Reliability Engineering Course - PetroEdge Asia

RELIABILITY 

ENGINEERING 

24 – 28 June 2013, Kuala Lumpur 

Your Expert Trainer: V Narayan 

Former Head of Royal Dutch Shell Group’s Centre of Excellence in Maintenance 

and Reliability Engineering, UK. 

Author of “Effective Maintenance Management – Risk and Reliability Strategies for Optimizing Performance”, 

Industrial Press Inc., NY. and Lead Author, 100 Years of Maintenance: Practical Lessons from Three Lifetimes, 

Industrial Press., NY. 

Hear what previous participants have said about V. Narayan’s previous Reliability courses in Asia: 

“V.Narayan has transformed me inside out on the way I believed and think about maintenance!” 

“Excellent fundamental course on that every maintenance practitioners must attend before embarking into a project.” 

“Well done, the course did really transform my point of view to a better understanding. This course is an essential and 

comprehensive guideline for people who are involve in industry” 

“The best and thoughtful Reliability training I’ve ever attended” 

“Well organized and interactive experience” 

Previous participants include the following world-class energy organisations: 

PETRONAS Carigali, Petronas Vinyl Chloride, Tasnee, Kuwait Oil Company, MMC Oil & Gas Engineering, ADGAS, Sarawak Shell, 

Talisman Malaysia, Brunei LNG, Murphy Oil Corporation, Oil India Limited, DIC (Malaysia), Bunduq Co Ltd, PTTEP, PETRONAS 

Penapisan, Petronas Carigali, Teknik Janakuasa, Vinyl Chloride Malaysia, Brunei LNG, Malaysia LNG, MTBE and many others 

Please visit us for more information: 

www.petroedgeasia.net 

Train your whole team at a convenient time and location with IN-HOUSE TRAINING 

Call +65 6741 9749 or email to info@asiaedge.net.

RELIABILITY ENGINEERING 

24 - 28 June 2013, Kuala Lumpur 

About the Reliability Engineering 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 

volumes 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 will benefit from this training? 

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. 

PetroEdge is a specialist Oil & Gas training provider with our key training hub based in Asia. Since inception in 2007, we have 

trained over 1000 engineers in various disciplines in the Energy sector. Our core focus is in developing competency in the local 

workforce of petroleum engineers and related professionals in leading national & international oil operators and contractors in 

this region. In our commitment to create sustainable skills development, we facilitate cost-effective skills transfer opportunities 

through world-class training courses with leading experts. Through our unique client engagement model and local presence, we 

are better positioned to fulfil critical learning requirements of Asian based organisations. 

To learn more about us, visit www.petroedgeasia.net 





5 Days Course Outline in Detail 

DAY 1 

08:30 – 08:50 

Welcome, Introduction, Safety issues 

� Objectives 

� Expectations from delegates 

� Discussion – how good is your facility reliability? 

09:10 – 09:50 

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 

09:50 – 10:10 Break 

10:10 – 12:30 

Reliability Engineering Concepts (continued) 

� 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 

12:30 – 13:15 Lunch 

13:15 – 15:00 

Reliability Engineering Application 

� Tools overview; RBDs, Reliability Modelling, FTA/ETA, 

FMECA, RCM, RBI, RCA 

� Computing value added, performance metrics 

� Making a Business Case 

15:00 – 15:20 Break 

15:20 – 16:30 

Human Error & 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 

16.40 Homework & Close 


Call +65 6741 9749 or email to info@asiaedge.net. 

DAY 2 

08:30 – 08:50 

Review of Day 1 & Homework 

08:50 – 10:00 

Degradation Mechanisms 

� Wear, Corrosion, Fatigue, Creep, Erosion ….. 

� Physical process – †yres & potholes, crack propaga�on 

� What do we understand by the term Maintenance? 

� Failure Patterns 

� Age-related and non age-related failures 

� Managing Degradation – Appropriate Tasks 

10:00 – 10:20 Break 

10:20 – 11:15 

Risk Management 

� What is Risk? 

