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Also available as In-house Course

at Discounted Price!
PC15

02

Preventive and Predictive Maintenance Strategies


Understanding the Maintenance Methodologies and Strategies for Reliability Improvement and
Maintenance Cost Optimization in Plant Environment

16-17 Apr
Kuala Lumpur

7-8 May

Penang

14-15 May

Johor Bahru

About the Trainer

Nadeem has more than two decades of diverse professional engineering experience in various industrial
sectors viz. Aviation, Power Plants and Petrochemicals. Key specialties include consulting, training and
development as a Mechanical Power Engineer in:
Process, Power Generation Plants & Aviation
- Life cycle Asset Management
- RCM based Maintenance & Reliability Program development and implementation
- Reliability Analysis & Risk Based Studies
- Remaining Life Assessment Studies, Evaluation, Extension Recommendations
Work-scope Optimization on Aero and Aero derivative Power Plant Turbo machinery
Maintenance Repair & Overhaul
Thermal and CCPP Power Generation Performance Evaluation
Critical / Rotating Equipment Performance / Functional Reliability & Specific Equipment Plans
Plant, Equipment Failure Analysis, RBD Modeling, FMECA, RCM Program Implementation
Focused Lean Six Sigma Certifications for Maintenance and Reliability Professionals
Well versed with RCM Tools & Softwares Weibull 6++, Minitab and Statistica

ABOUT THE

TRAINER

S. Nadeem Ahmed

MSc Engg (Power Plants)


Six Sigma MBB, USA

Course Description
This course is designed to provide pertinent information and practical insight about preventative & predictive maintenance management to improve the
performance of machines and extend their life in plant environment. A comprehensive understanding of the principles and practices of Maintenance
methodologies and philosophies with specific focus on predictive and preventive maintenance will be covered in detail with practical examples and case
studies. Participants can use the skills and knowledge gained in this course to:
Minimize the breakdowns failures in equipment and reduce downtime and cost
Perform regular preventive maintenance and condition monitoring of equipment
Repair vs. replacement decision during life cycle
Preventative Maintenance (PM) is a series of routine tests, measurements, adjustments, and parts replacement, to identify and resolve potential equipment
problems before they arise. Predictive Maintenance (PdM), or Condition Monitoring (CM) involves monitoring the machines vibration characteristics or
symptoms to diagnose its condition. This method relies on the machines condition to accurately schedule the repair interval. The course will explain when
to adopt PM or PDM, their relative merits and their implementation in actual practice. The course will be interactive covering extensive case studies and
reallife situations.

Course Benefits

Learning Objectives

Maintenance Methodologies & Philosophies


PM, PdM, Condition-based maintenance
Failure Root Cause Analysis FRCA
Maintenance Program Development
Maintenance Interval Adjustments with MPD
Equipment Specific Maintenance Program
Reliability Program Implementation & Control
Maintenance Cost control & Optimization
Maintenance & Reliability Data Analysis Tools & Technique
Life Extension and Evaluation of Equipment Based on
Maintenance Strategy
Recommendations for repair and Replace program

Advanced Preventive and Predictive Maintenance strategies


Equipment Specific Plans for optimum performance
Maintenance and Reliability Program Development
FRCA and FMECA understanding and Practical Implementation

Training Methodology
The training will be facilitated using modern techniques supported by case
studies from real plant environmentand videos. Deep understanding of
Maintenance strategies and philosophies as applied to rotating equipment,
static equipment and BOP will supplement the course. The Analysis tools
application to maintenance, reliability and failure analysis of plant, its
systems and equipment will be exercised with mini workshop during the
sessions. Participants are requested to bringtheir laptops to exercise
analysis software with their own plant & equipment functional and performance data.

For more info, please write to us at: marketing@biztreeventures.com or visit www.biztreeventures.com

Also available as In-house Course


at Discounted Price!

