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SE06
IMPLEMENTATION, INTEGRATION & MANAGEMENT OF 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.
Contents:
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 –v- 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
·
Equipment demographic analysis
·
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
·
Identify hazards
·
Evaluate the risks
·
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 –v- 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 –v- 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 – MTBF, Reliability etc.
Work request backlog analysis
Customer feedback analysis
Cost analysis
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