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7/28/2019 Faliure Root Cause Anlaysis
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About Te Organizer.U.N International was ormed with the objective o truly understanding the needs o each individual organization’straining requirements. Our strength lies in our ability to listen to our clients, understand their unique businessissues and assisting them to deliver the appropriate training solution based on the business challenges in the currentmarket situation.
Our vision is to be the No. 1 preerred training provider or all corporate companies by providing an innovativeapproach to your training requirements. We acilitate a training solution that is not only cost eective, buttailored to yield maximum benets. We deeply value our working relationship with our clients and constantly dedicate ourselves to exceed your expectations o us. Besides customizing in-house training solutions or corporatecompanies, we also oer public courses and conerences in various industries.
About Te rainer
Mr. S.Nadeem Ahmed has 20 years plus o diverse engineering experience in Industrialsectors as a Mechanical Engineer with Manuacturing and Engineering MRO Industry.For the past 15 years, he has worked with PK Engineering MRO acility on MaintenanceRepair, Overhaul, esting and Evaluation o urbo Machinery including Aero and Aero
derivative Gas urbine Power Plants and has diversied experience on General Electric,Rolls Royce and Pratt & Whitney Machines. As an international conerence speaker &trainer globally addressing Gas urbine Power Plants, Rotating equipment, Reliability engineering & lean Six Sigma topics, he has also trained numerous proessionals in thesame area within and outside his organization. Nadeem has also provisioned Processcompanies (Power Generation, Oil and Gas etc) on Eective Reliability ImprovementPrograms, Maintenance Management Strategies, Lean Maintenance and Six Sigma Process Improvement Strategies integrating the same with reliability solutions. He holds a Masters in MechanicalEngineering with Major in Termal Power Systems Engineering, is a Certied Six Sigma Master Black Belt romUSA & is well versed with the Quality, Six Sigma and Power Plant Equipment Reliability Analysis Sotware’s.
Plant & Equipment
Failure Root Cause Analysis
13 - 17 May 2013, Kuala Lumpur19 - 23 May 2013, Abu Dhabi
7/28/2019 Faliure Root Cause Anlaysis
http://slidepdf.com/reader/full/faliure-root-cause-anlaysis 2/4 TEL: +65 6376 3129 FAX: +65 6271 9029 EMAIL: [email protected] ONLINE: WWW.TUN.SG
Plant & Equipment Failure Root Cause Analysis 13 - 17 May 2013, Kuala Lumpur
19 - 23 May 2013, Abu Dhabi
Process and Power Plant Equipments play a major role in managing processes across the plant . The Equipmentis very expensive to maintain and as such unscheduled events / failures associated with equipment can have highimpact on direct and indirect operating cost of plant. This course is designed for professionals to have an insightinto equipment failure analysis, and aligning maintenance strategies and reliability program to control the same
ensuring performance factors, eciency and uptime.
The maintenance strategies and philosophies if not eectively controlled may result in failures which are dicultto control as such there is a strong need in plant environment to perform a thorough failure analysis through an
established system .
This course is designed to understand the concepts of Failure modes and analysis associated with plant criticalas well as non critical equipments with redening the existing Maintenance and reliability programs for themitigation of same in future. In depth understanding of various types of failures associated with equipment,their associated cost , and advanced analysis tools in software will be supported by case studies . The economic
and safety aspects as per RCM philosophy will supplement the course.
The comprehensive failure case studies for various equipment from Process and power generation viz Gasturbines, compressors , pumps , heat exchangers , HRSGs . Steam turbines, Fans , Conveyors etc will be discussedin detail . Advanced failure analysis tools and techniques as applied in Industrial Plants will be given a thoroughinsight. Performance parameters and associated variations due impending failure for various equipment and
their interpretation will be addressed in detail.
raining Methodology Te training will be acilitated using modern techniques . Supported by case stud-ies rom real plant environment , Videos . Te ailure Analysis tools application
to various types o Industrial Equipment will be exercised with mini workshop within the sessions . Te audience are requested to bring their laptops to exerciseailure analysis sotware with their own plant data .
Day 1Overview of Process Plants ypes o Plants
Process , Power Generation , Manuacturing •
Asset Management•
Special Facilities , LNGs•
Plant Economics a basic Insight•
Role o Equipment in Process Chain•
How plant equipment ail•
Videos•
Overview of Plant Equipment ypes o Equipment
Static vs Rotating •
Special purpose Equipment•
Plant systems , components•
Compressors , Gas urbines ,Fans•
Motors , Heat Exchangers , Boilers , HRSG•
Generators , ans , Structures etc•
Application o Equipment and their part in your process chain•
Importance o Equipment as an Asset in Plant•
Design or Perormance and Zero breakdown•
Videos•
Design, Operation and Total Cost OptimizationPlant as an Asset , Key Asset Management Strategies•
Basic design o equipment static and Rotating •
Structure and operation o critical equipment•
Maintenance Issues or Equipment ( General )Lie Cycle / Bath ub Curve•
Optimizing Operation over Lietime•
Optimizing Reliability o plant Equipment•
Lie cycle operating cost , Cost impact calculations•
Maintenance Cost Key Perormance Indicators•
Key maintenance issues with plant equipment•
Maintenance Management•
Maintenance Planning & Scheduling or plant EquipmentMaintenance Supervision / Skill Enhancement Working with external vendors versus sel-maintenanceypes o Maintenance and its Implications on equipment Failures.
