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SE08

IMPLEMENTATION, INTEGRATION & MANAGEMENT OF STATUTORY PRESSURE VESSELS INSPECTIONS

INTRODUCTION

Throughout the world it has long been recognised that loss of mechanical integrity of vessels containing fluids under pressure can cause loss of revenue, loss of business capability and even loss of life.  It is the intention of this seminar to introduce legislative requirements appertaining to pressure vessels and to provide tools and techniques that will allow the delegate to implement a programme thereby satisfying those requirements.  Both API and HSE are addressed.

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 Pressure Vessel Inspection 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 Pressure Vessel Inspection as an integral component in delivering cost effective production functionality in a safe and secure manner by securing a thorough knowledge of equipment condition.

THE COURSE

The safe and cost effective maintenance and operation of Pressure Vessels is crucial to the ongoing success of any enterprise which uses pressure vessels as a key component of the business. 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 Pressure Vessel Inspection Programme or auditing an existing programme. It covers all the steps required in developing a successful Pressure Vessel Inspection programme from initial recognition of a need, through management approval and system development until a well managed Pressure Vessel Inspection Programme 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 Pressure Vessel Inspection Programme 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 Pressure Vessel Inspection technologies.

*      Identify the Legislative Requirements

*      API 510

*      API RP 572

*      ASME VIII Boiler & Pressure Vessel Code

*      PSSR SI 2000 No.128

*      Prepare the solution for management

*      Cost analysis of Pressure Vessel Inspection –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 a PRESSURE VESSEL INSPECTION 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

*      Risk Based Inspection 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