PRINCIPLES OF RELIABILITY ENGINEERING

Transcription

1 Training Title PRINCIPLES OF RELIABILITY ENGINEERING Training Duration 5 Days Training Date & Venue Principles of Reliability Engineering April $3,750 Doha, Qatar In any of the 5 star hotels. The exact venue will be intimated soon. Training Certificate Define Management Consultants Certificate of course completion will be issued to all attendees. Training Fees 3,750 US$ per participant for Public Training including very useful, illustrative Materials/handouts, Tea/Coffee, Refreshments, International Buffet Lunch. TRAINING OVERVIEW INTRODUCTION & DESCRIPTION Reliability Engineering does not just infer Reliability but includes understanding, measuring and improving Reliability, Availability and Maintainability and is a large and complex subject. This 5-day practical workshop will provide delegates with an overview of the wide range of practical techniques to create a lasting improvement to Operations and Maintenance performance. Benefits of applying these techniques will be realised through improved reliability, reduced downtime, reduced spares costs and the unit cost of maintenance. The workshop will show how data should be collected in your CMMS or process control systems and how to effectively use this data. A short coming in most companies!!!. The results of a study can have many objectives i.e. to provide baselines to judge future improvements or can provide an immediate solution, e.g. conduct maintenance by a certain time or can support your RCFA study or to be used to model a system performance.

2 Other Best Practice Improvement Techniques including RCM, RCA/RCFA, and Operator Driven Reliability will be covered. We will cover other short coming regularly found in oil and gas, power and other process industries and present a model to audit your maintenance and reliability system. Many case studies will be presented including some early examples carried out by the author over 30 years ago but still very relevant today. The author has found that even with expensive CMMS systems, Failure Coding systems companies are still poor at collecting and using data to make improvements. This course will demonstrate what can be done with data at failure mode level, equipment level as well as a group of equipment. Reliability analysis can provide many metrics but must be integrated with team-based techniques to realise maximum benefits. At the end of the workshop, delegates should be able to apply the techniques covered and reap the benefits of improving their current asset maintenance and reliability system. TRAINING OBJECTIVES Learn from Reliability and RAM specialist and although many of the techniques can be done manually, excel or by using plotting paper we demonstrate what the latest reliability analysis software tools can do. This workshop focuses on application rather than mathematical theory. Understand how data must be collected into the CMMS and learn various techniques to analyse this data from the CMMS or Process Log information Understand the importance of analysing the total population not just the failures recorded in the CMMS Understand Weibull analysis and its relationship to the bath tub curve Understand the different elements of maintainability and how to measure the same Learn how MTBF is of no value in selecting tasks frequencies Understand different equipment performance measures and when to use them Learn techniques how to improve reliability and maintainability How to optimise maintenance decisions based on costs and evaluate different strategies from a cost, availability and downtime perspective (safe life, cost effective life, RTF, FTM and PdM)

3 Understand what RAM modelling is and how it can be used to conduct what ifs, evaluate policies for high value spares with both long lead times and stock out costs Understand different techniques for criticality and risk, what is criticality and priority for action Understand each phase of the reliability centered maintenance programme Learn a structured process to look for root causes including physical and human performance issues Understand the Operator Driven Reliability program TRAINING METHODOLOGY The seminar will be conducted along workshop principles with formal lectures, case studies and interactive practical exercises. There will be many opportunities for discussion and sharing experiences. Lectures will cover all necessary information to satisfy the course objectives. Slides, handouts, case studies, exercises, use of easy to use reliability analysis software. For those bringing a lap top a software demo can be installed WHO SHOULD ATTEND Reliability engineering and operations personnel involved in improving reliability, availability, safety, maintainability and profit performance in existing or proposed process systems and equipment. Participants should have foundation skills in statistical analysis and reliability techniques for equipment. If you are a manager, supervisor, engineer, logistics specialist, an academic or other professional seeking to understand reliability and uptime improvement, this workshop will be able to help you. It is aimed at people with a stake in Operational Success working in the Oil & Gas Industry such as the Reliability Team, Maintenance Engineering Team, Shutdown & Campaign Team, Barge & Subsea Team. The course has also been specifically designed to be of substantial benefit to both technical and non-technical personnel employed in the activities that support the O&M sector. TRAINING OUTCOME At the end of the course, the delegates will be able to: 1. Define measure and predict reliability. 2. Use the reliability equation to aid in improving equipment maintenance strategies.