� Quantitative Risk 

� ALARP and Residual Risk 

� Qualitative Risk 

� Decision Making 

� Selling ideas 

11:15 – 12:00 

Introduction to Reliability Centred Maintenance (RCM) 

� Maintenance in context (includes video presentation) 

� 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 

12:00 – 12:30 

Introduction to Risk Based Inspection 

� 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 

12:30 – 13:15 Lunch 

13:15 – 13:45 

Introduction to Instrumented Protective Functions 

� Layers of Protection 

� 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



13:45 – 14:15 

Introduction to Failure Mode, effects and Criticality 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 

14:15 – 14:45 

Introduction to Fault Tree and Event Tree Analysis 

� Terminology, Symbols, and Notation 

� Logic Diagrams 

� Assigning probabilities 

� Incorporating Human Error 

� Where to use FTA, ETA 

14:45 – 15:15 

Recap of RCM, RBI, IPF, FMECA, FTA, ETA 

15.15- 15:35 Break 

15:35 – 16:30 

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 

1640 Homework & Close 

DAY 3 

08:30 – 08:40 


08:45 – 09:15 

Revision of Topics to help us in exercises 

� Histograms 

� Probability Density Function 

� Cumulative Failure Function, Reliability Function, Hazard 

Rate 

� Different Distributions 

� Reliability Block Diagrams; Series, parallel. Bridge 

� Analytical and Simulation Modelling 

09:15 –1 0:00 

Exercises 

� Histogram plotting 

� Normalizing Histograms 

� Probability Density Function, Computing F(t), R(t). z(t) 

10:00 – 10:20 Break 

10:20 – 12:30 

Exercises – 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 

12:30 – 13:15 Lunch 

13:15 – 15:00 

Exercises – Reliability Block Diagrams 

� Series RBD example 

� Parallel RBD example 

� Bridge RBD example 

� Laboratory Ovens 

� Nested RBDs 

15.00- 15:20 Break 

15:20 -16:10 

Exercise – 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 

16:10 - 16:25 

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 

16:25 – 16:35 Summary & Questions 



Call +65 6741 9749 or email to info@asiaedge.net. 

DAY 4 

08:30 – 08:45 


08:45– 09:15 

The Reliability Improvement Process 

� An Important Business Process 

� Prerequisites, Elements and Structure 

09:15 – 10:00 

Prerequisites 

� Asset Register, Audits 

� Data required for Reliability Improvements 

10.00-10:20 Break



10:20 – 10:40 

Managing Human Reliability 

� Competence 

� Motivation 

� Behaviour 

10:40 – 12:30 

Getting The Basics Right – GTBR 

� OEE & TPM 

� Lubrication 

� Joint Tightness 

� Alignment 

� Balancing 

� Failure Elimination Culture 

12:30 – 13:15 Lunch 

13:15 – 14:00 

Planning 

� Reliability – Planning Objective 

� Tools and Techniques 

� Top Performers and Planning 

14:00 – 14:40 

Scheduling 

� Scheduling Objectives 

� Minimizing Production Losses 

� Maximizing Productivity 

� Managing Work Period Timing Effectively 

� Managing Effective Communications 

14:40 – 15:05 

Work Preparation 

� The follow through matters 

� Infrastructure and logistics 

� Work Permits 

� Equipment Readines 

15:05 – 15:25 Break 

15:25 – 16:20 

Condition Based Maintenance 

� Technical and Business Case 

� Process Steps 

� Application Examples 

� Effectiveness & Measurement 

16:20 – 16:30 

Compliance 

� Definition 

� Availability and Compliance 


DAY 5 

08:30 – 08:45 


08:45– 08:55 

Implementation of Reliability Improvements 

� When & Where to Apply – Selection of Projects 

� Preparing the Ground 

08:55 – 09:15 

Project Selection 

� Knowledge of Current performance 

� Identify Critical Systems 

� Identify Poor Performers 

� Set Objectives 

� Sponsor, Terms of Reference, Budget 

09:15 – 10:10 

Managing Change 

� Change is a process 

� Models 

� Bereavement Curve 

� Reliability Improvement requires Change 

� Socratic Method 

10:10 – 10:30 Break 

10:30 – 10:45 

Preparing the Ground 

� Communication Plan 

� Need for openness 

� Check data quality 

10:45 – 11:15 

Analysis and Measurement 

� Select the right tools, software 

� Use the same metrics before and after study 

� Follow the evidence, don’t ‘bend’ the data! 

