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Reliability Engineering Training Course

This Reliability Engineering Training Course provides a detailed overview of reliability engineering and its role in the asset’s life cycle. As an introductory course, its focus is much more on breadth rather than depth. It’s suited primarily for Maintenance and Reliability practitioners from process, energy and manufacturing industries including Oil & Gas, Petro-chemicals, Renewable Energy, Power, Chemicals and Pharmaceuticals.

Objectives

This training course aims to achieve:

  • Understanding of the reliability terms, its definitions and use
  • Understand the value of reliability engineering and the value it will bring to the organization
  • Knowledge of the reliability engineering tools, where it is mapped in the asset’s lifecycle and recognize its applicability in the workplace

Learning Outcomes

On successful completion of the course, participants will be able to:

  • Understand what Reliability Engineering is and the value it can deliver to the asset’s life cycle and the organization’s bottom line
  • Be knowledgeable of the tools in Reliability Engineering and know its application

Course Outline

Reliability Engineering Concepts

  • Terminology and definitions
  • Probability and Likelihood of Failure
  • Understanding basic statistical concepts: Mean, Median, Mode, Standard Deviation, Normal Distribution
  • Failure Histograms
  • Class room exercise
  • Failure distributions; simple analyses
  • Probability Density Function, Hazard Rates
  • Different Distributions
  • Metrics – MTTF, MTBF, MTTR
  • Relationship between Reliability, Availability & Maintainability
  • The Bathtub Curve
  • How to use reliability information for maintenance

Reliability Engineering Application

  • Tools overview; RBDs, Reliability Modelling, FTA/ETA, FMECA, RCM, RBI, RCA
  • Computing value added, performance metrics
  • Making a Business Case

Human Error and Reliability

  • People, Process and Plant; Reliability Tripod
  • Human Error major contributor to unreliability
  • Understanding Human Error
  • Physiological ^ Psychological Stress
  • Rule, Skill and Knowledge based errors
  • Error prone situations
  • Managing Error

Degradation Mechanisms

  • Wear, Corrosion, Fatigue, Creep, Erosion
  • Physical process – tyres & potholes, crack propagation
  • What do we understand by the term Maintenance?
  • Failure Patterns
  • Age-related and non age-related failures
  • Managing Degradation – Appropriate Tasks

Risk Management

  • What is Risk?
  • Quantitative Risk
  • ALARP and Residual Risk
  • Qualitative Risk
  • Decision Making
  • Selling ideas

Introduction to Reliability Centred Maintenance (RCM)

  • Maintenance in context
  • Why RCM is different
  • The seven RCM questions
  • The Operating Context
  • Failure Mode and Effect Analysis
  • Simple RCM Exercise – Kettle
  • Where to use RCM
  • RCM in Oil & Gas and Process Industry

Introduction to Risk Based Inspection (RBI)

  • Corrosion Circuits
  • Corrosion Rates; Design & Actual
  • Probability of failure, Susceptibility to failure
  • Consequences; HSE, Production loss, Asset damage
  • Process steps, Criticality, Confidence Rating, Inspection Interval factor, Remnant life, Next Inspection Interval
  • Non Age-Related failures
  • Strategy based tasks
  • Where to use RBI

Introduction to Instrumental Protective Functions (IPF)

  • IPF vs. Process Control
  • Cause-Consequence charts
  • Process Demand Categories
  • Consequences; HSE, Production loss, Asset damage
  • Safety Integrity Levels
  • Implementation
  • Spurious Trips/Alarms; Safe Failures
  • Testing, Coverage Factor and Maintenance
  • Where to use IPF

Introduction to Failure Mode, Effects and Critically Analysis (FMECA)

  • Failure Mode and Effect Analysis
  • Probability and its ranking
  • Detectability of Failure and its ranking
  • Consequence and its ranking
  • Risk Priority Number – Criticality
  • Where to use FMECA

Introduction to Fault Tree And Event Tree Analysis

  • Terminology, Symbols, and Notation
  • Logic Diagrams
  • Assigning probabilities
  • Incorporating Human Error
  • Where to use FTA, ETA

Introduction to Reliability Block Diagrams, Modelling

  • System Reliability
  • Series RBDs
  • Parallel RBDs
  • Complex RBDs, Nested RBDs
  • Bridge RBDs
  • System Analysis
  • System Analysis and Modeling
  • Analytical and Simulation Models

Simple Weibull Chart

  • Arranging the data set
  • Distribution of rank order, Benard’s approximation
  • Median ranks
  • Plotting the data points, best-fit line
  • Outputs: Shape and scale factors, B10, B1, B .1,B .01
  • Computing the pdf chart values
  • Forecasting failures
  • Weibull Video

More Complex Weibull Charts

  • Suspended data points
  • Censoring, Effect on ranks
  • The effect of preventive maintenance
  • Applying Benards approximation to get median ranks
  • Plotting Weibull chart points
  • Plotting the data points, best-fit line

Data Sources

  • Run length data; run meters, DCS, operating logs
  • CMMS; failure data, history text
  • Operators and Maintainers as sources
  • Publicly available sources, OREDA, IEEE
  • Errors in data sources, Independent & Identical conditions

Getting The Basics Right (GTBR)

  • OEE & TPM
  • Lubrication
  • Joint Tightness
  • Alignment
  • Balancing
  • Failure Elimination Culture