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RAM/RCM and SPOF [Single Point Of Failure] analysis for industrial plants
RCM Based Maintenance & Reliability Program
SPOF Analysis Understanding,
Development & Implementation

14-18 March 2016, Kuala Lumpur

About the Trainer


More than 26 years of diverse experience in the field of engineering. Worked for the industrial sector with a career as a Mechanical
Power / Reliability Engineer in Petrochemical Reliability , Power Plant Risk Based Study , Remaining Life Assessment , Training &
Consulting , Aero and Aero Derivative Gas Turbine Power Plant Maintenance , Repair & Overhaul , Testing / Evaluation and Defense
Manufacturing.
Key expertise in engineering MRO facility and maintenance; repair & overhaul of turbo machinery. Diversified
experience on GE, Rolls Royce and Pratt & Whitney Gas turbine engines. RCM program development and
implementation for Petrochemicals and Power Plants.
Global Consultant and Technical Trainer for Process and Power generation, Oil and Gas, Aviation Industry
addressing:

Maintenance and Reliability, Program Development & Optimization

Process and Power Plants, Risk Based Study, Remaining life assessment evaluation & extensions

Power and Process Plant Life cycle, Asset Management & Reliability Analysis

Thermal and Combined Cycle Power Gas Turbine, Power Plants performance Analysis

Critical / Rotating Equipment Performance / Functional Reliability & Specific Equipment Plans

Plant, Equipment RCA Root Cause Failure Analysis, RBD Modeling, FMECA

RAM / RCM Program Development and Implementation for Plants, Units, Systems

Asset Management Standards ISO 55000, PAS 55-1, 55-2

Work-Scope Optimization on Aero and Aero derivative Power Plant. Turbo machinery maintenance, repair & overhaul

Focused Lean Six Sigma Certifications for Maintenance and Reliability Professionals
> Trained number of professionals in the same area within and outside organization.
> Masters in Mechanical Engineering with Major in Thermal Power Systems Engineering.
> Six Sigma Master Black Belt from FBE LLC USA.
> Well versed with Reliability Analysis Tools, RCFA, RCM and Reliability Analysis Software weibull
6+, Minitab R16 Six Sigma Analysis software.

About The Organizer


T.U.N International was formed with the objective of truly understanding the needs of each individual organizations
training requirements. Our strength lies in our ability to listen to our clients, understand their unique business issues
and assisting them to deliver the appropriate training solution based on the business challenges in the
current market situation.
Our vision is to be the No. 1 preferred training provider for all corporate companies by providing an innovative approach
to your training requirements. We facilitate a training solution that is not only cost effective, but tailored to yield
maximum benefits. We deeply value our working relationship with our clients and constantly dedicate ourselves to exceed your expectations of us.
Besides customizing in-house training solutions for corporate companies, we also offer public courses and conferences in various industries.

TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG

Comprehensive practical course on RAM / RCM program development, implementation and


optimization in industrial with customer specific equipment reliability considerations and SPOF
analysis for plant critical equipment GTs, STs, HRSG, boilers, generators, transformers, fired heaters ,
heat exchangers , pumps , compressors , motors , piping , instrumentation and control systems, BOPs

Course Overview:
Industrial plant reliable operations and maintenance are paramount to overall effectiveness of plant business objectives ensuring
minimum downtimes and maintenance cost optimization. The variety of equipment such as Gas Turbines, HRSGs, boilers, steam
turbines, generators, heat exchangers, fired heaters, pumps, compressors and motors bring certain complexities when identifying problems and meeting the specific maintenance requirements. This 5 Days program is designed to assist the maintenance
management, technicians and engineers in identifying the various industrial plant operating performance and functional parameters, plant reliability considerations, and reliability tools as part of RCM Program development and implementations, criticalities and failure modes, consequences and mitigation characteristics and detailed SPOF analysis techniques .
The program is specifically designed for all aged industrial plants and will help participants in developing a proactive maintenance and reliability program with embedded RCM methodology & implementation for the whole plant, SPOF analysis with emphasis on specific equipment plans. Participants will also be provided understanding of preventive and predictive maintenance
programs with analysis of condition monitoring data and further corrections in maintenance program, introduction of RBIs (risk
based inspections) for the optimization of process plant maintenance schedule.
Industrial plant bad actors management programs with emphasis on trips, performance variations, production load cycling its
effects, turn around work-scopes optimization techniques will supplement the course with practical analysis exercises.
A thorough insight into the current practice gaps and resolution to avoid failures, maintenance cost and life cycle analysis will
supplement the course. Remaining life assessments, evaluations and recommendations and equipment repair and replacement
decisions as part of industrial plant objectives will be discussed in depth.
The asset management model as applied to plant equipment as part of RCM strategies will be discussed in detail with reference to
PAS-55 / ISO 55000 recommendations.

