7-9 April 2014, Al Khobar, Kingdom of Saudi Arabia: Featured Presentation by
7-9 April 2014, Al Khobar, Kingdom of Saudi Arabia: Featured Presentation by
7-9 April 2014, Al Khobar, Kingdom of Saudi Arabia: Featured Presentation by
com
Chris Walsh, Condition Based Ali M. Al-Shurafa, Senior. Joe Ekanem, Head of
Maintenance, Strategic Business Rotating Equipment Engineer, Maintenance, Addax
Manager, Petrofac Saudi Aramco Petroleum
Ibrahim Kobbia Ziyad Mustafa Assad Owidah Govind Kiran Kumar Reddy
Rotating Machinery Engineering Lead Engineer, Reliability and Planning Section Head, DUBAL
Section Leader Asset Management Department,
ADMA OPCO Marafiq
Dr. Ir. Hj. Mohd Abdul Karim Manish Kumar, Senior Rotating Ali Rafea Al Zahrani
Bin Abdullah, Group CEO, Equipment Engineer Machinery and Condition
Serba Dinamik Group Saudi Aramco Shell Refinery Monitoring Manager, Saudi
Company European Petrochemical
Company
Ayman Ejaimi
Lead Reliability Engineer
Saudi Aramco
Booking line: tel: +91 95 3550 2766 | fax: +91 80 49005100
Email: nasir.hussain@fleminggulf.com | www.fleminggulf.com
Gold SponsorS
Networking Partners
World ils
Booking line: tel: +91 95 3550 2766 | fax: +91 80 49005100
Email: nasir.hussain@fleminggulf.com | www.fleminggulf.com
KEY TOPICS
9:30 Workshop A Known Best Practice Maintenance and
Reliability Metrics/KPIs and how to use them
Objectives
Maintenance Strategies for Rotating Equipments • Internationally Known Best Practice Maintenance and Reliability
based on Criticality and Risk Mitigations Metrics/KPIs
• How KPIs are aligned with Known Best Maintenance and Reliability
Best Practices in Maintenance Planning and Practices
Scheduling • How to manage with a KPI Dashboard using Best Practice Metrics/
KPIs to improve performance and asset health
Equipment failures, challenges and different
• A few Simple tips you can use to implement these great KPIs/
ways to manage them Metrics
KPI‘s of Reliability, Availability, Maintainability • Lessons learned from many years of experience developing KPIs
with internationally known companies (no company names will be
Best practices for assessment, benchmarking of used in this presentation)
performance and health reviews of equipment and • Common traps which distract us from focusing on the right
systems metrics at the right time
Ricky Smith, Author of the “Rules of Thumb for Maintenance
Cost Involved in Maintenance and how to minimize and Reliability Engineers”, “ Lean Maintenance”, “Maintenance
them & Reliability Metrics/KPIs 101” and Past Chairman of Society for
Maintenance and Reliability Professionals
Spare parts Optimization: Availability and
Procurement of Spare parts 11:30 Prayer Break
Techniques and methods of Shaft Alignment and
their implementation 12:00 Lunch
10:40 Case Study: Reliability and Maintenance Effectiveness Implementation in SAP-PM by Using RCM Approach
• Preparation of asset register and gap analysis results
• Failure modes and effects and consequence analysis (FMECA) exercise results
• Benchmarking of present Plant routines with other similar organization
• Finalization of Plant Maintenance routines and uploading into Plant SAP system
Ijaz Ul Karim Rao, Director
Velosi Asset Integrity Limited
11:15 Precision Maintenance Strategies for enhancing performance and reliability (to be confirmed)
• Introduction to Precision Maintenance
• Developing low cost maintenance strategies the achieve high reliability and case studies
• How to implement the precision maintenance procedures?
Wael Ahmed El Akkawi, General Manager
Service Business Unit, Alfanar Technical Services
12:50 Steam Turbine Failure: 12:50 Effective closed loop Reliability incident
• Characteristics of the components of the Steam Turbine Management system
• Understanding Failure Mechanism • Real example of system Develop to manage Reliability
• Arrangements of Steam Turbine and its Application incident.
• Steam Turbine Availability and Failure Experience • Prioritization of Reliability incident based on Risk.
