applied reliability engineering for operating plant ([email protected])
TRANSCRIPT
Applied Reliability Engineering for Operating Plant6
th - 8th March, 2016
Radisson Blu Hotel, Dubai, U.A.E
● OverviewOver the 3 days, participants are reminded of the engineering basics of specific maintenance and condition monitoring technologies and how this influences their practical application to achieve a healthy, dependable, and profitable operation.
● Benefits of AttendingEXPLORE the uses of and benefits from applying reliability engineering practices, good operating and maintenance practice, predictive maintenance and defect removal at your plant or operations.
UNDERSTAND reliability engineering theory and practice, and use of condition monitoring in a wide range of applications.
DISCUSS participate in structured discussions of reliability engineering, condition monitoring and defect removal options, opportunities and traps.
UNDERSTAND the true cost of poor design & maintenance and how to explain it.
APPLY reliability engineering, predictive maintenance and defect removal to case study operations.
Trainer's Profile
Mike Sondalini
Reliability Soloutions Consultant
Engineering and Industrial Asset Management, Industrial Maintenance Management, ISO9000,ISO 9001-2008 Quality Management System, Lean Manufacturing and Six Sigma Consultant,Perth, Western Australia.
His more than 35 years in engineering and maintenance spans from mechanical engineering, strategic asset management to rotating equipment reliability. He was previously a mechanical engineer with the State Energy Commission of Western Australia, where he conducted equipment failure investigations and constructed improvement plans. He was then the maintenance manager for the Swan Brewery, responsible for overall plant reliability and project engineering. Mike then spent over 10 years as maintenance manager and head of maintenance engineering services for Coogee Chemicals. In this role, he successfully introduced condition monitoring and maintenance strategies that reduced production down time and maintenance costs.
His specialty is helping capital equipment intensive companies build sound business risk management practices, introduce world-class lean practices, develop ultra-high reliable enterprise asset management systems and instil the precision maintenance skills needed to continually improve plant uptime.
www.sq-intl.com +92 300 3482660 2
● Who Should AttendThe program provides material for a wide range of participants, covering basic theory to its practical application. Those that are more academically inclined can develop a deeper understanding of the theory as it applies in practice. However, even if the theory is only understood in a general way, the information is presented so concepts can still be practically applied. Thus it is suited to:
Maintenance Engineers/Managers
Shop-Floor personnel (Maintenance Fitters, Electricians)
Production Managers
Reliability Engineers
Condition Monitoring Technicians
Project Engineers
The workshop/training is intended for participants who are keen to participate and learn.
From industries:
Manufacturing, Mining, Chemical and Petrochemical, Oil & gas, Power, Utilities and other Infrastructure
● Training Schedule 8.30am Registration & Morning Coffee
9.00am Training Starts
10.45am Morning Coffee Break
11.00am Training Resumes
12.30pm Coffee Break
12.45pm Training Resumes
2.30pm End of Training / Onwards, Free discussion on Case Studies
In-House / In CompanyTraining SolutionsIf you have a group of 15 or more people that would benefit from this program, we can deliver this program exclusively tailored toyour organization. Please contact our inhouse training department at:
Websitewww.sq-intl.com
www.sq-intl.com +92 300 3482660 3
Course Outline
DAY ONE:
Asset Management, Dependability, Profitability, Safety & the Role of a Reliability Engineer
Who must do what to achieve plant profitability and the role of maintenance and condition monitoring in achieving continuous improvement.
● Asset Management Concepts● Roles and Responsibilities in achieving Profitability.● Striving for Continuous Improvement.● How Maintenance and Condition Monitoring Fit into this picture.
Reliability & Equipment Failure Concepts & Causes
The basics of when and why equipment deteriorates and fails are explained. The basic strategies to reduce deterioration, component failure, and direct and indirect maintenance cost are described. The indirect cost to a business generally far exceeds the amount identified in the maintenance budget.
● The when and why of equipment health deterioration.● Common poor maintenance practices and their impact.● The basics of reducing deterioration.● The true cost of poor maintenance.
Vibration AnalysisVibration analysis is the technique that often first comes to mind when thinking about condition monitoring. It is indeed a powerful technique to identify and diagnose bearing problems, unbalance, and misalignment in any rotating equipment.
● Vibration theory and its impact on equipment.● Displacement, Velocity and Acceleration measures.● vibration spectra and what they mean to maintenance.
Root Cause Analysis
Seeking the underlying causes (and not just the symptoms), is a great way to deal with our personal problems. This is also true in work situations. In organizations, an effective way to align thinking and agree on sound improvement plans and programs is to work as a team. The value of examining and investigating failed parts, likely failure mechanisms, and recommend improvements is presented.
● How to examine failed equipment to find worthwhile improvements.● Standard root cause presentations and where to apply● Setting & Controlling Scope – where to stop?● Who should be involved?● Dealing with personalities● Reporting Findings
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DAY TWO :
Journey to Maintenance Excellence
The cost advantages of appropriate use of condition monitoring and the attitude to equipment care to achieve best practice is discussed. A general overview of a wide range of CM techniques is provided. The management and coordination of condition monitoring activities is discussed.