Unscheduled Events and Non Routine Maintenance ( ailures)•
Benets & Learning ObjectivesUnderstanding Industrial Plant Equipment•
Basic Classications. Functional criticality •
Perormance and unctions degradation•
API , ANSI & ASME standards or Equipment•
Maintenance program efciency and eectiveness•
Equipment Failure Modes and Consequences•
Understanding ailure Analysis, tools and techniques.•
Detailed understanding o FMEA , ANOVA , RCM•
Advanced Data Analysis as applied to plant Equipment .•
Latest innovations in FRCA and CM or rotating equipment .•
Developing Specic equipment plans in view o ailure history .•
Implement Solutions such as FRACAS and reduction in Main Cost.•
Increasing daily revenue or Plant reducing ailures .•
Optimize perormance and efciency by learning rom condition monitor-•
ing Integrating the reliability program, maintenance Program and ailure•
analysis o equipment .
Practical Case studies to Evaluate and adopt solutions in industries•
Appropriate Analytical tools or maintenance decision making •
Who Should AttendMaintenance Management•
ManagersEngineersChie EngineersVice Presidents
Maintenance Sta •
Maintenance Planning Managers•
Maintenance Program Engineers•
Reliability Engineers / Managers•
Reliability Engineers•
Finance and procurement people•
7/28/2019 Faliure Root Cause Anlaysis
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Plant & Equipment Failure Root Cause Analysis 13 - 17 May 2013, Kuala Lumpur
19 - 23 May 2013, Abu Dhabi
Day 2Plant Equipment Integrity Management
Statutory, Saety, Operating and Maintenance Standards•
API , ASME and ANSI standards or plant equipment•
Documentation and Record Keeping requirements•
Auditing and Analysis o operating management systems•
Equipment Condition Monitoring or understanding ailuresest & Inspection, Inspection Data Gathering •
Vibration Analysis , Termal techniques•
Oil Analysis , Wear Debris Detection•
Online Monitoring o CBM data •
Perormance Monitoring and Analysis•
Other methods & Latest Developments•
Example , Advanced Gas turbine echnology •
Example , HRSG Heat recovery steam generator•
Root Cause Failure AnalysisIntroductory Concepts•
Root cause ailure analysis philosophy Te our-step problem solving approachTe importance o a priori ailure cause identication
Pareto analysis•
Identiying potential root causes•
Why analysis•
Blending root cause analysis approaches•
Pareto analysisFault tree analysis (FA)Event and causal actor analysis (ECFA)Barrier analysisManagement oversight and risk tree analysis (MOR)Change analysis , Critical incident technique (CI)Te 5-Whys technique
Fault tree analysis introduction•
FMEA ( ailure modes and Eects by Analysis )•
Systematic Approach FRACAS•
Day 3
Equipment Fatigue and Failure ModesCauses o Fatigue and ailures•
Aerooil / Impeller ailures in urbo Machinery •
Failure Videos•
Root Cause Failure Analysis Process , Failure Reporting •
Cause behind the cause•
Reliability improvement Program or Plant Equipment•
Use o Six Sigma tools and Methodologies•
Integrating Equipment Maintenance KPIs and Equipment Failures ModesCost per hour o Operation•
Restoration Work scoping Minimum Cost•
Mid and Final Overhaul•
MBO , MBUR , MF Considerations•
Lean Maintenance concepts•
Reliability, Availability, Maintainability, and Saety •
Impact o special and common cause variation on RAMS•
Work-Scope example o Gas turbine in LNG Applications•
Special Applications o Failure Analysis ools Discussions.LNG rains•
Power Generation Plants•
Oil Platorms•
Petrochemicals / reneries•
Process Plants , Cement , Fertilizer•
Rotating Equipment Reliability Programs in Applications•
More Perormance & Failure VideosGas urbines , Contained / Un-Contained•
Pumps , Compressors , Fans & Wind Mills•
Aviation Disasters due Rotating equipment•
Insurance issues•
Day 4Reliability Programs
Te RCM Process and Method•
Forecasting and predicting the ailures•
RCM Programs and Gains•
Reliability Program elements , Implementation and Control•
RCM Exercises , Reliability Analysis•
Understanding a Reliability Program Implementation•
Cost vs ROI on reliability program•
Perormance 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 unctioning ( base lines )•
Implementing RCB recommendations.•
Efectivity o Maintenance Program & Reduction In ailuresDocuments ( OEM , MPD , Operator specic Maintenance program,•
Modication)Plant Operator’s Maintenance Program , General Requirements•
Scheduled / Unscheduled Maintenance•
ask / Function Codes , Logistics and Man hour planning aspects•
Maintenance ask Packaging •
urn around Checks , Equalized Programs ,Phased Programs•
Maintenance ask 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.•
Efciency & Eectiveness o Equipment maintenance Program•
Inventory Monitoring to Support Equipment Maintenance Program•
Day 5Equipment Maintenance work scopes & Implications on Failure Modes
Work-scope planning guides ( OEMs)•
Work-scope Examples•
Gas urbines , HRSG ,Steam urbines , Generators , general Equipment•
Understanding work-scope cost•
HARD / SOF time threshold or Rotating Equipment•
Setting RBIs or ailure prediction and rends•
Economic lie o Capital equipment / ailure ImplicationsEPC issues•
Operation and Maintenance economics•
Direct and Indirect Cost Associated with Plant•
Maintenance Cost Baselines•
Maintenance Contracts – Cost Aspects•
Maintenance Cost Reporting •
Failure Costs rends in Lie Cycle o Plant•
Lie extension and evaluation or plant•
Te Risk equation and decisions•
Repair vs Replace ,Lease vs Buy-in•
LSA’s and Failure Warranties / Insurances•
Conclusion
7/28/2019 Faliure Root Cause Anlaysis
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lant & Equipment Failure Root cause Analysis
13 - 17 May 2013, Kuala Lumpur
19 - 23 May 2013, Abu Dhabi
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