2
Course Agenda

DAY

01
Overview of Plantsand Equipment Used

Maintenance Issues for Equipment (General)

Types of Plants
- Process, Power Generation
- Plant as an Asset, Special Facilities, LNGs
- Plant Economics, basic Insight
- Role of Equipment in Process Chain
- Static vs. Rotating Equipment
- Special Purpose Equipment
- Plant Systems, Components
- Compressors, Gas Turbines, Fans
- Motors, Heat Exchangers, Boilers, HRSG,
Generators etc.
- Application of Equipment and their part in your
Process Chain
- Importance of Equipment as an Asset in Plant
- Videos

Equipment Condition Monitoring Techniques

Equipment Fatigue and Failure Modes

Test & Inspection, Inspection Data Gathering


- In-house
- Subcontractor Maintained
- Rented or Leased Equipment
Vibration Analysis, Thermal Techniques
Oil Analysis, Wear Debris Detection
Online Monitoring of CBM data
Thermography
Ultrasonics
Performance Monitoring and Analysis
Other Methods & Latest Developments
Case Studies

Causes of Fatigue and Failures


Aerofoil / Impeller Failures in Turbo Machinery
Failure Videos, Root-cause Failure Analysis
Process, Failure Reporting
Cause Behind the Cause
Use of Six Sigma Tools and Methodologies

Maintenance Methodologies and

Lifecycle / Bath Tub Curve


Philosophies
Optimizing Operation over Lifetime
Reactive,Preventive, Predictive and
Optimizing Reliability of Plant Equipment
Proactive Maintenance
Lifecycle Operating Cost, Cost Impact Calculations
Preventive Maintenance (PM) Features
Maintenance Cost Key Performance Indicators
and Benefits
Key Maintenance Issues with Plant Equipment
Planning Preventive Maintenance
Maintenance Management
Prioritizing candidates for PM
- Maintenance Planning & Scheduling for Plant
Building credible PM Procedures
Equipment
Understanding & developing a PM Program
- Maintenance Supervision / Skill Enhancement
Preventive Maintenance Metrics
- Working with External Vendors vs. Self-maintenance Setting up Preventive Maintenance
- Types of Maintenance and their Implications
Requirements
Applying Preventive Maintenance to Plants
and Equipment

Equipment Maintenance KPIs /Overhauling


Work-scopes

Cost per hour of Operation


Restoration Work scoping at Minimum Cost
MTBO, MTBUR, MTTF Considerations
Lean Maintenance Concepts
Reliability, Availability, Maintainability
and Safety
Impact of Special and Common Cause
Variation on RAMS
Work-scope Example for Gas Turbine in
LNG Applications

DAY

02
Reliability Program for Plant Equipment
The RCM Process and Method
Forecasting and Predicting the Failures
- RCM Programs and Gains
- Reliability Program elements, Implementation
and Control
- RCM Exercises, Reliability Analysis
- Understanding a Reliability Program Implementation
- Performance Measurement and Parameters
- Monthly Plant Reliability Report
- Reliability Based Inspections
- MRB, RCB and RRB Functioning (Baselines)
- Implementing RCB Recommendations.

Maintenance Program Implementation

Equipment Maintenance Work-scopes

Documents (OEM, MPD, Operator specific


Work-scope Planning Guides (OEMs)
Maintenance Program, Modification)
Work-scope Examples
Plant Operators Maintenance Program,
- Gas Turbines, HRSG, Steam Turbines,
General Requirements
Generators, General Equipment
Scheduled / Unscheduled Maintenance
Understanding Work-scope Cost
Task / Function Codes, Logistics and Man-hour
HARD / SOFT Time Threshold for
Planning Aspects
Rotating Equipment
Maintenance Task Packaging
- Turnaround Checks, Equalized Programs,
Economic life of Capital equipment
Phased Programs
Maintenance Task Cards, Computerized Maintenance Operation and Maintenance Economics
- Direct and Indirect Cost Associated
Management Systems
with Plant
Maintenance Program Implementation and Development
- Maintenance Cost Baselines
Staggered Implementation Plan
Maintenance Contracts Cost Aspects
- Service Experience, Periodic Review
Maintenance Cost Reporting
- Inspection Interval Escalations
Life Extension and Evaluation for
- Successive Reviews and Amendments
Equipment
Lean Maintenance Concepts and Integration with
Repair vs. Replace, Lease vs. Buy decisions
Existing Programs
LTSAs
Efficiency & Effectiveness of Equipment
Best Mix of Qualities
Maintenance Program
Inventory Monitoring to Support Equipment
Maintenance Program

Exercises
Conclusion

For more info, please write to us at: marketing@biztreeventures.com or visit www.biztreeventures.com

Also available as In-house Course


at Discounted Price!

