Maintenance Cost Optimisation for Process & Power Generation Plants

Transcription

1 Reliability Imprvement Prgramme & Maintenance Cst Optimisatin fr Prcess & Pwer Generatin Plants Date: Venue: 24 t 28 September 2012 (5 days) Hliday Villa, Subang, Malaysia COURSE INTRODUCTION: This Curse emphasises the backgrund f Plant Maintenance/reliability Prgram in detail as part f the Plant asset management. It will specifically emphasize issues related t the develpment, implementatin and cntrl f maintenance prgram with additinal emphasis n Plant perfrmance, reliability, Remaining life assessment and Maintenance cst analysis. Asset Management Cncept as applied t Plant envirnment, its systems, structure and cmpnents will be discussed in detail. Maintenance strategy and varius cncepts may reduce cst, but all must be integrated t ensure high reliability levels. Cntinued cmpliance with the plant regulatry requirements, while fulfilling the challenges f cst reductins and effective maintenance prgrams, is f paramunt imprtance. OEMs and Operatrs shuld be n the same level f understanding. This curse will als prvide an insight int such understandings. Within this 5-day perid, yu will be guided thrugh the implementatin f an ptimised Maintenance Prgramme. Yu will fcus n the mnitring task and the relevance f the efficiency f the Maintenance Prgramme, in rder t fulfill the peratinal requirements and t avid unnecessary maintenance cst. Case studies with practical examples f maintenance wrk-scpes frm Thermal, Cmbined Cycle and prcess plants n plant systems, cmpnents and BOP will cmplement this curse. Cntinuing safe peratins is t be delivered by the plant Manufacturer fr the establishment f an apprved Plant maintenance prgram and must cntain the necessary details, including frequencies, f all maintenance required t be carried ut fr a safe and ecnmical Plant peratin. Implementatin f such maintenance prgramme requires the preparatin and planning f the maintenance tasks. These tasks are nrmally based upn the Maintenance Review Bard Reprt and the Manufacturer s Maintenance Planning Recmmendatin as detailed in the Maintenance Planning Dcument (MPD). In rder t establish an peratr s maintenance prgramme, the tasks and perids (interval/ frequencies) at which each part f the plant, system, cmpnents, accessries, equipment, instruments, electrical and cmmunicatin apparatus, and assciated systems and installatins shuld be inspected. Such implementatin includes the perids at which items as apprpriate shuld be checked, cleaned, lubricated, replenished, adjusted and tested as well. WHO SHOULD ATTEND: Maintenance Management Managers Engineers Chief Engineers Vice Presidents Maintenance Staff Maintenance Planning Managers Maintenance Prgram Engineers Reliability Engineers / Managers

2 Reliability Imprvement Prgramme & Maintenance Cst Optimisatin fr Prcess & Pwer Generatin Plants 24 t 28 September 2012 Hliday Villa Subang, Malaysia BENEFITS OF ATTENDING THIS COURSE: During this curse the audience will gain a deep and practical insight f the Plant Maintenance prgramme and ptimisatin with effective cst cntrl fr the same as this prgram is executed at flr level. Candidates will acquire a thrugh knwledge f all the maintenance dcuments, analysis tls and advanced plant life cycle cncepts. The reliability requirements in plant envirnment are getting vide imprtance and this curse will give audience a thrugh understanding f Plant Reliability Prgramme with RCM methdlgies and practically implementing the same. The curse is designed t train the prfessinals / Plant Peple n tls and techniques with practical case studies and mini wrkshps. Plant Life cycle Understanding Plant Maintenance prgram develpment Plant reliability Prgram Implementatin and cntrl Maintenance Cst cntrl & Optimizatin Lean maintenance methdlgies Maintenance & reliability Data Analysis tls and techniques. Remaining life Assessment TRAINER S PROFILE: S. Nadeem (Masters In Mechanical Engineering (Thermal Pwer Plants /Bachelrs In Mechanical Engineering / Six Sigma MBB (Certified ) Has mre than 20 years f diverse engineering experience in Industrial sectrs with career as a Mechanical Engineer with Manufacturing and Engineering Maintenance Repair Overhaul Industry. Fr the past 14 years wrking with PIA Engineering MRO facility n Maintenance Repair, Overhaul, Testing and Evaluatin f Turb Machinery including Aer and Aer derivative Gas Turbine Pwer Plants. Diversified Experience n General Electric, Rlls Ryce and Pratt & Whitney Machines. Present assignments include the Lean Six Sigma Integratin with Reliability Prgrams & third Party MRO Business Develpment f Aer Gas Turbine/Aer derivative Gas Turbine Repair, Refurbishment and Overhaul. Internatinal Cnference Speaker/ Event Trainer glbally addressing Gas Turbine Pwer Plants, Rtating equipment, Reliability Asset Management Management, lean Six Sigma. Trained Number f prfessinals in the same area within and utside rganizatin. Prvisined Prcess cmpanies (Pwer Generatin, Oil and Gas etc) n Effective Reliability Imprvement Prgrams, Maintenance Management Strategies, Lean Maintenance and Six Sigma Prcess Imprvement Strategies integrating the same with reliability slutins. Masters in Mechanical Engineering frm University f Engineering & Technlgy Lahre Pakistan with Majr in Thermal Pwer Systems Engineering Six Sigma Master Black Belt frm FBE LLC USA. Well versed with Micrsft Office and varius ther Quality and Pwer Plant Equipment Reliability Analysis Sftware s.

