Course Description

 

Risk Based Inspection is one of several techniques which are recommended by API for the safe and cost effective maintenance and operation of static equipment including pressure vessels, piping and tanks. This comprehensive 5-day programme has been designed to benefit both qualified new professionals as well as experienced professionals who may be involved in the rollout of a new Risk Based Inspection system or auditing an existing system.
 
It covers all the steps required in developing a successful Risk Based Inspection   programme from initial recognition of a need, through management approval and system development until a well managed Risk Based Inspection system is in place and operational.

Course Objective

 

·         To provide a step-by-step guide to developing a Risk Based Inspection system starting with foundations and building up to best practice that will deliver maximum business benefits.  

·         To provide opportunities to discuss the implementation and integration within the production environment. 

·         Provide an opportunity to learn these concepts through practical exercises

 

Who Should attend?

 

It is recommended that all Maintenance, Reliability, Engineering and technical support staff  especially including leadership and management attend this workshop.
 
If you and your company are interested in maintaining a safe, cost effective organisation, this will be a very valuable course

Course Outline

 

Day 1

Start with a justification to management to get capital and operational funding.  This includes a description of the problem(s) and overview of the solution(s).

*      Introduction

-      Seminar overview identifying objectives and goals

-      Associate the delegates to teams for workshop activities

-      Introduction to Risk Based Inspection technologies.

*      Identify the Potential Improvement Scenario

-      Basic reliability overview with statistical analysis of static plant performance

-      Pareto analysis and identification of bad actors

-      Benchmarking across the industry

*      Prepare the solution for management

-      Cost analysis of RBI ¡Vv- Status Quo

-      Resource analysis

-      Prepare the presentation to management for budget authorisation

Day 2

Design a project to implement the initial stages such as software installation, equipment demographic analysis etc.

*      Starting the Project

-      Recruit an RBI team with relevant expertise

-      Baselining

„h         Equipment demographic analysis

„h         Identify the failure mechanisms as per API 571

-      Identify suitable measurement technologies

-      Equipment and contractor selection

-      Define and acquire logistical support

*      Risk Assessment of the subject equipment

-      Cause Mapping & Bow-Tie Analysis

„h         Identify hazards

„h         Evaluate the risks

„h         Quantify controls and mitigations

-      Fitness for Service evaluation

Day 3

Manage the project and the capital budget.  This stage involves periodic progress reports to management.

*      Develop the RBI Plan

-      Pilot area selection

-      Inspectable units selection

-      Inspection procedures

*      Project definition & rollout

-      Software tools

-      PERT & GANTT charts

-      Change management

-      Post pilot rollout

*      Continuous Improvement

-      Training

-      Procedures

*      Project Progress Reporting

-      Functional ¡Vv- operational reporting (project)

-      Routines, procedures, processes

-      Define progress reports (budgetary & technical)

Day 4

Handover of the project to the operational division.  At this point we have to consider how to integrate the operational aspects of the new way of working so that the inspection, production and maintenance teams are involved.

*      Work Practices

-      Technical qualification

-      Functional responsibilities

-      Functional ¡Vv- operational (routine) reporting

-      RBI work flow

*      Reporting

-      Anomalies

-      Define report content

-      Getting the recommendations to where they do most good

-      Overview reports

*      Continuous Improvement

-      Acceptance criteria

-      Case history reviews

-      Fitness for Service as per API 579

Day 5

Develop Key Performance Indicators so that managers can maintain control of the process.

*      CMMS Integration

-      CMMS requirements

-      Operational planning

*      Key Performance Indicators

-      Reliability & statistics ¡V MTBF, Reliability etc.

-      Work request backlog analysis

-      Customer feedback analysis

-      Cost analysis