• Best Maintenance Practices for Steam Turbines • Effectively Managing Reliability incidents History
• New Technologies in Steam Turbines • Knowledge management of Reliability incidents Analysis
Bakheet Ali Al-Zahrani, Manager Stationary Mechanical RCA.
Saudi European Petrochemical Company, SABIC affiliate • Recommendation Management and communication vehicle
to stake holders.
13:25 Strategic Maintenance Approach: Continuous Irshad Mohammad, Senior Reliability Engineer, Qatargas
Monitoring and Condition Based Maintenance
• Reality of today: Optimise production, minimise 13:25 Reliability Challenges and Solutions for Steam
maintenance cost. Turbine Admission Valves
• Standard system components i.e. sensors (wireless), signal • Understand the common designs of steam admission valves
processors, condition monitor, diagnosis, prognosis and • Analyze the symptoms and risks of the faced problems
decision support. (three cases)
• Incorporating Asset Management ISO 55000 and • Implement practical solutions to restore turbine operation
competency certification as a strategic maintenance tools • Use presented illustrations and cases as guide for similar
Dr. Ir. Hj. Mohd Abdul Karim Bin Abdullah, Group CEO problems
Serba Dinamik Group Ali M. Al-Shurafa, Senior. Rotating Equipment Engineer
Saudi Aramco
14:00 Maintenance Strategies for rotating equipments
and Risk Mitigations 14:00 Five Why‘s – Problem Solving Technique to
• Understanding the maintenance definitions improve reliability in plant
• Different approaches to perform maintenance and new • What is meant by Five Why‘s?
challenges • Why do we need Five Why‘s?
• Condition based Maintenance and Monitoring • How to encourage people to use it by Kano Model?
• Causes of Machinery Breakdown and how to minimize them • Examples of successful implementation
Ali Rafea Zahrani, Machinery and Condition Monitoring Saleh Saeed Al-Mozaie, Engineer
Manager Root Cause Analysis, Marafiq
15:05 Warehousing of spare parts 15:05 Implementing Six Sigma to improve the Reliability
• Spare parts optimization: Determining the optimum of Rotating Equipmemts
quantities of spare • Six Sigma Process Improvement Strategies
• Classes of Spare Parts: Insurance Spares, Unit Replacement • Use of Six Sigma Methodologies
Spares, Consumables Manish Kumar, Senior Rotating Equipment Engineer
• Spare parts Availability and Procurement Saudi Aramco Shell Refinery Company
• New Strategies based on Reliability and cost driven spare
parts
15:40 Asset Management: Enhancing Asset Technical
• Improvements to be done during purchasing stage of the
Integrity
equipment
• Asset registers and priority of strategy around criticality
• Designing Integrity, Sustaining and Operating with
15:40 Deluge Water Pump Modifications Integrity,when is necesary unit replacement
• Assessment and Analysis • Process Plant type influence in Asset Management,
• Performance verification (Upstream, Downstream, chemical)
Ayman Ejaimi, Lead Reliability Engineer, Saudi Aramco Representative from Saudi Aramco
16:15 Panel Discussion – Performance Evaluation: 16:15 Shaft Alignment Methods and Procedures
Condition Monitoring vs Planned Maintenance • Protocol for the implementation of good shaft alignment
• Performance Tracking and continuous tracking of for Rotating Machinery
equipment condition • Precision Alignment: Alignment Tolerance
• Advantages and Disadvantages of Condition Monitoring • Symptoms of Misalignments
and Planned Maintenance • Benefits of Shaft Alignment
Ibrahim Hadi, Sr. Manager Maintenance, IbnSina, SABIC • Thermal Expansion of Machine and Thermal growth
Krishna Kumar, Reliability Centered Maintenance Lead calculation
QatarGas
SPEAKERS BIOGRAPHY
Ricky Smith, Past Chairman of the Society for Ijaz Ul Karim Rao, Director
Maintenance and Reliability Professionals and Author of Velosi Asset Integrity Limited
