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 Risk Based Strategies For Inspection & Maintenance (O9240) QR Code

Risk Based Strategies For Inspection & Maintenance

Overview:

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

Course Objectives:

At the end of this course the participants will be able to:

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

Targeted Audience:

  • 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

Course Outlines:

Unit 1: 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

Unit 2: 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 the Consequences of Failures

Unit 3: Overview of API 571 - Recognition of Conditions Causing Deterioration of Failure:

  • Overview of over 60 damage mechanisms found in refineries
  • A 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

Unit 4: 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 of Risk Assessment
  • Risk Assessment Elements
  • Qualitative, Semi-quantitative, and Quantitative Assessment

Unit 5: 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 DataBase
  • Shared Database by RBI and RCM
  • Importance of Data Quality
  • Computerized Maintenance Management Systems

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