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

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

This LAKESHORE ISL Risk Based Strategies for Inspection & Maintenance (RBI & RBM) training 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.

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

Seminar Outline

DAY 1

Course Objectives and Overview

• 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

DAY 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
• 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
• Active damage mechanisms in critical plant equipment
• Inactive or “unlikely” mechanisms
• Identification for assessment, including
• 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

DAY 4

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 data base by RBI and RCM
• Importance of Data Quality
• 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
• 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