalty.
Other Terms & Conditions and Privacy Policy are as mentioned
on our website at www.biztreeventures.com

Course fee: USD 2,950 per participant


Registration closing date: 23 March 2015
Payment Methods:
1. Cheque / Bank Draft
Made payable to: BizTree Ventures Sdn Bhd
Address: NW-3A-30, Cova Square, Jalan Teknologi
Kota Damansara, 47810 Kuala Lumpur, Malaysia
2. Bank Transfer
Account Name: BizTree Ventures SdnBhd
Account No.: 564490411615
Bank Name: Maybank (Malayan Banking Berhad)
Swift Code: MBBEMYKL
Bank Address: Lot C21-C, Concourse Expansion Suria,
Kuala Lumpur City Centre, 50088 Kuala Lumpur, Malaysia

For enquires & registration, please contact us at:

Mobile: +6012 427 5260 or Email: marketing@biztreeventures.com

About BizTree Ventures


BizTree Ventures Sdn Bhd is a Malaysia based company engaged in promoting quality learning in accordance with international
practices. At BizTree, we are dedicated to the development of technical professionals through a comprehensive portfolio of
training programs on wide ranging technical topics for various industrial sectors viz. Oil & Gas, Petrochemicals, Manufacturing,
Process and Power Generation.
Formed by professionals with successful track record in the related sectors, BizTree has association with internationally
recognized and experienced trainers and aspires to become a solutions provider of choice for all industrial sectors globally.
The company has several differentiators in the training industry:
Breadth of technical training programs specially structured for various industrial sectors
In-house courses that are customized to meet the client's specific training needs
Web-based courses via webinars supported by case studies and videos from real industrial environment
Seminars organised as full-day and half-day programs on wide ranging technical topics
Long-term implementation programs tailored to meet the client's plant, equipment and process requirements
Highly experienced certified trainers of international repute
A management team of professionals with more than 20 years experience
BizTree desires to empower you with in-depth analysis, critical thinking and practical knowledge of current trends and ideas
supported by world-class trainers who would bring real-life experience to the learning environment.

For more info, please write to us at: marketing@biztreeventures.com or visit www.biztreeventures.com