Risk-Based Inspection  in Maintenance

An Intensive 5-day Training Course

Risk-Based Inspection
in Maintenance

Risk-Based Inspection in Maintenance

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Why Choose this Training Course?

The cornerstone of plant integrity is ensuring that facilities are correctly designed, and operated and maintained within the equipment design envelopes. The profitability of the facilities is significantly impacted by the cost-effectiveness of inspection and maintenance strategies and programs in place. Plant equipment is subjected to deterioration mechanisms and potential damage throughout their service life. To know with confidence the current condition of plant equipment, we need to inspect the equipment. Moreover, to determine the next inspection date, we need to understand the deterioration mechanisms to which the equipment will be exposed and their effects. This entails identifying the deterioration mechanisms; determining their rates; acceptability criteria; and the extent, frequency, and methods for inspecting this equipment.

Traditionally, prescriptive inspection practices were developed based on experience and in some cases in response to significant failure cases. In general, they did not take full account of failure risks nor of the degradation mechanisms that the equipment is exposed to in operation. As a result, some companies would not do enough inspection and precipitate avoidable failures, while others would unnecessarily overspend, resulting in significant waste of resource.

Risk Based methodologies enable the assessment of the likelihood and potential consequences of equipment failures. RBI & RCM provide companies the opportunity to prioritize their equipment for inspection; optimize inspection methods, frequencies and resources and develop specific equipment inspection plans. This results in improved safety, lower failure risk, fewer forced shutdowns, and reduced operational costs.

The risk-based approach requires a systematic, and integrated use of expertise from the different disciplines that impact plant integrity. These include design, materials selection, operating parameters and scenarios, and understanding of the current and future degradation mechanisms and of the risks involved.

What are the Goals?

  • To provide clear understanding of the key aspects of Risk Based Inspection, its advantages and limitations, and how it is linked to Reliability Centered Maintenance and to fitness-for-service assessment.
  • To show you how to develop a successful Risk Based program at your facility, and to 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.

Who is this Training Course for?

  • Operations, maintenance and engineering professionals and supervisors,
  • Engineers and other technical staff with responsibilities for inspection, maintenance, assessment and mitigation of plant equipment degradation
  • Those who want to use Risk Techniques effectively in their plants.

How will this Training Course be Presented?

The course combines presentation of the key principles, methods, and best practices backed up 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

Daily Agenda

Day One
  • 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
Day Two
  • 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
Day Three
  • 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
Day Four
  • Reliability Centred Maintenance (RCM)
    • Definitions
    • Evolution
    • Key Elements of RCM
  • Reasons for implementing RCM
    • Benefits and Limitations of using RCM
    • RCM as a part of plant integrity management
    • Economic benefits
  • Development of Inspection Plan (Based on Risk Ranking)
    • Inspection planning guidance
    • Need for some speculative/exploratory inspection
  • Implementation
    • Essentials for Establishing a Successful Risk Based Program
    • The Team - Recommended Structure and Mandate
  • Inspection History, Interpretation
    • Equipment Criticality Rating
  • Equipment Data Base
    • Shared data base by RBI and RCM
    • Importance of Data Quality
    • Computerized Maintenance Management Systems
Day Five
  • 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

Certificate

  • On successful completion of this Training Course / Online Training Course, a PetroKnowledge Certificate / E-Certificate will be awarded to the delegates.

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Frequently Asked Questions

  • To register online through our website, please click “Enroll Now” on the course page, complete and submit the form. A confirmation e-mail and instructions will be sent to the participant’s e-mail.
  • You may also get in touch with our Registration Team on
    +971 50 981 7386 | +971 2 557 7389 or send an email to reg@petroknowledge.com

  • Payments can be made in USD or UAE local currency AED (Arab Emirates Dirhams) either by Bank Transfer or by Credit Card. Our Bank Account details will be provided on the invoice.
  • Course fees are payable upon booking unless a valid, authorized Purchase Order is provided and accepted.
  • Invoices will be sent via email/courier to the ID/name and address provided.
  • The course fee shall be settled prior to course start date. Corporate payments with existing payment policy shall be relayed to us in advance.

Upon successful registration online, enrolment on the respective training course will be confirmed by Registration Team by e-mail along with the invoice and joining instruction.

For corporate fees and group registration, please send your query to info@petroknowledge.com.

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