practical reliability engineering - petroedge

PRACTICAL RELIABILITY ENGINEERING 26 – 30 July 2021| Virtual Instructor Led Training (VILT)

Conducted by your Expert Instructor:

Mr. Kenneth Lees BSc, MSc With 30+ years of experience for Shell, BP and ARAMCO around the world, Mr. Lees is a Reliability and Maintenance Specialist who has advanced expertise in developing and implementing Reliability Improvement Programs, Maintenance & Integrity Optimisation, Maintenance Backlog Reduction and R&M Training Programs, in a variety of industries.

PRACTICAL RELIABILITY ENGINEERING 26 – 30 July 2021 | Virtual Instructor Led Training (VILT)

About this Virtual Instructor Led Training (VILT):

The reliability of a Plant or Facility determines its performance – process safety, environmental and cost performance all

depend on it. It is thus a pivotal driver, which we can use to make significant business gains. Unfortunately, it is often seen

as a black art, best left to mathematicians or other specialists. This practical training course will show you that it is easy to

understand and explains how to use data from operating and maintenance records and get the results.

Learning Outcomes:

The links between maintenance and reliability, and the effect of Reliability on Process & Environmental Safety, Production

volumes and maintenance costs will become clear.

By attending this 5-day training course, you will acquire the following:

Learn reliability terms, their definitions and its use.

Practice exercises to determine e.g., MTBF, MTTR, Scale and Shape factors etc. and learn how to use these to

determine maintenance strategies and operating philosophies.

Find out how Plant availability depends on reliability and see how configuration affects the outcome.

Study different failure distributions and see why these matter. Exercises on spares holdings will show them how to

optimize these to meet service level and cost considerations.

A number of tools including RCM, RBI, FMECA, IPF, RBD, FTA, ETA, and Modelling will be covered briefly, so that you know

what to use where. Failure analysis using RCA will be discussed. The Business Process to manage Reliability Improvement

and a roadmap to achieve high performance will be included.

Who will Benefit from this Training?

Engineers from industries including Oil & Gas (Upstream and Downstream), Power Generation, Chemicals, Pharmaceuticals

and Manufacturing can apply the learning to their advantage. They can be from Production, Maintenance, Projects, Design

and Inventory Management teams.

For optimal results, a University degree in Science or Engineering is desirable, as some mathematical background

knowledge is necessary. Managers, supervisors or support staffs from different disciplines are all suitable.

VILT Delivery Schedule

The VILT will be delivered online in 5 sessions comprising 3.5 hours per day, with 2 breaks of 10 minutes per day. The delivery schedules are as follows:

PetroEdge is recognised by the Society for Maintenance & Reliability Professionals (SMRP) as an approved provider of continuing education and training aligned with key subject areas related to reliability and physical asset management.

Call us at +65 6741 9927 or email to [email protected]. For more information, visit us at

www.petroedgeasia.net

mailto:[email protected]

http://www.petroedgeasia.net/

Conduct this training course in-house for more effective savings! Call us at +65 6741 9927 or email to [email protected]. For more information, visit us at



VIRTUAL INSTRUCTOR LED TRAINING (VILT) COURSE OUTLINE SESSION 1 / DAY 1

Introduction & Welcome

• Objectives

• Expectations from delegates

• Discussion – how good is your facility reliability?

Reliability Engineering Concepts

• Terminology and definitions

• Probability and Likelihood of Failure

• Understanding basic statistical concepts: Mean, Median, Mode, Standard Deviation, Normal Distribution

• Failure Histograms

• Failure distributions; simple analyses

• Group exercises

Break (10 minutes)

Reliability Engineering Concepts (Cont’)

• Probability Density Function, Hazard Rates

• Different Distributions

• Metrics – MTTF, MTBF, MTTR

• Relationship between Reliability, Availability & Maintainability

• The Bathtub Curve

• How to use reliability information for maintenance

• Group exercises

Break (10 minutes)

Human Error & Reliability

• People, Process and Plant; Reliability Tripod

• Human Error a major contributor to unreliability

• Understanding Human Error

• Physiological & Psychological Stress

• Rule, Skill and Knowledge based errors

• Error prone situations

• Managing Error

Homework & End of Session 1 / Day 1

SESSION 2 / DAY 2

Review of Day 1 & Homework

Degradation Mechanisms

• Wear, Corrosion, Fatigue, Creep, Erosion

• Physical process - tyres & potholes, crack propagation

• What do we understand by the term Maintenance?

