Risk-Based Inspection and Maintenance Strategies

Introduction:

In an organization, Risk-Based Inspection (RBI) and Risk-Based Maintenance (RBM) approaches are structured methods for evaluating the probability and impact of equipment and infrastructure failures. These strategies allow for prioritizing and optimizing inspection and maintenance activities, enhancing safety, reducing equipment malfunctions, minimizing unplanned shutdowns, and lowering operational costs. Understanding these risk-based strategies is essential for developing effective maintenance and inspection procedures.

The Risk-Based Inspection and Maintenance Strategies course is designed to provide participants with a thorough understanding of RBI and RBM concepts, risk assessment methods, and practical applications. The course covers how to determine optimal inspection and maintenance actions based on risk profiles, aiming to develop proactive maintenance plans that improve safety, reliability, and cost-effectiveness.

Objectives:

Upon completion of this Risk-Based Inspection and Maintenance Strategies course, participants will be able to:

• Master RBI and RBM concepts, including their practical application and benefits.
• Understand how RBI and RBM enhance plant equipment and infrastructure reliability.
• Describe the interconnection between RBI and Reliability Centered Maintenance (RCM).
• Perform risk-based fitness-for-service evaluations.
• Develop and manage effective RBI and RBM programs.
• Apply methods for likelihood and consequence analysis.
• Define optimal inspection intervals based on degradation mechanisms.

Training Methodology:

• Case Studies
• Workshops
• Simulations
• Group Discussions
• Interactive Exercises
• Scenario Analysis
• Project-Based Learning

Course Outline:

Unit 1: Importance of Inspections with Respect to Plant Integrity and Maintenance Costs

• Purpose and Importance of Inspection
• Key Performance Indicators for Inspection
• Typical Inspection Approaches and Their Limitations
• Introduction to Risk-Based Management Principles
• Risk Evaluation: Failure Probability and Impact
• Risk Control: Elimination and Reduction
• Risk Communication, Awareness, and Handling
• Risk Assessment Principles and Methods

Unit 2: How to Conduct Risk-Based Inspection (RBI) Strategy

• Definitions and Core Components of RBI
• Development and Benefits of RBI
• RBI as Part of Plant Integrity Management
• API Risk-Based Inspection Programs and Standards
• Analytical Tiers of RBI Study
• Integration of RBI with Other Codes and Standards

Unit 3: Identifying Risks and Conditions

• Damage Mechanisms and Failure Modes
• Standard Damage Events: Corrosion, Fracture, Fatigue, etc.
• Appraisal of Deterioration Mechanisms
• Active and Inactive Damage Mechanisms
• Choosing Appropriate Materials for Deterioration
• Asset Management and Risk Management Integration

Unit 4: Creating an Inspection Work Plan Based on RBI Risk Levels

• Guidelines for Inspection Planning
• Justification for Recommended Inspections
• Elements of a Successful RBI Program
• Structure and Mandate of the RBI Team
• Inventory Management and Equipment Criticality Assessment
• RCM and RBI Integrated Database
• Importance of Data Quality and CMMS

Unit 5: Adjusting Resource and Maintenance Intervals Based on Risk Assessment

• Evaluation of Inspection Results
• Data Quality in RBI
• Corrosion Rate and Useful Life Calculation
• Fitness-for-Service Assessment
• Estimation of Failure Consequences and Inspection Frequencies