“Rules of Thumb for Maintenance and Reliability Mr. Ijaz Ul Karim Rao is based in VELOSI Abu Dhabi and Director
Professionals”, “Maintenance and Reliability Metrics/ KPIs for Asset Integrity Services with over 23 years of working experience
in the oil and gas industry. He has been working on design and
101”, “Lean Maintenance”
commissioning of process, safety, mechanical and piping system for different
Ricky Smith has over 30 years of experience in maintenance as a Maintenance oil and gas projects. He had worked and managed different Asset Integrity
Manager, Maintenance Supervisor, Maintenance Engineer Adviser, Maintenance Management Projects for both the upstream and downstream industry. He also
Training Specialist, and Maintenance Consultant. Today he is a Senior worked for different Verification and Certification projects for ADMA-OPCO, BP,
Reliability Advisor for Allied Reliability Group. Ricky has worked with hundreds of Total Fina Elf, Shell, Premier Oil and others. Presently, he is involved in Asset
facilities, mines, refineries and industrial plants worldwide to develop reliability, Integrity Management projects including RBI, RCM and other risk related activities
maintenance, and technical training strategies in over 35 countries. Prior to joined for Middle East based companies (Saudi Aramco, ADCO, ZADCO, QP, Takreer,
Allied Reliability Group in 2008, Ricky worked as a professional maintenance ADGAS and QP), in South East Asia (Murphy Oil, Talisman and BSR) and Equion
employee for Exxon, Alumax (one of three plants certified with World Class Energy Limited based in Columbia, South America. He has pioneered a software
Maintenance status in the world), Kendall Company, and Hercules Chemical, product „VAIL - Plant“ – a full integrity management system for both onshore
providing the foundation for his reliability and maintenance experience. Ricky is and offshore installations. This product caters inspection and maintenance
the Past Chairman of the Society for Maintenance and Reliability Professionals management to the automation needs of an expanding base of clients.
(SMRP) Oil and Gas Special Interest Group (SIG) and served on the SMRP Metrics
Development Team. Ricky is the co-author of the following books in Maintenance
and Reliability (amazon.com)
- Rules of Thumb for Maintenance and Reliability Engineers by Elsevier Publishing Jim Cooper, Chief Engineer, Howden
- Industrial Repair, Best Maintenance Repair Practices by Elsevier Publishing Jim graduated with a first class honours degree in Mechanical
- FRACAS: Failure Reporting, Analysis, Corrective Action System by MRO-Zone. Engineering from the University of Aberdeen in Scotland in 1972.
com He worked for Babcock Energy Limited for 9 years in their Research
- Planning & Scheduling Made Simple by MRO-Zone.com Centre in Renfrew Scotland working on subjects including both
- Maintenance & Reliability Metrics/KPIs 101 by MRO-Zone.com conventional and fluidised bed combustion. He has subsequently worked for
Ricky is a Certified Maintenance and Reliability Professional (CMRP) , Certified Howden for 32 years and is presently the Chief Engineer of Heater Technology
Maintenance and Reliability Technician (CMRT) with and the Society for for Howden Global. In addition to heater development activities, Jim has spent
Maintenance and Reliability Professionals (SMRP), and a Certified Plant many years studying the field performance of both air preheater and gas gas
Maintenance Manager with the Association for Facilities Engineers (AFE) heater installations throughout Europe, the Far East, the Middle East and the
US. He provides direct technical support on heater technology and applications
to all of Howden’s international Companies, has written and presented several
Samuel Thomas, Advisor, Reliability and Asset international papers on the subject and holds a number of associated patents.