● Organizational attitudes needed for adoption of condition based maintenance.
● Overview of a wide range of condition monitoring applications.● The management and coordination needed for an effective condition
monitoring program.
Lubrication Monitoring
The need for good lubrication is explained by revising the basic theory of friction and lubrication films. Choices of lubricants are discussed and the need for cleanliness and correct additives is emphasized A wide range of lubrication monitoring techniques and their effectiveness is explored.
● The purpose of lubrication & how it works.● The choice of lubricants and the importance of cleanliness.● The role and effectiveness of a wide range of lubrication CM
techniques.
Criticality & Risk Ranking
The application of risk and criticality thinking to plant operation, reliability and maintenance are described. The use of Criticality ranking techniques to prioritise a typical set of maintenance and improvement proposals, leading to a work plan which takes safety, maintainability and production imperatives into account in a systematic manner is discussed.
FMECA – RCM - Maintenance Strategy Review
“Operate-to-failure” is applicable in some situations but more often proactive and predictive maintenance are more cost effective. An Overview of Failure Modes Effects Analysis, Reliability Centered Maintenance and a simpler strategy review approach is given. Rational selection of maintenance and CM test strategy is based on equipment health, criticality, and the availability of cost effective condition monitoring techniques. These issues are explored by examples.
● When is “operate-to-failure” best?● Overview of Failure Modes Effects Analysis,● Reliability Centered Maintenance and a simpler strategy review
approach.● Selection of CM test interval over a component's life.
Thermography
Hollywood war movies often show soldiers doing amazing things because they can see in the dark with “night vision”. The real application of thermography to industrial plant is explored and amazing things are possible in identifying not only hot electrical joints, but also problems with mechanical overload and misalignment.
● Thermal radiation theory (emissivity & black bodies).● critical camera adjustments.● diagnosis using thermal images.
www.sq-intl.com +92 300 3482660 5
DAY THREE:
Key Performance Indicators, Benchmarking & Cost Benefit Analysis
The development of useful KPIs (Key Performance Indicators) for maintenance and plant health are explained with emphasis on the use of both “leading” and “lagging” KPI’s. Current best practice dashboard KPI sheets and the cascade of overall plant KPIs to department KPIs are presented. The objectives and use of benchmarking is also presented. Typical best practice values are presented together with the relative advantages and disadvantages of different approaches. The establishment of a plant OEE (Overall Equipment Effectiveness) measure and its use to drive improvement is also explored with a case study.
Cost benefit analysis using both qualitative and quantitative approaches is presented with emphasis on estimation the true cost of failure. Simple spread sheet methods of quantitative analysis are described together with the meaning of Net Present Value of money and how to take it into account and how to present the sensitivity of the findings to cost estimate uncertainty.
Ultrasonics
The use of ultrasonic monitoring is described and the way it can be employed to detect leaks, electrical system problems, faulty steam trap operation and early warning of bearing failures. Its use in ensuring re-greasing practices do not under or over grease bearings – both have significant cost implications.
● What is Ultrasonics.● Why is it becoming increasingly important in equipment monitoring.● Use to detect leaks, faulty steam traps, bearing & electrical problems
and to monitor re-greasing.
Ultrasonics is rapidly becoming a vital aspect of a good equipment monitoring program. The basic theory of sound and its application to equipment condition monitoring are presented. Use of ultrasonic monitoring to diagnose early faults with bearings, and leakages in valves, steam traps and other equipment is covered.
Human Factors & Organizational Issues
All Root Causes of every problem are human errors. Someone (or almost everyone’s) expectations did not align with reality as it eventuated. Someone, group, organization failed to act (Operate, Maintain Equipment, Respond, or Manage) as others (and probably themselves) in hindsight would have preferred. Even a design error is a human error. The objective is NOT to find someone to blame rather - If the organization management systems that allowed the incident to happen are not changed the fault has not been corrected in a way that will prevent repetition.
● What drives human/management error?● How do we eliminate or reduce them or their impact?
Implementation of Improvements
The use of small reliability improvement teams to identify and develop reliability improvement proposals is presented. The preparation of clear and concise maintenance procedures is explained. The implications of changes in expenditure on plant health and safety over time and the issues involved in achieving a truly safe plant are discussed.Like gears people need to be engaged to get into action - with inaction, unwise decisions or poor support to front line staff having possibly delayed, but often severe impact.
Group Presentations
Participants are grouped into several teams of 4 to 6 members and asked to develop a presentation to the other teams. Presentations are to be based on real situations within their plant and show the application of reliability improvement techniques or unresolved issues on which they seek input from others. The presentation sessions are facilitated to ensure all participants are given an opportunity to participate.
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Applied Reliability Engineering for Operating Plant
Faysal Bank Limited
Swift Code: FAYSPKKA
(USD 2,995)
6th - 8th March 2016,Dubai,U.A.E
Venue: Radisson Blu Hotel ,Dubai, U.A.E
6-8 March, 2016, Radisson Blu Hotel, Dubai, U.A.E
Regular Price
Applied Reliability Engineering for Operating Plant