• Failure Patterns

• Age-related and non age-related failures

• Managing Degradation – Appropriate Tasks

Break (10 minutes)

Reliability Engineering Applications

• Tools overview: Reliability Block Diagrams (RBDs), Reliability Modelling, Fault Tree Analysis/Event Tree Analysis, Failure Modes and Effects, Criticality Analysis (FMECA)

Break (10 minutes)

Reliability Engineering Applications (Cont’)

• Further Tools: Reliability Centred Maintenance (RCM), Risk-Based Inspection (RBI), Root Cause Analysis (RCA), Instrumented Protective Functions (IPF)

• Computing value added, performance metrics

• Making a Business Case

Homework &End of Session 2 / Day 2

SESSION 3 / DAY 3


Risk Management

• What is Risk?

• Quantitative & Qualitative Risk

• ALARP and Residual Risk

• Decision Making Revision of Topics to help us in Exercises • Histograms • Probability Density Function • Cumulative Failure Function, Reliability Function,

Hazard Rate Break (10 minutes)

Revision of Topics (CONT’) • Different Distributions

• Reliability Block Diagrams; Series, parallel. Bridge

• Analytical and Simulation Modelling Distribution

Break (10 minutes)

Exercises • Histogram plotting • Normalizing Histograms • Probability Density Function, computing F(t), R(t), z(t) • Weibull Charts • RBDs







SESSION 4 / DAY 4


Introduction to Reliability Block Diagrams & RAM Modelling

• System Reliability

• Series & Parallel RBDs

• Complex RBDs, Nested RBDs

• System Analysis and Modeling

• Analytical & Dynamic Simulation Models

Break (10 minutes)

Data Sources

• Run length data; run meters, DCS, operating logs

• CMMS; failure data, history text

• Operators and Maintainers as sources

• Publicly available sources, OREDA, IEEE

• Errors in data sources, Independent & Identical conditions

Break (10 minutes) The Reliability Improvement Process

Pre-requisites, Elements and Structure

• Asset Register

• Getting The Basics Right (GTBR)

• Failure Elimination

• Planning, Scheduling& Work Preparation

• Condition Based Maintenance

• Compliance


SESSION 5 / DAY 5


Implementation of Reliability Improvements

• When & Where to apply – Selection of Projects

• Preparing the ground

• Identify Critical Systems

• Identify Poor Performers

• Set Objectives

• Sponsor, Terms of Reference, Budget

Break (10 minutes)

Group Exercise

• Test

Break (10 minutes)

Managing Change

• Reliability Improvement requires change

• Change is a process

• Models

• Bereavement Curve

Analysis, Measurement and Tracking Results

• Select the right tools, software

• Use the same metrics before and after study

• Follow the evidence, don’t “bend” the data!

• Publish ALL results, good or bad

• Report, Present Results

• Communicate to stakeholders

End of Session 5 / Day 5 & Course Wrap-Up






About your Expert VILT Instructor:

Mr Kenneth Lees Mr. Lees is a Maintenance and Reliability specialist with advanced expertise in developing and implementing Reliability Improvement Programs, Maintenance & Integrity Optimisation, Maintenance Backlog Reduction and Operations Excellence. He has 20 years of experience working for Shell in Asia, Europe and the Middle East, four years with BP in the UK & Norway, and 5 years with ARAMCO in KSA. A Certified Reliability Leader with a Masters Degree in Reliability Engineering, Mr Lees complements this professional knowledge with a positive and enthusiastic approach that motivates and stretches trainees on his courses.

