Developing and Implementing a Comprehensive Operations & Maintenance Plan

27 - 29 November, 2017. Park Royal Hotel. Kuala Lumpur. Malaysia

Widen your Competitive Edge - Protect your Assets Enhance Plant Performance

Introduction

So how do you go about setting up all of the maintenance requirements for several thousand discretely maintainable assets? This was the challenge facing
us when we needed to set up the maintenance requirements package for a baggage handling system at a new airport terminal in a major international
airport. From previous experience, and the Airport requirements, we had a good idea of what needed to be done. The challenge was about the sheer size
of the system - with a total asset base of over 28,000 discretely maintainable assets, we needed to find a more efficient way of doing things. As a result of
this we applied a three-step process that delivers a robust maintenance plan, based on clearly defined strategies, which is easy to review and enables the
implementation of changes when necessary. We have found that the principles hold well irrespective of the size of the system.

Methodology

Assets are assets, what can be difficult about identifying them? Well that depends entirely on how far you might want to go down the asset tree. Take a
conveyor for example, do we take the asset structure down to component level, such as the drive motor, or do we leave the asset at convey or level and
take the motor as a component? We defined a maintainable asset as a piece of equipment that can be isolated individually, and as a result we opted for the
latter. This course is aimed at individuals being developed for maintenance management roles. It focuses on developing and enhancing your maintenance
plans, in line with your business criticality and covers the following topics mentioned like diagram for better understanding:

COMPLETE MAINTENANACE PLAN/STRATEGY MANAGEMENT

Is plant & equipment

?

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Designed & 3produced
20274751 By
Fax: MAWA
+60 3 7865 1533
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IMPORTANT DISCUSSION & KEY TAKE AWAY:

Operations

Administration To ensure effective implementation and control of operation activities.

Conduct of Operations To ensure efficient, safe, and reliable process operations.
Equipment Status Control To be cognizant of status of all equipment.
Operator Knowledge and Performance To ensure that operator knowledge and performance will support safe and reliable
plant operation.

Maintenance

Administration To ensure effective implementation and control of maintenance activities.

Work Control System To control the performance of maintenance in an efficient and safe manner such that economical, safe, and
reliable plant operation is optimized.
Conduct of Maintenance To conduct maintenance in a safe and efficient manner.
Preventive Maintenance To contribute to optimum performance and reliability of plant systems and equipment.

Engineering Support

Engineering Support Organization and Administration To ensure effective implementation and control of technical support.
Equipment Modifications To ensure proper design, review, control, implementation, and documentation of equipment design
changes in a timely manner.
Equipment Performance Monitoring To perform monitoring activities that optimize equipment reliability and efficiency.
Engineering Support Procedures and Documentation To ensure that engineer support procedures and documents provide
appropriate direction and that they support the efficiency and safe operations of the equipment.

Administration

Organization and Administration To establish and ensure effective implementation of policies and the planning and control of
equipment activities.
Management Objectives To formulate and utilize formal management objectives to improve equipment performance.
Management Assessment To monitor and assess station activities to improve all aspects of equipment performance.
Personnel Planning and Qualification To ensure that positions are filled with highly qualified individuals.
Industrial Safety To achieve a high degree of personnel and public safety.

STRATEGIES TO BE FOCUS DURING THE SEMINAR:

OPERATION Capacity factor Relates actual plant or equipment operation to the

full-capacity operation of the plant or equipment. This is a measure of actual
operation compared to full-utilization operation.
Work orders generated/closed out Tracking of work orders generated
and completed (closed out) over time allows the manager to better
understand workloads and better schedule staff.
MAINTENANCE ENGINEERING
O&M Backlog of corrective maintenance An indicator of workload issues and
Integration effectiveness of preventive/predictive maintenance programs.
O&M
Safety record Commonly tracked either by number of loss-of-time
INTEGRATION
incidents or total number of reportable incidents.
Energy use A key indicator of equipment performance, level of efficiency
achieved, and possible degradation.
Inventory control An accurate accounting of spare parts can be an
important element in controlling costs. A monthly reconciliation of
inventory on the books and on the shelves can provide a good measure
of your cost control practices.
TRAINING ADMINISTRATION
Overtime worked Weekly or monthly hours of overtime worked has
workload, scheduling, and economic implications.
Environmental record Tracking of discharge levels (air and water) and
O& M Integration Fig.. non-compliance situations.
Staff turnover High turnover rates are also a sign of low worker morale.
Significant costs are incurred in the hiring and training of new staff.

