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

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

ORGANISATIONAL IMPACT

• Identification and assessment of active degradation mechanisms
• Implementation of a Risk Based Inspection program would result in significant measurable improvements improved plant integrity
• Fewer failures
• Optimization of inspection and maintenance plans and resources
• Reduction in operating costs

PERSONAL IMPACT

• Delegates will acquire the knowledge necessary to apply the risk-based methodology
• Delegates will acquire the skills necessary to apply the risk-based methodology
• Enhance competence in RBI
• Enhance performance level
• Contribute additional value to the organization

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

outline

• 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
• Workshop 3 - Case studies involving a number of equipment damage and failures, and learnings
• 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
  • Workshop 4 – Case Study: Risk-based categorization of equipment and failure modes
  • 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
  • Workshop 5 - Case Study - Assessment of defects in critical equipment