Introduction

This Reliability Professional – RP Training Operations course will help you to enhance the body of knowledge comprehensively by addressing and examining equipment reliability and maintenance (R & M) as well as overall asset management, people, and technical skills.

The methodology involved reliability and risk assessment, major hazard scenario development, root cause analysis, establishing a performance standard, developing maintenance, inspection and testing plans, implementing assurance activities and, finally, issuing a key performance indicator.

Goals

Participants will learn:

• How to develop more robust asset integrity maintenance and reliability philosophy.
• Learning about asset management integration and learning from incidents of major failures.
• Risk and hazards management.
• How to get the most out of Computerized Maintenance Management Systems (CMMS).

TRAINING OBJECTIVES

• Recognize the fundamentals of Reliability Engineering and Maintenance Management.
• Ensure good understanding of hazardous risks.
• Establishing safe procedures for operations and maintenance activities.
• Selecting effective control measures for hazardous risks.
• Establishing effective emergency management plans and emergency response actions.
• Learning from failures: decision analysis of major disasters.

Training Methodology

The Reliability Professional training course covers essential skills such as the introduction to the function of asset integrity management and how it integrates with and impacts operations, arrangement of inspection and maintenance cycles for with regards to plant operating equipment, and description of controls and procedures that are observed to control equipment stresses due to continuous or frequent operations.

Throughout this program, there will be a set of small quizzes of multiple-choice timed questions aimed as a rehearsal for timing and measuring knowledge gained from the material covered. Within the program, delegates will be guided by a professor who is an expert in Maintenance Asset Management and Reliability Engineering. Delegates will be offered authored books and up-to-date publications in the field that contain case studies of covered topics.

TRAINING SUMMARY

This Reliability Professional training course covers essential skills related to risk analysis such as appreciating safety measures and learning from major failures as well as from near misses. This allows you to develop deeper understanding of risk modelling, asset integrity, and analysis of existing and potential safety barriers. This is crucial towards improving the uptime, reducing risk and increasing productivity.

Target Groups

• Reliability Engineers and Managers.
• Technicians and managers who need knowledge of managing hazardous materials and complex machinery.
• Operators and shift supervisors involved in hazardous substances management and programs.
• HSE personnel involved in safety management systems.
• Super intendents and Engineers required having knowledge of process safety aspects of plant operation.
• Reliability & Safety Engineers.
• Other personnel interested asset management integrity.

Program Content

Day 1 - Manufacturing Process Reliability

• Accident investigation (root cause failure analysis).
• Failure Mode and Effects Analysis (FMEA).
• Root cause Analysis for rotating.
• Fault Tree Analysis (FTA) and Reliability Block Diagrams (RBD).
• Cut sets and minimum cut sets for assessing vulnerability in equipment.
• Reliability Centred Maintenance (RCM).

Day 2 - Equipment Reliability  

• Basic Definitions and KPI Standards for Equipment Reliability..
• MTBF/Failure rate/MTTR/Repair rate.
• Equipment availability.
• Percent planned or unplanned maintenance.
• Maintainability.
• Failure trends using Weibull Analysis.
• Replace/repair decision making.
• Condition Based Maintenance (CBM).
• Chronic problem equipment.
• Pareto Analysis.
• Main Criticism of Existing Management of Computerized Maintenance Systems.
• The Asset Management Framework.
• The Enterprise Resource Planning (ERP) Systems..
• The Decision-Making Grid (DMG) Approaches.
• Selection of Appropriate Maintenance Strategies.
• Integration of RCM, TPM, and CBM Approaches.

Day 3 - Failure Analysis and Reliability

• Elementary Statistics and Standards.
• Reliability Models.
• Learning from Major Failures Case Studies in Process Industries.
• Learning from Major Failures Case Studies in Oil and Gas Industries.
• Root Cause Analysis and Extractions of Specific and Generic Lessons.
• Reflection on Why Systems Fail.

Day 4 - Statistical Failure Analysis and Reliability

• Further Reliability Definitions and Standards.
• Examples of the Planning Process..
• Hazard Function and Bath Tub Curve.
• Weibull Analysis.
• Case Studies from Rotating Equipment.
• Case Studies of Major Failures in other Industries.

Day 5 - Condition Based Maintenance

• General Purpose CBM.
• The P-F Curve..
• Principles of Vibration Monitoring.
• Thermal Monitoring.
• Acoustic Emission.
• Lubricant Monitoring.