Venue

Dates

Kuala Lumpur

16-17 Apr 2015

USD 1,950 per participant

Penang

7-8 May 2015

USD 1,950 per participant

5% for 3 5 participants
7% for 6 8 participants
10% for 9 or more participants

14-15 May 2015

USD 1,950 per participant

Plus, early bird discount!

Johor Bahru

Price

Discounts on Group registration

Broad Terms & Conditions


Registration: A business contract will be signed between the
Client and BizTree at least 15 days prior to the course date.
Fees: Course fee is inclusive of trainer related costs, training
material, stationery, IT support, meals and refreshments.
Payment Terms: Fee must be paid in full within 15 days after the
business contract is signed (registration). Payment can be via
either of the two methods mentioned above. BizTree reserves the
right to refuse enrolment/registration of the participants if
payment is not received on time. All payments must be made in
Malaysian Ringgits unless otherwise stated on the business
contract.
Substitutions: BizTree may allow the Client to substitute
participant(s) with same number of other participant(s) at no extra
charge, provided if the Client has paid the course fee in full.
Substitutions must be received in writing by BizTree by mail or
email 5 days prior to the start of course.
Discounts: BizTree at its discretion may offer 'Early Bird
Discount' or Team Discount. In order to be considered for
discounts, the Client must pay the course fee full after signing the
contract (registration) and before the scheduled course date.

Others: While every reasonable effort will be made to adhere to


the advertised package, BizTree reserves the right to change
event dates, sites or location or omit event features, or merge the
event with another event, as it deems necessary without penalty.
Other Terms & Conditions and Privacy Policy are as mentioned
on our website at www.biztreeventures.com

Course fee: USD 1,950 per participant


Registration closing date: 26 March 2015
Payment Methods:
1. Cheque / Bank Draft
Made payable to: BizTree Ventures Sdn Bhd
Address: NW-30-3A, Cova Square, Jalan Teknologi

Kota Damansara, 47810 Kuala Lumpur, Malaysia

2. Bank Transfer
Account Name: BizTree Ventures Sdn Bhd
Bank Name: Maybank (Malayan Banking Berhad)
Account No.: 564490411615
Swift Code: MBBEMYKL
Bank Address: Lot C21-C, Concourse Expansion Suria KLCC,
Kuala Lumpur City Centre, 50088 Kuala Lumpur, Malaysia

For enquires & registration, please contact us at:


Mobile: +6012 427 5260 or Email: marketing@biztreeventures.com

About BizTree Ventures


BizTree Ventures Sdn Bhd is a Malaysia based company engaged in promoting quality learning in accordance with international
practices. At BizTree, we are dedicated to the development of technical professionals through a comprehensive portfolio of
training programs on wide ranging technical topics for various industrial sectors viz. Oil & Gas, Petrochemicals, Manufacturing,
Process and Power Generation.
Formed by professionals with successful track record in the related sectors, BizTree has association with internationally
recognized and experienced trainers and aspires to become a solutions provider of choice for all industrial sectors globally.
The company has several differentiators in the training industry:
Breadth of technical training programs specially structured for various industrial sectors
In-house courses that are customized to meet the client's specific training needs
Web-based courses via webinars supported by case studies and videos from real industrial environment
Seminars organised as full-day and half-day programs on wide ranging technical topics
Long-term implementation programs tailored to meet the client's plant, equipment and process requirements
Highly experienced certified trainers of international repute
A management team of professionals with more than 20 years experience
BizTree desires to empower you with in-depth analysis, critical thinking and practical knowledge of current trends and ideas
supported by world-class trainers who would bring real-life experience to the learning environment.

For more info, please write to us at: marketing@biztreeventures.com or visit www.biztreeventures.com