Management Division, Maaden Phosphate Company
Samuel has 35 years of experience in various industries like
Petrochemical, Fertilizers, Nuclear and has worked as a Dr. Ir. Hj. Mohd Abdul Karim Bin Abdullah
Consultant, Design and Maintenance Engineer, Project-in charge, Dr. Ir. Hj. Mohd Abdul Karim Bin Abdullah, (PE.Mech. Engineering
Superintendent-Reliability Department and General Manager Technical. He has & Ph.D in Industrial Engineering) is the Founder and President of
been working in Saudi Arabia for past 15 years. Presently Samuel is Working as Serba Dinamik Group Berhad. He has acquired more than 26 years
an Advisor in the Maintenance and Reliability Division of Maaden Phosphate of hands-on experience in managing, supervising, lecturing and
Company in Saudi Arabia, the largest DAP complex in the world. Prior to this, carrying out various tasks related to turbomachinery maintenance nation-wide
he has worked in SABIC in Saudi Arabia as Mechanical Engineering Specialist in Malaysia and internationally and other integrated engineering and financial
in Maintenance and Reliability Division. Samuel has published 17 national and tasks. He has been involved in field management and supervision for overhauling
international technical papers and was a member of IAEA committee for studying of steam turbines, gas turbines, reciprocating & centrifugal compressors and
Environment Impact of Radioactive Effluents. pumps of various made / brand.He has been awarded the Best Enterprise
and Manager of the Year 2013: Oxford Summit of Leaders, United Kingdom;
European Award for Best Practices, Vienna 2013 and The STAR Business Award:
Entrepreneur of the Year Award 2013
Chris Walsh, Condition Based Maintenance, Strategic
Business Manager, Petrofac
Crisris Walsh, is a Fellow of the Institution of Mechanical Engineers,
Ziyad Oweidah, Lead Engineer, Reliability and Asset
and has over 30 years experience in maintenance engineering. The
last 15 years in maintenance of rotating machinery for the oil and Management Department, Marafiq
gas industry. Chris lead maintenance engineering and condition monitoring Ziyad Oweidah has over 17 years of experience in significant
groups in the coal, power and other process engineering industries specialising areas of growth and leadership during career and held leadership
in vibration analysis and performance management of equipment . Chris is a positions in maintenance, reliability, technical services as RCM lead
member of the management team of maintenance engineering consultancy Engineer Mechanical, Planning superintendent and supervisor in Maintenance
Plant Asset Management (part of Petrofac) and currently leads the Condition (Desalination and Steam Turbine) at Marafiq company ,currently he serve as
Based Maintenance strategic business globally. Lead Reliability Centered Maintenance (RCM) implementation program in
Marafiq Power plant from inception to final stage. conducted RCM analyses on
various systems and developed maintenance strategies with objective to enhance
plant reliability. Ziyad is certified as Skilled Level RCM facilitator by Shell Global
Ali M. Al-Shurafa, Senior. Rotating Equipment Engineer
Solution. He achieved his Bachelor Degree in Mechanical Engineering from King
Saudi Aramco Abdulaziz University, Jeddah.
Ali M. Al-Shurafa is a senior vibration and rotating equipment
engineer. Currently Mr Ali is based at Ju’aymah NGL Plant, Saudi
Aramco. He worked previously as a faculty member at the Jubail
Joe Ekanem, Head of Maintenance, Addax Petroleum
Industrial College and prior to that he served as a commissioning engineer for the
Saudi Electricity Company. Al-Shurafa is heavily involved in rotating equipment Joe Ekanem is currently the Acting Head of Maintenance for petroleum
troubleshooting and reliability improvements. Mr. Ali developed and conducted multi-national, Addax Petroleum (Sinopec). A holder of a BSc
many academic and industrial short courses and workshops. Mr. Ali is a certified degree in mechanical engineering (honors). He majored in Rotating
Vibration Specialist (ISO 18436 Cat III) since 2002. Machinery Engineering and Management in Cranfield University,
UK. Joe is a rotating machinery and maintenance professional with over 15 years
of experience covering onshore/offshore oil and gas production maintenance.
Booking line: tel: +91 95 3550 2766 | fax: +91 80 49005100
Email: nasir.hussain@fleminggulf.com | www.fleminggulf.com
SPEAKERS BIOGRAPHY
His interests include turbo-machinery, gas turbines, compressors, equipment Ahmad AL Amoudi, Acting Reliability Section Head
strategy & maintenance, life cycle cost (LCC) and CMMS implementation. He is Petro Rabigh
a Chartered Engineer and member of several engineering bodies. Before joining
Ahmad has a total of 22 years of experience in rotating equipment
Addax in 2012, Joe spent over 14 years with ExxonMobil in various positions
and reliability. He is currently the Acting Reliability Section Head
within the oil & gas industry machinery maintenance.
at PetroRabigh. He joined PetroRabigh in 2008 and supported the
commissioning and startup of the new complex. His responsibilities includes
troubleshooting, commissioning, project specification, execution for rotating
Arafat Al-Jabri, Technical Manager equipment projects and shop acceptance. Ahmad is considered as rotating
Water and Electricity Company equipment specialist. He started his career with Samref (Saudi Aramco-
Arafat Aljabri has over 18 years of experience boasting his ExxonMobil Yanbu Refinery ) in November 1990, ever since he is working in
caliber from an Operations Manager at Saline Water Conversion the field of machinery. Ahmad earned a Bachelor of Science (B.Sc.) degree in
Corporation (SWCC) in Operation to Desalination & Power Plant Mechanical Engineering from King Fahd University of Petroleum & Minerals
Manager. At SABIC, he served as Staff Production Engineer and then was a (w:st=“on“Saudi Arabia) in August 1990.