Tel: +60 3 20274751 Fax: +60 3 7865 1533 Email: waseem@mawaevents.com web: www.mawaevents.com
 BENEFITS OF ATTENDING IMPORTANT O&M STRATEGIES

The goal of a maintenance manager is to employ a management system FAST STARTS

that optimizes the use of scarce resources (manpower, equipment, Engine/fuel system/controls/emissions
material, and funds) to maintain the facilities and equipment that are uprates/improvements/enhancements to enable fast
the responsibility of the maintenance organization. The system should starting of existing turbines in both simple- and
combined-cycle service.
provide for integrated processes giving the manager control over the
Improvements/enhancements to enable other grid ancillary
maintenance of all facilities and maintainable equipment from servicessuch as black start, synchronous condenser, etc.
acquisition to disposal.
NEW SKILLS/WORKFORCE DEVELOPMENT
Learn How to Address all resources involved O&M staffing plan (permanent employees) for the next 10
years in terms of numbers, skills development required, etc,
Learn How to Maintain maintenance inventory
PERFORMANCE IMPROVEMENTS
Learn How to Record and maintain work history Starting reliability.
Availability.
Learn How to Include work tasks and frequencies Emissions reduction.
Thermal performance monitoring program.
Learn How to Provide feedback information for analysis Benchmarking.
Data retention and analysis.
Learn How to Reduce costs through effective maintenance Diagnostic and analytic tools.
On-staff or contract service for monitoring.
planning
Program for identifying/correcting deficiencies; trigger
points for action.
Learn How to determine if the system is to be an asset and a Staff awareness/training.
usable tool Condition-based maintenance program.
M&D center.
Learn How to Manage Critical Equipment
PLANT SAFETY PROCEDURES
Learn How to apply CMMS that allows an operator to keep NFPA (56, 70E, 85, 850, etc).
accurate and detailed records of each piece of equipment. ASME Boiler & Pressure Vessel Code.
IEEE.
Discussing basis for planning, scheduling, and executing
scheduled maintenance, planned versus corrective OUTAGE MANAGEMENT
Planning process.
Learn How to improving equipment life and to avoid any Outage safety programs.
unplanned maintenance activity Pitfalls to avoid from previous outages.
Personnel responsibilitiesplant staff, fleet specialists,
Learn How to minimize equipment breakdowns. contractors.
Improving upon past performancee.g., reducing outage
cost, shortening the schedule.
Learn How to maximize equipment operational availability,
Planned-outage strategye.g., shut down or run 1 x 1 while
while minimizing equipment downtime working on one GT and HRSG.
Forced-outage strategy.
Learn How to create lasting equipment reliability by Pre-outage inspection program to fine-tune outage scope.
removing the causes of equipment failure.
O&MGENERATORS, TRANSFORMERS, HIGH-VOLTAGE
Learn How to Manage always produce high plant availability ELECTRICAL GEAR: Best practices for:
and maximum production uptime. Inspection.
Maintenance.
Drive your operational maintenance costs low with the right Repair.
plant maintenance management processes and practices. Upgrade.
Safety.
Create high plant reliability by selecting and using the proper
equipment maintenance management strategies. O&MMECHANICAL: MAJOR EQUIPMENT, BALANCE-OF-PLANT
Inspection.
Learn How to Maintain high operational plant availability to Maintenance.
Repair.
maximize your production
Upgrade.
Learn How to focused preventive and predictive maintenance
PREDICTIVE ANALYTICS
strategies to drive your plant and equipment reliability ever Vulnerability analysis: How do you determine whats most
higher likely to cause a forced outage at your plant?

