Risk Based Strategies for Inspection & Maintenance

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

Targeted Groups:

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 Objectives:

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

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
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

Targeted Competencies:

Being multi-disciplined
Realistically applicable to plant integrity
Designing with future scenarios in mind
Consideration of all potential degradation mechanisms
Understanding of the risks involved
Awareness of Fitness for Service assessment techniques

Course Content:

Unit 1: 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 2: 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 3: 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