� Apply corrections/confidence limits if data quality is 

suspect 

� Publish ALL results, good or bad 

� Communicate to Stakeholders 

11:15 – 12:30 Test 

12:30 – 14:30 Lunch & Prayer Time 

14:30 – 14:45 

SWOT the Solutions 

� Every solution isa potential problem 

� Evaluate downsides 

� Plan mitigation 

14:45– 15:00 

Track Results 

� Check metrics and report KPIs 

� Share results and credit contributions 

� Report, Present Results 

15:00 – 15:30 

Review Learning 

� Test results 

� Recap 

� Q & A 

1540 Certificate & Close 





About bout your expert trai trainer trai 

ner – 

V. V. Narayan Narayan 

Narayan 

V. Narayan 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 Management. 





Kuala Lumpur, Malaysia EARLY BIRD � NORMAL � TEAM DISCOUNTS 

Reliability Engineering 

5 Day Training Course 

24 – 28 June 2013, Kuala Lumpur SGD 4750 SGD 4950 

In-House Training 

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For further information about On-site Solutions, please +65 67419927 or email info@asiaedge.net 

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� Phone: +65 6741 9927 

� Fax: +65 6747 8737 

REGISTRATION FORM 

DELEGATE DETAILS 

PetroEdge recognises the value of learning in 

teams. Group bookings at the same time from the 

same company receive the following: 

3 or more at 5% off 

5 or more at 7% off 

8 of more at 10% off 

Early bird pricing is exclusive of team discounts and 

other promotions. 

Please note 

- Indicate if you have already registered by Phone +Fax +Email +Web 

- If you have not received an acknowledgement before the training course, please call us to 

confirm your booking. 

- Photocopy this form to register multiple delegates. 

PAYMENT METHODS 

By Cheque/ Bank Draft 

Make Payable to Asia Edge Pte. Ltd. 

By Direct Transfer 

Please quote your invoice number with the remittance advise 

Account Name: Asia Edge Pte. Ltd. 

Bank Number: 508 Account Number: 762903-001Swift Code: OCBCSGSG 

All bank charges to be borne by payer. 

Please ensure that Asia Edge Pte Ltd receives the full invoiced amount. 

PAYMENT POLICY 

Payment is due in full at the time of registration. Full payment is mandatory for event 

attendance. By submitting this registration form, you have agreed to Asia Edge Pte Ltd’s payment 

terms 

CANCELLATIONS & SUBSTITUTIONS 

You may substitute delegates at any time. ASIA EDGE PTE LTD does not provide refunds for 

cancellations. For cancellations received in writing more than seven (7) days prior to the training 

course you will receive a 100% credit to be used at another ASIA EDGE PTE LTD training course 

for up to one year from the date of issuance. For cancellations received seven (7) days or less 

prior to an event (including day 7), no credits will be issued. In the event that ASIA EDGE PTE LTD 

cancels an event, delegate payments at the date of cancellation will be credited to a future ASIA 

EDGE PTE LTD event. This credit will be available for up to one year from the date of issuance. In 

the event that ASIA EDGE PTE LTD postpones an event, delegate payments at the postponement 

date will be credited towards the rescheduled date. If the delegate is unable to attend the 

rescheduled event, the delegate will receive a 100% credit representing payments made towards 

a future ASIA EDGE PTE LTD event. This credit will be available for up to one year from the date 

of issuance. No refunds will be available for cancellations or postponements. 

ASIA EDGE PTE LTD is not responsible for any loss or damage as a result of a substitution, 

alteration or cancellation/postponement of an event. ASIA EDGE PTE LTD shall assume no 

liability whatsoever in the event this training course is cancelled, rescheduled or postponed due 

to a fortuitous event, Act of God, unforeseen occurrence or any other event that renders 

performance of this training course impracticable or impossible. For purposes of this clause, a 

fortuitous event shall include, but not be limited to: war, fire, labor strike, extreme weather or 

other emergency. 

PROGRAM CHANGE POLICY 

Please note that speakers and topics were confirmed at the time of publishing; however, 

circumstances beyond the control of the organizers may necessitate substitutions, alterations or 

cancellations of the speakers and/or topics. As such, ASIA EDGE PTE LTD 

reserves the right to alter or modify the advertised speakers and/or topics if necessary. Any 

substitutions or alterations will be updated on our web page as soon as possible. 

ASIA EDGE PTE. LTD. 

Company Registration No: No. 200710561C 

Copyright@ 2005 ASIA EDGE PTE LTD. All rights reserved. 

This brochure may not be copied, photocopied, reproduced, translated, or converted to any 

electronic or machine-readable form in whole or in part without prior written approval of ASIA 

EDGE PTE LTD

Reliability Engineering Course - PetroEdge Asia

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