Practical Work Experience:

Reliability & Maintenance Manager, Shell International

Managed, coached and lead multi-discipline teams (Mechanical, Electrical, Instrument, Inspection & SCADA) for Shell European EP Facilities to drive up Equipment

Availability, while assuring Technical Integrity at Optimal Cost. Drove TR-MIE (Total Reliability, Maintenance Integrity Execution) and ORIP (Operational Reliability

Improvement) for OSO (Oil South Operations) in Oman. Successfully achieved and sustained ‘Calculative’ for TR-MIE and ORIP for the Marmul Facility, (one of

only two Shell facilities worldwide). Maintenance & Integrity Lead during evaluation of selected ventures, projects and farm-ins. Introduced Lean Processes to

eliminate non-value adding activities and Visual Management to improve visibility and communication. Mentored new GDP (Graduate Development Program)

Engineers for Reliability & Maintenance, Operations Readiness & Assurance, Integrated Activity Planning & HSSE Risk Management. Presented to Technical

Steering Committees (Shell) and Joint Venture partners (external) on RAM Assurance, Reliability Improvement and Maintenance Optimisation.

Reliability & Maintenance Lead, Shell UK Exploration and Production

Responsible for providing expertise in reliability engineering and maintenance strategy to new projects. Was a founding member of the Shell R&M ‘Centre of

Excellence’ team, responsible for providing expertise in reliability engineering and maintenance strategy to greenfield and brownfield projects. Co-developed

Maintenance Strategy Review (MSR) procedure to establish risk-based maintenance strategies using Reliability Centred Maintenance (RCM) and Operations in

Projects (OIP) standard, integrating operations, safety and project design. Implementation of these standards made major performance improvements to 22

Shell Expro installations in the North Sea. PM and Shell Representative to OREDA (Offshore Reliability Database) Steering Committee (long term International

JIP on reliability of E&P process and safeguarding equipment). Managed the creation of a comprehensive Reliability Database, using failure records from 15

Offshore Platforms over a 17-year period and applying Weibull analysis. It includes a Relief Valve Database analysing some 14,000 test bench records, as well as

one for Gas, Heat and Smoke Detectors. Was a regular lecturer in RCM at the Shell Training Centre in Holland, conducting 14 sessions over an 8-year period.

Provided Reliability Engineering Support to BP (Dyce) with the primary responsibility of visibly improving the reliability of the SNS (Southern North Sea) producing assets, comprising 17 offshore installations (15 NUIs + 2 Manned). Lead Defect Elimination Teams and conducted Incident Investigations to eliminate root cause of failures. In addition, conducted Vulnerabilities Review to determine low probability, high consequence events (sleeping tigers), foreseeable but not visible.

Senior Program Development Analyst, ARAMCO (Arabian American Oil Company), Kingdom of Saudi Arabia. Developed and taught reliability and maintenance training courses for ARAMCO Gas Oil Separator Plants (GOSPs). Performed task analyses and designed programs of instruction, including support media. Responsible for the practical and theoretical instruction of Saudi Arabian Nationals employed in ARAMCO plants.

Kenneth has published many articles and presented papers at International Conferences. He has worked in the upstream and downstream Oil and Gas Industry Sectors, Engineering, Chemical and Pharmaceutical Industries. He has also worked in several countries and cultures, including Saudi Arabia, Malaysia, Korea, USA and the United Kingdom. Kenneth is currently on the faculty of Shell Open University and Heriot-Watt University, Scotland, for their MSc Programme in Reliability and Safety Management.





petroEDGE® delivers energy industry skills-based training courses in major cities around Asia, catering for every stage of your organisation’s development path. Since our inception, we have provided wide range of management development training, business strategy and technical skills training courses to over 100 leading international corporations and government establishments.

Our growing client profile:

Almansoori Wireline Services (Thailand) Maersk Drilling PT Perusahaan Gas Negara

Arabian Bridge Company for Oil Services Maersk Oil Qatar PT PLN (Persero) Kantor Pusat

Asetanian Marine Pte Malakoff Corporation Berhad PTT Exploration & Production

Bangladesh Oil, Gas & Mineral Corp Malaysia LNG PTTEP International Limited

Bergen Group ASA Malaysia Marine & Heavy Engineering PTTEP Iran Company Limited

BG Exploration and Production India Malaysia-Thailand Joint Authority PTTEP Oman Company

BJ Services Company Middle East Media Chinese International PVD Offshore Services Co.