3 Reliability Imprvement Prgram and Maintenance Cst Optimisatin fr Prcess & Pwer Generatin Plants 24 t 28 September 2012 (5 days), Hliday Villa Subang, Malaysia COURSE OUTLINE: This curse utlines the backgrund f Plant maintenance / reliability prgram ptimisatin and will specifically emphasise the cst mnitring, methds and steps required fr the determinatin and implementatin f the same. Plant asset management strategies with advanced reliability requirements (Prgrammes) t meet plant perfrmance standards will be discussed in detail. DAY 1 / 08:30-09:00: Registratin / Welcme Cffee/Tea 09:00 10:15: Understanding Plant Envirnment - Prcess, Plant and Peple - Manpwer, Measurement, Materials, Methds - Rle f a Plant in Business Objective. - Missin, Visin and values. - Crprate Business Plans and impact n Plant Envirnment 10:15-10:30: Mrning Tea break 10:30 12:30: Understanding Plant Envirnment - Prcess, Plant and Peple - Manpwer, Measurement, Materials, Methds - Rle f a Plant in Business Objective. - Missin, Visin and values. - Crprate Business Plans and impact n Plant Envirnment 13:30 15:15: Plant design Objective / Prcurement / EPC Issues - Design requirements fr a Plant - Prcess Plants Pwer Generatin Plants *Thermal Pwer Plants *Cmbined cycle pwer plants 15:15 15:30: Afternn Tea break 15:30 16:30: *Bilers, Gas turbines, HRSG, Steam Turbine and Generatrs * Design trends (Typical machines OEM examples) *Critical Plant Equipment, Rtary Kilns, Furnaces etc. 16:30 17:30: *Cmmissining Phase *EPC Issues, Deviatin frm design *OEMs perspective / Owner End f Day 1 DAY 2 / 08:30 09:00: Mrning Cffee/Tea 09:00 09:15: Intrductin t Plant Maintenance 09:15 10:15: Maintenance Organizatin and expsitin Maintenance Philsphies / Strategies Assciated Maintenance prcedure 10:15 10:30: Mrning Tea Break 10:30 11:00: Asset Management Cncept PAS55-1 / PAS55-2 understanding 11:00 11:30: Cntents f the Maintenance Prgram Types f Maintenance Strategies Gas Turbines, HRSG, Bilers, Steam Turbines, Generatrs

4 Reliability Imprvement Prgramme & Maintenance Cst Optimisatin fr Prcess & Pwer Generatin Plants 24 t 28 September 2012 (5 days) Hliday Villa Subang, Malaysia DAY 2 / (Cnt d) 11:30: - 12:30: Critical prcess equipment, furnaces, distillatin twers etc. Misc Rtating & Static Equipment / structures (BOP) 13:30 14:30: Plant Life Cycle Understanding Understanding Plant Life (Design) vs Actual Useful life. 14:30 15:30: Effect f Plant Maintenance strategy n life Understanding criticality f prcess / equipment 15:30 15:45: Afternn Tea Break 15:45 16:45: Risk Analysis and Life extensin evaluatin and recmmendatins Prcess, Pwer Generatin Plants 16:45 17:30: Examples, GTs, Steam turbines, Bilers, Generatrs, BOP Cmplete Risk Reprt example, criticality Analysis End f Day 2 DAY 3 / 08:30 09:00: Mrning Cffee/Tea 09:00 10:15: Failure Cnsideratins and Analysis - Definitins, Philsphy, Fail Safe Design Cncept - System Cnfiguratin and Redundancy - Nn Redundant / Redundant Single Path, Parallel, Multiple Path System 10:15 10:30: Mrning Tea Break 10:30 11:30: - Life Cycle Prcess, Classificatin f Failures - MSG, MSG-2 and MSG-3 Maintenance Prcess and Decisin Lgic 11:30 12:30: - RCM Reliability Centered maintenance prgram in Plants - Failure Effect Categrizatin / criticality -Time-t-Failure, Failure scenari s 13:30 14:30: Plant Maintenance and Perfrmance Data Cllectin - Prime surces f Infrmatin, Types f Data & Cllectin System - Prcess Flw Diagram, Reprts and Repeaters 14:30 15:30: - Cmpnent Remvals and Failures, Trips n Plant. - Service Difficulty / Occurrence Reprt, Structural Irregularity Reprt 15:30 15:45: Afternn Tea Break 15:45 16:30: - Analysis Techniques, Six Sigma Tls, Distributin Fitting fr Data - Data Display and Reprting 16:30 15:30: - Plant Perfrmance Reprt, Statistics Summary - Statistics, Variatins, Critical Failure Reprt, End f Day 3

