Reliability Engineering

24 – 28 JULY 2017, KUALA LUMPUR, MALAYSIA

About The Course

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 volume 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 Should Attend

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.

The American Society of Mechanical Engineers conducts two courses every year on Risk & Reliability Strategies based entirely on the book “Effective Maintenance Management: Risk and Reliability Strategies for Optimal Performance” by V. Narayan.

A copy of this book will be issued free to all participants at this course and will be utilised during the training conducted by the author.

Course Faculty - V. Narayan

V NarayanNarayan retired from The Royal Dutch Shell Group of Companies in 2002, after a distinguished career in maintenance and project engineering.
As the Head of Maintenance Strategy Group, Shell UK Exploration and Production, he was involved in the following assignments:
  • Created a new process and authored a standard to build in Reliability into new Projects. This process, called ‘Operations in Projects’ is now extensively used in all major Shell Projects. This clear Business Process enables Shell to maximise Life Cycle Net Present Value by designing lean Plants with high Reliability.
  • Created 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 14000 test bench records, as well as one for Gas, Heat and Smoke Detectors.
  • Managed the Internal Consultancy Services and later extended it to other
Shell Companies as Head of Shell’s Centre of Excellence for the E&P sector.
Provided Training and Consultancy Services to Shell Companies in Brunei, Philippines, Argentina, Australia, Gabon, Nigeria and Oman.
  • Was the Custodian of Shell Standards relating to Maintenance Strategy.
  • Was a regular lecturer in RCM at the Shell Training Centre in Holland, conducting 14 sessions over an 8 year period.
  • Carried out a Maintenance Review of Shell Gabon’s Oil Production Facilities,
As Maintenance and Reliability Adviser, Shell International, The Hague, he was involved in the following
  • Created Shell’s process and Performance Indicators, for Bench-Marking Maintenance Performance of Refineries and Gas Plants. This methodology is still in use today.
  • Carried out a Maintenance Audit of Woodside Petroleum’s LNG Plant in
Western Australia.
  • Coordinated the Shell Group Refineries participating in the external Bench-Marking studies conducted by Solomon Associates Inc.
  • Facilitated a major Root Cause Analysis at a Shell Chemical Plant in The Netherlands.
  • Carried out a review of a major Shutdown execution at Pernis, the largest Shell Refinery, identifying significant improvement opportunities. Many of these are now embedded in their planning process.
  • Carried out an audit of the Planning of the largest Shutdown at Shell’s
Stanlow Refinery.
  • Was a founder member of the Shell MERIT team, which made major improvements to Refineries’ maintenance performance. Shell now sells this process to third parties.
  • Identified best practices and opportunities for business improvement in fields of reliability, maintenance, inspection and projects in Shell Refineries, and Gas Plants.
  • Created and edited Shell’s Reliability Newsletter promoting best maintenance and operating practices and techniques worldwide.
He has published many articles and presented papers at International Conferences. He has worked in the upstream and downstream Oil and Gas Industry sectors, Engineering, Automobile and Pharmaceutical Industries. He has worked in several countries and cultures, including Saudi Arabia, India, Malaysia, the Netherlands, and the United Kingdom. He is currently on the faculty of Shell Open University and Robert Gordon University, Aberdeen, in their MSc programme in Asset Integrity

Topics Covered

  • Reliability Engineering Concepts &Application
  • Human Error & Reliability
  • Degradation Mechanisms
  • Risk Management
  • Reliability Centered Maintenance (RCM)
  • Risk Based Inspection (RBI)
  • Instrumental Protective Functions (IPF)
  • Failure Mode, Effects and Critically Analysis (FMECA)
  • Fault Tree and Event Tree Analysis
  • Reliability Block Diagram Modelling
  • Simple and Complex Weibull Chart Exercise
  • Data Sources
  • Getting The Basics Right (GTBR)
This training course has a limited attendance for up to 20 participants only. Sessions commence at 9am on all days, with short intervals at 10.30am and 3.30pm respectively. Refreshments will be provided in the short intervals. Lunch will be provided at 12:30pm for 1 hour. Sessions will end at 5pm on all days.

Unique Features with powerEDGE Training

• Pre-Course Questionnaire to help us focus on your learning objectives
• Detailed Course & Reference Manual for Continuous Learning and Sharing
• Practical Exercises & Case Examples to better understand the principles
• Limited class size to ensure One-to-One Interactivity
• Assessment at the end of the course to help you develop a Personal Action Plan