BP Exploration & Operating Vietnam Mid-Continent Equipment Group Pte Ranhill Engineers & Constructors

BP Exploration Operating Company MISC Berhad Rhodia Asia Pacific Pte

BP Indonesia / Singapore & Vietnam Mitsui Oil Exploration Co. Repsol

Brunei LNG MMS (Insurance Brokers) Royal Norwegian Embassy

Brunei Petroleum Murphy Oil Corporation Sabah Shell Petroleum Co

Brunei Shell Petroleum Co National Healthcare Group Sapura Energy

Cairn Energy India Pty Nations Petroleum (SE Asia) Sapuracrest Petroleum Berhad

Carigali Hess Operating Co. Newfield Peninsula Malaysia Inc. Sarawak Shell Berhad

Carigali PTTEPI Operating Company Nipon Oil Exploration (Malaysia) Saudi Arabian Oil Company

CGG Veritas (M) Oceaneering International Saudi Basic Industries Corp

Charnavon Petroleum Offshore Geo-Surveys Schlumberger Oilffield (S) Pte

Chevron Asia South Optimal Chemicals (M) Scomi Oiltools

Chevron Thailand E & P Optimal Olefins (M) Shell Eastern Petroleum

CNOOC PC Vietnam Shell MDS (Malaysia)

Cuulong Joint Operating Company PCPP Operating Company Shell Saudi

Det Norske Veritas (DNV) As Pearl Energy (Nam Conson) Sime Darby Plantation Sdn Bhd

Det Norske Veritas Pte PERMATA Singapore Petroleum Co.

Dof Subsea Australia Pty Permata - PMTSB SN Aboitiz Power

DPS Bristol (M) Pertamina Learning Center S-Oil Corporation

Esso Malaysia Berhad PetroEnergy Resources Corp. Talisman Malaysia

ExxonMobil E & P Malaysia Inc. Petrofac Malaysia Limited Tately N.V.

First Gas Power Corporation Petroleum Insitute of Thailand Technip Geoproduction (M)

Genting Oil & Gas Petroleum Well Logging Co. Teknik Janakuasa

Geomechanics International Petrolux Temasek Holdings Pte

Greatwall Drilling Company PETRONAS Holdings Tenaga Nasional Berhad

Halliburton Energy Services, Inc. PETRONAS Carigali Thang Long JOC

Hercules Tanjung Asia PETRONAS Carigali Vietnam Limited TL Offshore

Hess (Thailand) Limited Petronas Dagangan Berhad Total (China) Investment Co. .

Hoang Long Hoan Vu JOC PETRONAS Gas TOTAL E&P Indonesia

Intisari Oildfield Service PETRONAS Methanol (Labuan) Trans Thai Malaysia

Intra Oil & Services Bhd PETRONAS Penapisan (Melaka) Transwater API

Japan Vietnam Petroleum Compan Petrousaha Engineering Services Tri-M Technologies (S)

Kavin Engineering & Svcs Pte Petrovietnam Drilling & Well Services Truong Son JOC

Kebabangan Petroleum Operating Co. Powertium Marine University New South Wales

KUFPEC Regional Ventures (Indonesia) Premier Oil Indonesia Vastalux

Lam Son JOC PT Halliburton Indonesia Velesto Offshore Drilling

Lion Rig Builder Pte PT Medco E&P Indonesia Vinyl Chloride (Malaysia)

Lundin Malaysia B.V. PT Pertamina (Persero) Head Office YTL Power International Berhad





petroEDGE® boasts an unrivalled teaching faculty. All of our partners and consultants have extensive management and technology experience coupled with a track record in delivering high quality courses to professionals in leading oil majors globally. We are members of the esteemed Energy Institute and the CPD Certification Service. We are also proud to have been inducted as an approved training provider of Institute of Leadership & Management for 4 of our training programmes. Our Lubricants courses are certified by the International Council for Machinery Lubrication and the United Kingdom Lubricants Association. Our Process Hazard Assessment using the HAZOP Technique and HAZOP Team Leader Training and Process Safety Engineering courses are accredited by The Institution of Chemical Engineers. We are also recognised by the Society for Maintenance & Reliability Professionals as an approved provider of continuing education and training aligned with key subject areas related to reliability and physical asset management. The mark of approval received from these accreditation bodies highlights the confidence given to the quality of our training courses.