5 Reliability Imprvement Prgramme & Maintenance Cst Optimizatin fr Prcess & Pwer Generatin Plants 24 t 28 September 2012 (5 days) Hliday Villa Subang, Malaysia DAY 4 / (Cnt d) 08:30 09:00: Mrning Cffee/Tea 09:00 10:15: Reliability Prgrams - Reliability Analysis - Understanding a Reliability Prgram Implementatin - Cst vs ROI n reliability prgram - Perfrmance Measurement and Parameters 10:15 10:30: Mrning Tea Break 10:30 11:00: - Mnthly Plant Reliability Reprt *Plant Systems, cmpnents, structures Critical systems *Critical systems and rtating equipment 11:00 11:30: - Reliability Based Inspectins - MRB, RCB and RRB functining (base lines) - Implementing RCB recmmendatins 11:30 12:30: Maintenance Prgram Implementatin - Dcuments (OEM, MPD, Operatr specific Maintenance prgram, Mdificatin) - Plant Operatr s Maintenance Prgram, General Requirements - Scheduled / Unscheduled Maintenance - Task / Functin Cdes - Lgistics and Man hur planning aspects - Maintenance Task Packaging *Turn arund Checks *Equalized Prgrams *Phased Prgrams 13:30 15:00: - Maintenance Task Cards, Cmputerized Maintenance Management Systems - Maintenance Prgram Implementatin and Develpment *Staggered Implementatin Plan *Service Experience *Peridic Review *Inspectin Interval Escalatins *Successive reviews and amendments - Lean Maintenance Cncepts and integratin with existing prgrams - Efficiency & Effectiveness f maintenance Prgram - Inventry Mnitring t Supprt Maintenance Prgram 15:00 15:15: Afternn Tea Break 15:15 16:15: - Plant Maintenance wrk scpes *Wrk-scpe planning guides (OEMs) *Wrk-scpe Examples - Gas Turbines, HRSG, Steam Turbines, Generatrs, BOP, Furnaces, Kilns, Rtating Equipment, Systems viz, fuel, electrical, Hydraulic, air etc. 16:15 17:30: - Understanding wrk-scpe cst -HARD / SOFT time threshld fr *Systems *Cmpnents *Structure End f Day 4

6 Reliability Imprvement Prgramme & Maintenance Cst Optimisatin fr Prcess & Pwer Generatin Plants 24 t 28 September 2012 (5 days) Hliday Villa Subang, Malaysia DAY 5 / 08:30 09:00: Mrning Cffee/Tea 09:00 10:15: Maintenance Cst - Direct and Indirect Cst Assciated with Plant - Maintenance Cst Baselines - Maintenance Cntracts Cst Aspects - Maintenance Cst Reprting, Data Analysis - Cst Benefit Mdel, Change Prpsals - Cst Analysis 10:15 10:30: Mrning Tea Break 10:30: - 11:30: Maintenance Organizatin Expsitin - Dcuments / manuals - Overall Expsitin manual - Engineering prcedures manual - Assciate maintenance prcedures - Reliability Reprts 11:30 12:30: Plant life extensin and Evaluatin - Develping a base line study level fr Plant - Remaining Life Assessment - Current reliability levels / Last shutdwn / turnarund reprts - RBIs current state / Future - Life Evaluatin questinnaire. - Risk assessment f systems / cmpnents - Recmmendatins fr life extensins, wrk-scpes - Investments int plant assets. 13:30 14:00: Case study 1400 MW plant life extensin. 14:00 15:00: Case Studies - Reliability Imprvement Prgram (Example) 15:00 15:15: Afternn Tea Break 15:15 16:15: - Maintenance Planning (Case Study / wrkshp) 16:15 17:15: - Maintenance Cst Analysis (Wrkshp) 17:15 17:30: - Cnclusin End f Day 5 ADMINISTRATION DETAILS: Venue : Hliday Villa, Subang, Malaysia Date : September 2012 Time : 9.00am t 5.00pm Others: HRDF Claimable under SBL Scheme Fr mre infrmatin kindly cntact: J: / Trixie : General Line: ORGANISED BY: Learning... Passin fr Life