Risk Based Inspection Implementation Integration and Management
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Risk Based Inspection Implementation Integration and Management Course
Introduction:
The API recommends a number of methods, including risk-based inspection, for the safe and economical upkeep and operation of static equipment, such as tanks, pipes, and pressure vessels. Both certified new professionals and seasoned experts who may be involved in the implementation of a new Risk-Based Inspection system or auditing an existing system would benefit from this extensive 5-day training.
Course Objectives:
- 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
Who Should Attend?
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 organization, this will be a very valuable course.
Course Outlines:
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
- Course 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 ¡Vv- Status Quo
- Resource analysis
- Prepare the presentation to management for budget authorization
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
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 ¡Vv- operational reporting (project)
- Routines, procedures, processes
- Define progress reports (budgetary & technical)
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 ¡Vv- operational (routine) reporting
- RBI workflow
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
Develop Key Performance Indicators so that managers can maintain control of the process.
CMMS Integration
- CMMS requirements
- Operational planning
Key Performance Indicators
- Reliability & statistics ¡V MTBF, Reliability etc.
- Work request backlog analysis
- Customer feedback analysis