TRAINING COURSES

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

Start Date: 4 Mar 2018
End Date: 8 Mar 2018
Duration: 5
Fees:
Country: Lebanon/Beirut
Category: Engineering and Technical Programs
Details:

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

Training Methodology

The course combines presentation of the key principles, methods, and best practices and enforces the learnings with case studies and Question & Answer workshops to maximize the benefits to the participants. The comprehensive course notes and presentation material will provide valuable reference.

Organizational 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

seminar outline

Day 1

Course Objectives and Overview

         Significance of Inspection in Plant Integrity and Maintenance Costs

o    The real function of inspection

o    Inspection Key Performance Indicators

         Common Inspection Strategies and Their Limitations

         Risk-Based Decision-Making Fundamentals and Tools

o    Risk Assessment - Probability of failure, consequences of failure

o    Risk Management Avoidance, mitigation

o    Risk Communication.

         Understanding and Managing Risk

o    Principles Risk Assessment

o    Risk Assessment Elements

o    Qualitative, semi-quantitative, and quantitative assessment

         Workshop 1- Illustrative Example of Risk Assessment

Day 2

Risk Based Inspection (RBI)

         Definitions

         Evolution

         Key Elements of RBI

         Reasons for implementing RBI

o    Benefits and Limitations of using RBI

o    RBI as a part of plant integrity management

o    Economic benefits

         API Risk-Based Inspection Methodology

o    API RP 580

o    API BRD 581 Various levels of RBI Analyses

         Impact of RBI on Related API Codes, Standards, and Recommended Practices

o    API 510, 570 and 650

o    API 579 Fitness-For-Purpose

         API Risk Based Inspection Software

         Workshop 2 - Q&A on API RBI Methodology

Day 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

o    Active damage mechanisms in critical plant equipment

o    Inactive or "unlikely mechanisms

o    Identification for assessment, including

o    Impact of simultaneous mechanisms

         Selection of Suitable Materials for Specific Deterioration Mechanisms

         Integrated Asset Management

o    Linking Risk Assessment, RBI, and RCM

o    Managing Risk Using RBI

         Workshop 3 - Case studies involving a number of equipment damage and failures, and learnings

Day 4

Development of Inspection Plan (Based on RBI Risk Ranking)

         Inspection planning guidance

         Need for some speculative/exploratory inspection

         RBI Implementation

o    Essentials for Establishing a Successful RBI Program

o    The RBI Team - Recommended Structure and Mandate

         Developing Equipment and piping systems/circuits Inventory

         Inspection History, Interpretation

o    Equipment Criticality Rating

         Equipment Data Base

o    Shared data base by RBI and RCM

o    Importance of Data Quality

o    Computerized Maintenance Management Systems

         Workshop 4 Case Study: Risk-based categorization of equipment and failure modes

Day 5

         Inspection Interval Optimization Based on Assessed Risk

         Evaluation of Inspection Results

o    Data Quality

o    Corrosion Rate calculations

o    Remaining Life Calculations

         Fitness-For-Service Assessments

         Estimation of Consequences of Failures

         Workshop 5 - Case Study - Assessment of defects in critical equipment

 
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