Learning Objectives
A-Z of an industrial plant
Plant equipment basic classifications
Plant performance and functional standards, major checks ,
rotor, boiler assessments , critical equipment plans
Advance maintenance management in plant
Eliminate unplanned down time, improvement in maintenance
program
Latest innovations in RCM, FRCA and CM for modern plants
Reliability tools understanding and applications
RCM implementation strategies and issues resolutions for
success
Implement solutions that reduce the cost per hour of operation
SPOF - Single point of failure analysis
Increasing daily revenue for industrial plant
Optimize performance and efficiency by adopting updates in

condition monitoring
Effective reliability program to optimize the performance of the
equipment
RCM based reliability program design, implementation and

control for whole plant
Practical case studies , evaluate and adopt solutions after SPOF
analysis in industrial plants
Appropriate use of analytical tools for maintenance decision
making

Key Benefits
Equipment performance evaluation throughout life cycle
Understanding life extension,
Understanding equipment key maintenance performance
indicators
Plants bad actors management and analysis
Operational cost monitoring and analysis
Criticality analysis, RBD modeling
Systems & equipment repair vs. replacement decision
Improved job performance, decision making capabilities
Technology transfer between participants

Who Should Attend


Maintenance Managers
Maintenance Engineers
Reliability Engineers
Asset Managers and Team
Failure Analyst
Maintenance Planner
Maintenance and Reliability program Team

TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG

RAM/RCM and SPOF [Single Point Of Failure] analysis for industrial plants
RCM Based Maintenance & Reliability Program
SPOF Analysis Understanding,
Development & Implementation
14-18 March 2016, Kuala Lumpur
Training Methodology

The training will be facilitated using modern techniques, supported by case studies from real industrial plant environment and
videos. The analysis tools application to plant maintenance, reliability and SPOF analysis will be exercised with mini
workshop within the sessions. Participants are requested to bring their laptops to exercise analysis software with their own
plant data. Repair vs. replacement decisions on specific equipment will be exercised during the course.

Scope of Training

Day 1
Understanding industrial plant types and designs
Performance and functional variations on industrial plant
equipment.
Understanding reliability in industrial plant environment
Plant reliability roadmap
Types of reliabilities- functional, performance, process etc.
Understanding layers of protection in plants, SIL
Mechanical , electrical & instrumentation systems
reliability
Understanding RCM program and its historical
development
Complete understanding of maintenance strategies and
philosophies
Data sources , run length data , run meters, DCS, operating
logs
CMMS , failure data, notification text , operators and
maintainers as sources
Publicly available sources, OREDA, IEEE
Errors in data sources, independent & identical conditions
Defining critical systems / equipments / components
GTs , boilers , HRSGs , generators , steam turbines , HEs ,
fired heaters, misc. systems
Identifying functions of critical systems / equipments /
components
Day 2
Plant criticality analysis , FMECA
Performance Vs functional reliability
Calculating reliability, availability & maintenance ( RAMs
Practical Exercises )
Understanding MTBF, MTTR , MTTF , MODT and Weibull
analysis & shape factors
SPOF analysis understanding
Understanding bath tub curve
Statistical distribution fitting to plant / equipment data
Statistical reliability program, understanding reliability
alert levels ( Green , Amber , Red )
Practical exercises on process plant equipment
Day 3
SPOF detailed understanding
SPOF analysis for plant , system , subsystem , equipment /
components & integrations

Redundancy and mitigation characteristics


Analysis for plant systems, subsystems , equipment /
components
Identifying functional and performance failures / failure

modes, consequences
29 steps RCM process for a failure mode
Reviewing the FRCA studies in process plants
Using cause mapping , FTA , ETA in reliability and SPOF
studies
Identifying critical TAGS on process plant.
Maintenance costing, CAPEX and OPEX vs LTSAs
Understanding mitigations like, additional PM tasks and RBIs.
Inventory levels variation with plant reliability
Day 4
Auditing the existing preventive maintenance program and reliability
program
Developing a reliability block diagram ( RBD modelling )
Critical performance and condition monitoring TAGs identification for
process plant equipment
Understanding existing maintenance and reliability programs
PM vs PDM vs RTF strategies
Developing of maintenance and reliability (KPIs) and GAPs measurement
Weibull analysis, analysing MTBF, MTTR, MTTF for PP systems/
equipment
RAM / RBD model parameters evaluation
Understanding existing SAP history and review for GAPs
Mechanical, electrical, instrumentation and condition monitoring PM task
analysis
Effective use of maintenance historical data base. OREDA
Day 5
RAM / RCM & SPOF project scopes
Use of Soft-wares in RCM analysis
RCM equipment specific case studies ( Mini Workshops )
Redefining Maint.Tasks in Maint.Strategy
Reliability Improvement in Systems / equipments / components
Making RCM a success plant wide, developing a culture
Plant performance, functional and financial gains through RCM
Extending RCM study into RLA study for plant systems/ equipment/
components.
Specific recommendations for quality and condition monitoring for
reliability success in plants
Subcontract repair reliability Vs OEM repair reliability
LTSAs (Long Term Services Agreement ) review
Conclusions & course closure

TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG

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Yes! I/We Will attend RAM/RCM and SPOF [Single Point Of Failure] analysis for
industrial plants course on:
14-18 March 2016, Kuala Lumpur
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RAM/RCM and SPOF [Single Point Of Failure] analysis


for industrial plants course

14-18 March 2016, Kuala Lumpur

SGD 5499
( Save $500 )

: +65 6271 9029

SGD 5999

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TEL: +65 9743 4606 FAX: +65 6271 9029 EMAIL: LINDA@TUN.SG ONLINE: WWW.TUN.SG