API 580/581/ASME PCC-3: Risk-based Inspection Program, Technology and Planning Methods

About the Course

This 5-day interactive API 580/581/ASME PCC-3: Risk-based Inspection Program, Technology and Planning Methods training course will give the delegates a deep understanding of the methodology used on API 580/API 581 for determining assets (equipment & piping) Risk category and hence spent inspection budget and resources on the right place which will be reflected on the safe operation and asset's reliability.

During this programme, the overall stages of developing an inspection plan based on the risk and not traditionally time-based will be discussed in detail. These stages will start with collecting and verifying the required data for the study, such as (mechanical data, PID drawing, PFD, process data, temperature, pressure, corrosive constituents, etc.). The 2nd stage will be the assessment of the probability of failure and discussing different damage mechanisms, corrosion rates and damage modes that affect the probability of failure POF, and the 3rd stage will be assessing the Consequence of Failure (COF) and all factors impacting on it in addition to mitigation factors that could decrease COF beside inspection program. The 4th stage will assess the overall risk and risk category and develop an inspection plan. The 5th and last stage will discuss the overall study's documentation process and Reassessment steps.

Core Objectives

The delegates will achieve the following objectives:

• Familiarise with all stages of developing RBI study 
• Differentiate between different types of RBI 
• Ability to assess all factors affecting POF 
• Ability to assess all factors affecting COF 
• Know how to calculate the Risk 
• Understand the responsibilities of different parties of RBI study 
• Familiarise different types of damage modes and mechanisms 

Training Approach

This training course combines the theoretical principles of risk-based and its stages as it approaches inspection planning, then links it to the operational situation in the typical petrochemical/refining plant. It is accompanied and illustrated by real-life examples and, in several cases, first-hand experience, giving a unique transition from theory to practice that will provide support and guidance during the pre-examination process. Furthermore, the practical workshops will allow the delegates to combine their professional knowledge and experience with the newly acquired knowledge during the programme to solve practical problems.

The Attendees

This training course could be for anyone interested in asset integrity and the safe operation of the planet as inspection, corrosion, maintenance, operation, and safety engineers.

Likewise, it will be valuable to the professionals but not limited to the following:

• Inspection Engineer
• Corrosion Engineer
• Asset integrity Engineer
• Process Engineer
• Safety Engineer
• Operation Engineer

Daily Discussion

DAY ONE: OVERVIEW OF RISK MANAGEMENT

• Application & Exam
• Introduction
• Scope, Terms, & Definitions
• Basic Risk Assessment Concepts
• What is Risk?
• Risk Management and Risk Reduction
• Overview of Risk Analysis
• Inspection Optimisation
• Relative Risk vs Absolute Risk

DAY TWO: REQUIRED DATA AND ASSESSING DAMAGE MECHANISMS

• Introduction to Risk-based Inspection (RBI)
• Key Element on RBI Program
• Consequence and Probability for RBI
• Types of RBI Assessment
• Management of Risks
• Planning The RBI Assessment
• Establishing Objectives and Goals of an RBI Assessment
• Initial Screening
• Establishing Operating Boundaries
• Selecting a Type of RBI Assessment
• Estimating Resources and Time Required
• Data and Information Collection for RBI Assessment
• RBI Data Needs
• Data Quality
• Codes and Standards: National and International
• Sources of Site-specific Data and Information
• Damage Mechanisms and Failure Modes
• Accumulated Damage

DAY THREE: RISK ASSESSMENT

• Assessing the Probability of Failure
• Introduction to Probability Analysis
• Units of Measure in the POF Analysis
• Types of Probability Analysis
• Determination of POF
• Assessing the Consequence of Failure
• Introduction to Consequence Analysis
• Types of Consequence Analysis
• Units of Measure in Consequence Analysis
• Determination of COF
• Risk Determination, Assessment, and Management
• Determination of Risk
• Risk Management Decisions and Acceptable Levels of Risk
• Assumptions
• Risk Presentation
• Risk Management

DAY FOUR: RISK MANAGEMENT AND REASSESSMENT

• Risk Management with Inspection Activities
• Managing Risk by Reducing Uncertainty through Inspection
• Identifying Risk Management Opportunities from RBI Results
• Establishing an Inspection Strategy Based on Risk Assessment
• Managing Risk with Inspection Activities
• Managing Inspection Costs with RBI
• Reassessment and Updating RBI Assessments
• RBI Reassessments
• Roles, Responsibilities, Training, and Qualifications
• RBI Documentation and Recordkeeping

DAY FIVE: CASE STUDY AND EXAMINATION

• Summary of Risk-Based Inspection Pitfalls
• General
• Planning
• Data and Information Collection
• Damage Mechanisms and Failure Modes
• Assessing POF
• Assessing COF
• Risk Determination, Assessment, and Management
• Risk Management with Inspection Activities
• The Risk Management Activities
• Reassessment and Updating RBI Assessment
• Roles, Responsibilities, Training, and Qualifications for RBI Team Members
• RBI Documentation and Recordkeeping
• Case Study API 581
• Examination Questions