4 3. Analyze system design to determine if projected capacity will meet capital requirement. 4. Analyze and improve system safety. 5. Predict life cycle costs to make buy/replace decisions and to determine which equipment or system will create the most value for the business. 6. Develop the equipments MTBF and MTTF and also to improve the plant Overall Equipment Efficiency (OEE). DAILY CONTENT The course content will include the following will be covered in 5 days of time. o Introduction to Reliability Engineering o Basic Reliability Theory o Reliability Engineering Fundamentals Reliability engineers vs. maintenance engineering; and the Engineered Maintenance Strategy. o Reliability failure analysis and reporting Topic 1 Current Problems in Maintenance Discussion of current issues in maintenance, the effects of poor reliability, the need for good info for decision making, developing a Best Practice Strategy Topic 2 How to Collect Better Data Causes of poor data with examples from various oil and gas operators Failure coding structures incl ISO14224, Presentation of a structured feedback reporting process Topic 3 Data Types and Data Handling Techniques Data Types Process data and CMMS data, Complete and Censored data, How to analyse equipment that are repaired on failure and failures replaced with a unit replacements Topic 4 Understanding, Measuring and Improving Reliability Defining reliability, Failure patterns early life, random and wear out failures, Looking at the bath tub curve and synergy with the human life.

5 Discuss reliability steady state metrics MTBF, MTTR, MTBF, Discuss reliability based on time, exponential, weibull parameters Example calculating using software (students can also have hands on practice), Statistical charts probability, pdf plots Techniques and tactics to reduce repair times and downtimes Topic 5 Understanding, Measuring and Improving Maintainability Defining maintainability, Discuss maintainability steady state metrics MTTR Discuss reliability based on time Mmax, MTTR, Elements of Downtime including wrench time Techniques and tactics to reduce repair times and downtimes Topic 6 Understanding, Measuring and Improving Availability Hierarchy of Plant, system and equipment KPIs, Developing a production time model Developing 5 measures of availability and utilization, What do these measures really mean What measures shall we use for critical equipment and medium critical equipment A structured approach to improving availability when the plant manager demands a 2% increase Topic 7 Optimising Replacement Decisions Principles of replacement decisions Demonstrating how MTBF has little value in determining when to replace items Looking at unit maintenance costs using different probability distributions The Unit cost of maintenance versus replacement time plots the sweet spot for optimisation Evaluating the P-F Interval using degradation analysis Topic 8 RAM Modeling and Simulation Introduction to RBDs, Steady States and Time dependent data, System Configurations Evaluating Hot, Cold and Standby systems

6 Evaluating the various results RAM Study Process, Throughput Analysis, Life Cycle Cost Data Topic 9 Criticality Analysis How to establish criticalities for each item of equipment, we look at two measures criticality and prioritisation Topic 10 Reliability Centred Maintenance Overview of RCM phases including: Understanding Functional Analysis Failure Modes & Effect Analysis Failure Characteristic Analysis Strategy Selection Task specification and Task Packaging Topic 11 Basic Root Cause Analysis Techniques Introduction to different root case analysis techniques How to conduct incident investigations and look for root causes using a structured approach ( we go through the complete step by step process) How to evaluate corrective actions Topic 12 Root Cause Failure Analysis How to investigate equipment failures and look for both physical and root causes What is a FRACAS System Topic 13 Operator Driven Reliability (incl First Line Maintenance) Key features the hamburger model 6 step equipment management model Early Equipment Management Case Studies, Pre & Post Tests, Group Discussions, Last day review will be carried out...