Tel: +60 3 20274751 Fax: +60 3 7865 1533 Email: waseem@mawaevents.com web: www.mawaevents.com
Course Contents

Identifying all the assets and creating an asset register

Identifying asset classes

Defining how critical an asset is to your business
Calculating the penalty cost of asset failure
Identifying maintenance strategies that support the business
Defining the maintenance strategies to be assigned to asset classes

A brief overview of:

RCM (Reliability Centred Maintenance) analysis,

FMEA (Failure Mode Effect Analysis),
RAMS (Reliability and Maintainability Studies)

Identifying the maintenance tasks associated to the asset classes

Creation of the maintenance plan
Identification of spares requirements (very brief detail as this is covered in a separate course)
Development of the computerized maintenance management system CMMS
Enhancing the maintenance strategies

A brief overview of:

RCA (Root Cause Analysis),

Six Sigma DMAIC process (Define, Measure, Analyse, Improve, and Contro l

Training of the maintenance team

Managing deviations from the plan

Describe overall responsibility for the operation, maintenance, repair, and replacement at the project level
Describe responsibility for the operation, maintenance, repair, and replacement of each ECM.
Define different conditions under which Repair and Replacement (R&R) work will be performed, and the source
of funds for performing R&R activities.

Define reporting requirement for O&M activities and its frequency.

Submission of the ECM-specific O&M checklists by the ESCO.

ESCO provides O&M training & submits the Operations and Maintenance Manual for ECMs, including:

1. New written operations procedures;

2. Preventive maintenance work procedures and checklists.

periodically reports on maintenance work performed on ECMs

Identification of O&M issues that can adversely affect savings persistence

Correct Equipment Maintenance Management Strategy Selection makes All the

Difference

You select and apply maintenance strategy with the purpose of controlling failure.
Your maintenance management starts on the project drawing board. If you only
select your maintenance management strategies when the equipment is installed,
you will always be fighting a losing battle!

Tel: +60 3 20274751 Fax: +60 3 7865 1533 Email: waseem@mawaevents.com web: www.mawaevents.com
CONSULTANT:

MALCOLM HIDE SENIOR

SENIOR CONSULTANT & MANAGING DIRECTOR

Malcolm Hide is an independent maintenance consultant, with over 30 years of experience in maintenance practices and setting up maintenance
systems. He started his career in the Steel Industry, where he was ultimately responsible for the redesign of the water cooling system on a blast
furnace. He then went on to further his experience in the Oil and Gas Industry where he ran the condition monitoring department, performing
Vibration analysis, Oil analysis and Laser alignment on hundreds of pumps, motors, turbines and generators. From there he moved into an abattoir
and processed meat factory as the maintenance manager, where he was also responsible for a rebuild of around 50% of the factory while still
maintaining the production environment inside the rebuild areas. He then moved on to the BOC group of companies, where he became responsible
for monitoring and delivering maintenance best operating practices to their air separation plants worldwide.

Following this, Malcolm joined the team delivering the baggage system for Heathrow Terminal 5, which is made up of over 17km of conveyor
systems, over 100 PLCs and in excess of 24,000 individually maintainable items. He was responsible for defining the maintenance strategy,
developing the maintenance plan, defining the maintenance team size, setting up all system-related training requirements, and setting up their
CMMS. This experience has lead him to developing this process of setting up a basic maintenance plan, which he has now been able to successfully
apply on several other sites. The process has reduced the time to implement a comprehensive maintenance plan covering all maintenance strategies
significantly.
Client List:
CLIENTS INCLUDE:

Mittal Steel South Africa (Formerly known as ISCOR)

Sasol Renown Food Products
BOC Gases
OXIM
Vanderlande Industries
BAA Heathrow Airport
Babcock Airports
Shop Direct Group
Airbus

TESTIMONIALS:

The training was great; I wish my entire plant could have this training. Maintenance Manger, LaFarge

A fantastic structure with a knowledgeable instructor. Maintenance Planner/Reliability Engineer, Graphic Packaging

Excellent! Well worth the time and money. Mechanic, Xcel Energy
I would love for this class to come to our plant, for the team. It would help the maintenance technicians do the job they want to do.
Maintenance Supervisor
Very detailed training Reliability Team Member

For Further Contact/ Registration:

Mr. Waseem Shahzad - Director - Sales & Marketing. MAWA EVENTS SDN BHD

No. 857, Block A2 -Leisure Commerce Square

No 9. Jalan PJS 8/9, 46150 Petaling Jaya,
Selangor, Malaysia

Tel: +60 111 637 3203 Fax +60 3 7865 1533 Email: waseem@mawaevents.com

MAWA EVENTS SDN BHD

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 Developing and Implementing a Comprehensive Operations & Maintenance Plan
REGISTRATION FORM
27 - 29 November, 2017. Park Royal Hotel. Kuala Lumpur. Malaysia

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