Training Risk Based Strategies for Inspection and Maintenance (RBI & RBM)

Training Risk Based Strategies for Inspection and Maintenance (RBI & RBM)

INTRODUCTION

Risk Based Inspection (RBI) methodology enables the assessment of the likelihood and potential consequences of pressure equipment failures. RBI provides companies the opportunity to prioritize their equipment for inspection; optimize inspection methods, frequencies and resources; develop specific equipment inspection plans; and enable the implementation of Reliability Centered Maintenance. This results in improved safety, lower failure risks, fewer forced shutdowns, and reduced operational costs.

The risk-based approach needs:

• To be multi-disciplined
• To be realistically applicable to plant integrity
• Design with future scenarios in mind
• Consideration of all potential degradation mechanisms
• Understanding of the risks involved
• Awareness of Fitness for Service assessment techniques

PROGRAM OBJECTIVES

• To provide clear understanding of the key aspects of Risk Based Inspection, its advantages and limitations
• To provide a clear understanding of how it is linked to reliability-centered maintenance
• Understand how fitness-for-service assessment affects the Risk
• To show you how to develop a successful RBI program at your facility
• Provide you with the practical and effective methods you need to perform practical likelihood and consequence analysis
• Show you how to develop optimum Inspection intervals for individual equipment based on the assessment of the active degradation mechanisms

WHO SHOULD ATTEND?

• Operations Engineers
• Maintenance Engineers
• Engineering Managers and Supervisors
• Technical Staff with responsibilities for inspection, maintenance, assessment and mitigation of plant equipment degradation, and who want to use RBI effectively in their plants

PROGRAM OUTLINE

Course Objectives and Overview

• Significance of Inspection in Plant Integrity and Maintenance Costs
  • The Real Function of Inspection
  • Inspection Key Performance Indicators
• Common Inspection Strategies and Their Limitations
• Risk-Based Decision-Making Fundamentals and Tools
  • Risk Assessment - Probability of failure, consequences of failure
  • Risk Management – Avoidance, Mitigation
  • Risk Communication
• Understanding and Managing Risk
  • Principles Risk Assessment
  • Risk Assessment Elements
  • Qualitative, Semi-quantitative, and Quantitative Assessment
• Workshop 1- Illustrative Example of Risk Assessment

Risk Based Inspection (RBI)

• Definitions
• Evolution
• Key Elements of RBI
• Reasons for implementing RBI
  • Benefits and Limitations of using RBI
  • RBI as a part of plant integrity management
  • Economic Benefits
• API Risk-Based Inspection Methodology
  • API RP 580
  • API BRD 581 – Various levels of RBI Analyses
• Impact of RBI on Related API Codes, Standards, and Recommended Practices
  • API 510, 570 and 650
  • API 579 Fitness-For-Purpose
• API Risk Based Inspection Software
• Workshop 2 - Q&A on API RBI Methodology

Overview of API 571 - Recognition of Conditions Causing Deterioration of Failure

• Overview of over 60 damage mechanisms found in refineries
• Detailed discussion of some common damage mechanisms: Internal and external corrosion, brittle fracture, fatigue, SCC, HIC, internal and external corrosion
• Identification of Deterioration Mechanisms & Failure Modes
  • Active damage mechanisms in critical plant equipment
  • Inactive or “unlikely” mechanisms
  • Identification for assessment
  • Impact of simultaneous mechanisms
• Selection of Suitable Materials for Specific Deterioration Mechanisms
• Integrated Asset Management
  • Linking Risk Assessment, RBI, and RCM
  • Managing Risk Using RBI
• Development of Inspection Plan (Based on RBI Risk Ranking)

• Inspection Planning Guidance
• Need for Some Speculative / Exploratory Inspection
• RBI Implementation
  • Essentials for Establishing a Successful RBI Program
  • The RBI Team - Recommended Structure and Mandate
• Developing Equipment and Piping Systems / Circuits Inventory
• Inspection History, Interpretation
  • Equipment Criticality Rating
• Equipment Data Base
  • Shared Database by RBI and RCM
  • Importance of Data Quality
  • Computerized Maintenance Management Systems
• Inspection Interval Optimization Based on Assessed Risk

• Evaluation of Inspection Results
  • Data Quality
  • Corrosion Rate Calculations
  • Remaining Life Calculations
• Fitness-For-Service Assessments
• Estimation of Consequences of Failures

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