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AP04

API 580 & 581

RISK BASED INSPECTION
as per API 580 & PSSR SI 2000 No.128.

THE RESULTS

Organizations that manage the condition and optimise the performance of equipment in the area of Maintenance are consistently able to better compete on the global stage. The participants and their teams are better positioned to positively influence the organization with innovative ideas and techniques that in turn produce a higher performing organization.

THE BENEFITS

Individuals exposed to this training will develop expertise in the area of developing a Risk Based Maintenance strategy through a project-based implementation and maintaining that strategy through good management techniques. They will learn why the best companies in the world see Risk Based Inspection as the key to delivering cost effective production functionality in a safe and secure manner by securing a thorough knowledge of equipment condition.

THE COURSE

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.

THE DELEGATES

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

THE GOALS

  • 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

THE PROCESS

This workshop is designed to be a hands-on, stimulating experience. The program is highly interactive with many discussion and facilitated practice sessions.


 

Course objectives    

 

  • 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 RBI 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

 

Global competition and more demanding legislative requirements are making most companies face a continuous need to improve performance without impairing safety, environment or in other ways damaging the reputation.

 

To achieve these simultaneous objectives a realistic, structured and systematic approach is required:

  • Definition of the context
    • what are the issues, who are the stakeholders, what is acceptable
  • Hazards identification
    • what can go wrong
  • Hazards analysis
    • how likely is it, how bad can the consequences be
  • Total risk assessment
    • is it acceptable
  • Risk management plan development
    • what could be done to mitigate risk
  • Selection and implementation of measures
  • Monitoring and review.

 

 

Course Outline

 

Day 1

1.1 Course Objectives and Overview

 1.2 Significance of Inspection in Plant Integrity and Maintenance Costs

  • The real function of inspection
  • Inspection Key Performance Indicators

 1.3 Common Inspection Strategies and Their Limitations

 1.4 Risk-Based Decision-Making Fundamentals and Tools

  • Risk Assessment - Probability of failure, consequences of failure
  • Risk Management – Avoidance, mitigation
  • Risk Communication.

 1.5 Understanding and Managing Risk

  • Principles Risk Assessment
  • Risk Assessment Elements
  • Qualitative, semi-quantitative, and quantitative assessment

 1.6 Workshop 1- Illustrative Example of Risk Assessment

 

Day 2

2.1 Risk Based Inspection (RBI)

  • Definitions
  • Evolution
  • Key Elements of RBI

 2.2 Reasons for implementing RBI

  • Benefits and Limitations of using RBI
  • RBI as a part of plant integrity management
  • Economic benefits

 2.3 API Risk-Based Inspection Methodology

  • API RP 580 
  • API BRD 581 – Various levels of RBI Analyses

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

  • API 510, 570 and 650
  • API 579 Fitness-For-Purpose

 2.5 API Risk Based Inspection Software

 2.6 Workshop 2 - Q&A on API RBI Methodology

 

 

Day 3

 3.1 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

 3.2 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

 3.3 Selection of Suitable Materials for Specific Deterioration Mechanisms

 3.4 Integrated Asset Management

  • Linking Risk Assessment, RBI, and RCM
  • Managing Risk Using RBI

 3.5Workshop 3 - Case studies involving a number of equipment damage and failures, and learnings

 

 Day 4

 4.1 Development of Inspection Plan (Based on RBI Risk Ranking)

  • Inspection planning guidance
  • Need for some speculative/exploratory inspection

 4.2 RBI Implementation

  • Essentials for Establishing a Successful RBI Program
  • The RBI Team - Recommended Structure and Mandate 

 4.3 Developing Equipment and piping systems/circuits Inventory

 4.4 Inspection History, Interpretation

  • Equipment Criticality Rating

4.5 Equipment Data Base

  • Shared data base by RBI and RCM
  • Importance of Data Quality
  • Computerized Maintenance Management Systems

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

 

Day 5

 5.1 Inspection Interval Optimization Based on Assessed Risk

 5.2 Evaluation of Inspection Results

  • Data Quality
  • Corrosion Rate calculations
  • Remaining Life Calculations

5.3 Fitness-For-Service Assessments

5.4 Estimation of Consequences of Failures

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