The CPD Certification Service helps organisation provide certified CPD and acts as a point of contact for those seeking to obtain certified CPD material. It supports further learning initiatives being undertaken by Government, professional institutions, trade associations, individual organisations, training providers, suppliers and so on. For more information, visit www.cpduk.co.uk.

The Energy Institute (EI) is the professional body for the energy industry, delivery good practice and professionalism across the depth and breadth of the sector. The purpose of the EI is to develop and disseminate knowledge, skills and good practice towards a safer, more secure and sustainable energy system.

In fulfilling this purpose, the EI addresses the depth and breadth of energy and the energy system, from upstream and downstream hydrocarbons and other primary fuels and renewables, to power generation, transmission and distribution to sustainable development, demand side management and energy efficiency. A Royal Charter membership organisation, the Energy Institute provides a wealth of expertise in energy matters, serving as a home for energy professionals and a scientific and technical reservoir for industry. It is licensed by the Engineering Council to offer Chartered, Incorporated and Engineering Technician status to engineers and also by the Science Council and Society for the Environment to offer registration as Chartered Scientist and Chartered Environmentalist. The EI is an international organisation serving its members in around 80 countries. For more information, visit www.energyinst.org.

The Institute of Leadership and Management (ILM) is Europe’s foremost leadership and management body. At ILM, we are passionate about the power of leadership and management to transform people and businesses. We believe that good leadership and management creates effective organisations, which builds social and economic prosperity. ILM work with organisations in all sectors to help them define, develop and embed the leadership and management capability they need to succeed. ILM provides qualifications in leadership and management, coaching and mentoring and specialist areas such as social enterprise. For more information, please visit https://www.i-l-m.com.

Our programmes approved by ILM are: International Oil & Gas Executive Development Program, Human Competency & Capability Development, Leadership Team Dynamics in Oil & Gas and Technical Report Writing & Presentation Skill for Oil & Gas Professionals.

The International Council for Machinery Lubrication is a vendor-neutral, not-for-profit organization founded to facilitate growth and development of machinery lubrication as a technical field of endeavor. Among its various activities, ICML offers skills-based certification testing for individuals in the fields of machine condition monitoring, lubrication and oil analysis. For more information, visit https://www.icmlonline.com/. Our programme certified by ICML is Lubricant Analysis and Condition Monitoring.

The UK Lubricants Association (UKLA) actively represents member company’s interests both at home and overseas. Representing the majority of the UK Lubricants Industry, the UKLA is actively engaged with other trade associations on matters impacting the industry through participation in consultation, representation and lobbying to UK and European Government and industry authorities. For more information, visit www.ukla.org.uk. Our programme accredited by UKLA is Lubricants Blending and Quality Assurance.

Founded in 1922, the Institution of Chemical Engineers (IChemE) is a multi-national institution with primary offices in the UK and Australia. We exist to advance chemical engineering’s contribution for the benefit of society. IChemE members can be found in a wide range of industry sectors, and at different stages of their careers. They play a key role in our governance and day-to-day operations. IChemE is led by members, supports members and serves society. For more information, please visit https://www.icheme.org/. Our programmes accredited by IChemE are Process Hazard Assessment using the HAZOP Technique and HAZOP Team Leader Training and Process Safety Engineering.

Visit us at www.petroedgeasia.net or contact us directly at +65 6741 9927 or email to [email protected] for more information.



http://www.cpduk.co.uk/

http://www.energyinst.org/

https://www.i-l-m.com/Learning-and-Development

https://www.i-l-m.com/

https://www.icmlonline.com/

http://www.ukla.org.uk/

https://www.icheme.org/





EARLY BIRD NORMAL TEAM DISCOUNTS petroEDGE recognises the value of

VIRTUAL INSTRUCTOR LED TRAINING (VILT) 26 – 30 July 2021

SGD 3,299 USD 2,410

SGD 3,499 USD 2,610

learning in teams.

Group bookings at the same time from the same

company receive the following:

3 or more at 5% off

petroEDGE In-house Training Yes, I would like to organise this training on-site and save on total course fees! For further information about

5 or more at 7% off 8 of more at 10%

On-site Solutions, please call +65 67419927 or email [email protected] All other promotions including early bird are exclusive of the group discount.

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