Root Cause Analysis (RCA) Team Leader at Marafiq. Arafat is currently working
with Water & Electricity Company, Riyadh, Saudi Arabia as Technical Manager.
Arafat is certified as Skilled Level RCA facilitator by Shell Global Solution. Arafat Govind Kiran Kumar Reddy, Planning Section Head,
is also a Root Cause Analysis Certified Trainer and is using his expertise in leading DUBAL
RCA investigation teams. He is also an accredited Professional International
Govind Kiran Kumar Reddy has 17 years of experience in the Power
Trainer in Creative Problem Solving & Decision Making by American Strategic
Industry, spanning a wide range of projects, technical, IT, Logistics,
Planning Center apart from other accreditations. He achieved his Bachelor
Procurement, commercial and management roles. He is currently
Degree in Chemical Engineering from King Saud University in Riyadh and he
working with Dubal, as a planning section head. He has an Engineering degree
concluded his EMBA from King Abdulaziz University, Jeddah.
in Mechanical and has successfully completed Masters in Business Administration
with Finance as specialization.
Gold Sponsor : Howden the London Stock Exchange (symbol: PFC). Petrofac designs and builds oil & gas
facilities; operates, maintains and manages facilities and trains personnel;
Howden designs, engineers and supplies air
enhances production; and, where it can leverage its service capability, develops
and gas handling equipment, including
and co-invests in upstream and infrastructure projects. Petrofac’s range of
industrial fans, process gas compressors and
services meets its customers’ needs across the full life cycle of oil & gas assets.
rotary heat exchangers. Established over 150
With more than 18,000 employees, Petrofac operates out of seven strategically
years ago as an engineering firm, Howden
located operational centres, in Aberdeen, Sharjah, Abu Dhabi, Woking, Chennai,
has grown to become a worldwide
Mumbai and Kuala Lumpur and has a further 24 offices worldwide.
organisation with over 6,000 employees and companies in 26 countries. As an
OEM, we deliver spares, maintenance and repairs, engineered solutions and
training into the aftermarket arena. We have knowledgeable and experienced
Bronze Sponsor: National Mechanical Engineering Services
technical advisors on a global basis. Our advisors are backed by engineering
personnel who can support your needs through access to original drawings, National Mechanical Engineering Services is
design know-how and full, detailed information on parts. a young, dynamic, global service provider to
the oil & gas, power generating, and mining
industry. NMES is located in Muscat, Oman,
Gold Sponsor : Alfanar Technical Services and has an extensive network of subsidiaries
and agencies in the UAE, Qatar, Bahrain,
Alfanar Technical Services (ATS), an integral
Belgium, Italy, Indonesia, Korea, and Argentina. Further expansion is currently
part of the alfanar Group, has evolved as a
under progress and targets the Kingdom of Saudi Arabia and Malaysia as the
leading service provider in the GCC and
next countries where agencies or subsidiaries will be located. With a global client
MENA regions for the rewinding, repairing
portfolio, catering to clients such as General Electric, Alstom, Siemens,
and overhauling of Motors, Transformers,
Woodgroup, Occidental, GDF Suez, and Freeport mining, NMES delivers tailor-
Turbines and Generators. With its state of the
made solutions aimed at reducing or eliminating the downtime during repairs or
art facility in the industrial hub of Jubail, ATS offers the most advanced repair and
shutdowns, resulting in more production time, lower turnaround costs, and
rewinding solutions for the maintenance of rotating equipment. ATS has the
overall better profitability for our client’s stakeholders.
