API-580/581: Introduction to Risk Based Inspection (RBI) Methodologies and Practices in Refineries

Introduction

The course is based on API RP 580 Risk-Based Inspection and API Publication 581, Base Resource Document. The course first explains feasible means and alternatives for achieving a successful RBI program without undue complications. This course deals with the RBI framework and methodology in a simple straight forward manner to establish and implement a risk-based inspection program best suited for the company objectives. Its utility is based on the premise that a few vital types of equipment in a process plant contribute a majority of the risk. Consequently, if these few types of equipment can be identified, then testing and inspection can be focused on them rather than several low-risk items.

RBI helps to prioritize their equipment for inspection, optimize inspection methods and frequencies, and develop an effective inspection plan commensurate with the risk contribution and equipment condition. The course is focused on the methodology of the actual implementation of RBI in the Oil and Gas industry. It covers advanced knowledge of RBI implementation in addition to the knowledge required for passing the Certification Examination. The candidates should possess at least one certification out of API 510, API 570, or API 653 certifications.

Objectives

• Introduction to the basic concept of Risk-Based Inspection and the basis for the API 580 RBI program and methodology
•  Understand the purpose, scope, and examination of the critical steps in the RBI process
• Overview of deterioration mechanisms and failure modes affecting the plant equipment 
• Understand the purpose, scope, and examination of the critical steps in the RBI process.
• Overview of deterioration mechanisms and failure modes affecting the plant equipment.
• Introduction to the risk-based inspection priority matrix and the means to utilize its results in determining inspection priorities.
• Introduction to the ISO risk plot and its use, especially in combination with the risk-based inspections priority matrix.
• Discussion of risk-based inspection documentation and recordkeeping needs.
• Understanding of the basic concepts of risk acceptance, risk assessment, risk perception, risk mitigation, and managing residual risk.
• Introduction to the risk-based inspection priority matrix and the means to utilize its results in determining inspection priorities
• Introduction to the ISO-Risk plot and its use, especially in combination with the risk-based inspections priority matrix  
• Discussion of risk-based inspection documentation and record-keeping needs
• Understanding of the basic concepts of risk acceptance, risk assessment, risk perception, risk mitigation, and managing residual risk.
• Event tree analysis; Fault tree analysis, Qualitative and quantitative assessment and evolution of inspection approaches
• Understand reassessments and means for updating RBI.
• Implementation of RBI in the Oil and Gas industry.

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

• Individuals who are responsible for implementing risk-based inspection programs within their own company or plant facility.
• Mechanical integrity, equipment reliability, and inspection personnel who are responsible for maintaining the serviceability of process plant equipment based on a cost-effective inspection program.
• Maintenance personnel, operations supervisors, and process specialists who are expected to make decisions regarding the suitability of equipment for continued service.

Course Outline

   Module 1:

• Introduction, What is RBI, Scope of RBI, Purpose & Utility of RBI
• Common Definition RBI,
• Definition of Risk, Relative Risk v/s Absolute Risk
• Relationship between inspection & risk
• Types of RBI assessments
• Qualitative, Quantitative and semi- Quantitative approaches

   Module 2:

• Planning RBI assessment
• Selecting the type of RBI assessment
• Identifying deterioration Mechanisms
• Introduction to Qualitative Analysis
• Likelihood category, Consequence category
• A step-by-step method for Qualitative analysis
• Understanding the damage factors
• Determine likelihood category
• Determine the consequence category and Risk category
• Preparation of Risk matrix, Analysis, and conclusion

  Module 3:

• Introduction to Quantitative analysis
• Flammable effects, Toxic effects,
• Business interruption effects
• Estimation of release rate and post leak response
• Risk Evaluation, Risk-weighted consequences

   Module 4:

• Introduction to semi-quantitative approach
• Likelihood analysis, Consequence analysis
• Risk management post RBI analysis
• Inspection strategies post RBI analysis
• Using RBI findings to evolve an inspection strategy in Oil and Gas industry.

   Module 5:

• Inspection Effectiveness
• Optimizing Inspection Methods and frequencies
• Risk mitigation and follow-up
• Re-assessment and updating RBI
• Implementation of RBI in Oil and Gas industry.