advantage of having the largest test bed and the most modern test lab at par to
the international standards. The motors division also carries out a Motor
Assessment and Life Assessment Programs to ensure the healthiness of the
Associate Sponsor : Velosi Asset Integrity Ltd. (VAIL)
equipment. With services ranging from Selective Plating, servicing of explosion
proof motors, etc., it also has the distinction of being the only facility in the Velosi Asset Integrity Ltd (VAIL) is a subsidiary
Middle East to rewind a 200MVA transformer. ATS also has the advantage of of Velosi International and one of the leading
having an integrated Preformed Coils manufacturing division ensuring the service providers in Asset Integrity
minimum lead time ensuring the highest quality. Management (AIM) business. Our range of
services covers both upstream and
downstream of hydrocarbon industry
Gold Sponsor : Serba Dinamik including oil and gas production, LNG and LPG plants, refineries, petrochemical
and fertilizer plants. We have successfully executed numerous AIMS related
SERBA DINAMIK INTERNATIONAL LIMITED
projects for a vast number of clients including BP, QP, GASCO, ADGAS, TAKREER,
(SERBA) offers an integrated engineering and
ZADCO, KJO, SAUDI ARAMCO, PTTAR, SNGPL, OGRA, OGDCL, SSGC,
contracting industrial solutions to the oil and
PETRONAS, MURPHY, Talisman and many others. VAIL is also one of the leading
gas and power sectors with specialisation in
providers of software solutions for asset integrity and reliability management for
providing a comprehensive rotating
the oil and gas, petrochemical and power industries.
equipment solutions from installation,
commissioning, troubleshooting and maintain, repair plus overhaul of various
brands and make. SERBA have service centres set up in strategic location in
Workshop Leader : National Instruments
various countries globally and maintain a professional pool of field service
personnel who can be mobilised worldwide 24 x 7 basis. SERBA also offer Asset National Instruments is a technology pioneer
Management solutions in compliance to international standards to ensure and industry leader in measurement and
client’s asset integrity are in its optimum condition. automation, delivering today’s most
advanced technologies for monitoring and
control. Since 1976, engineers and scientists,
Silver Sponsor: Petrofac in virtually every industry, have used flexible,
high performance NI products to create reliable, user-defined systems. With the
Petrofac is a leading international service
graphical system design approach, which combines graphical programming
provider to the oil & gas production and
software and modular, open hardware, NI has redefined how engineers work
processing industry, with a diverse customer
throughout the entire product design cycle, resulting in reduced time to market
portfolio including many of the world’s
and lower development costs.
leading integrated, independent and national
oil & gas companies. Petrofac is quoted on
Booking line: tel: +91 95 3550 2766 | fax: +91 80 49005100
Email: nasir.hussain@fleminggulf.com | www.fleminggulf.com
Networking Partner : Barrak Al Fares Trading Est. Networking Partner : SMH International
BARRAK AL-FARES has been actively involved SMH is a certified ISO-9001 and
in the industrial scenario in the kingdom for OSHAS-18001 Operation and Maintenance
over 6 years now. We are supplying products, company specialized in Rotating Equipment.
customized solutions, and specialized Its main business operation is situated in
engineering services for the complete Jubail KSA and manages a chain of satellite
reliability needs of oil refineries, petrochemical offices located in London-UK, Abu Dhabi-UAE
plants, chemical plants, desalination plants, power plants etc. Our principal and Kerala-India. SMH‘s core business is to provide the essential services to Oil &
office is based in Dammam, Saudi Arabia. However we also have expanded our Gas, Petrochemical, Refinery and Utility companies, ensuring uninterrupted
operations in all Middle East countries like Bahrain, Qatar, UAE, Kuwait, Oman productivity of their machineries and equipment particularly turbines, gearboxes,
etc. In addition we are specialized in long term manpower supply for the pumps, and other rotating equipment. We maintain a pool of expert technicians
construction, maintenance, Inspection needs of plants. We strive to maintain a and engineers in and outside the kingdom who can respond to the immediate
high level of after-sales service for both repairs and spare parts. And we have a needs of our valued clients. Additionally, we maintain our own machining and
well trained team of engineers to perform services for condition monitoring and fabrication facility, which is strategically located at the Industrial Support Area of
other reliability needs of plants. the Jubail Industrial City allowing us quick response to our industrial clients’
emergency needs.