API RP 691: Advanced Risk-Based Machinery Management

About the Course

The comprehensive 5-day API RP 691: Advanced Risk-Based Machinery Management training course aims to equip delegates with advanced knowledge and practical skills in risk-based inspection (RBI) tailored for the refining, petrochemical, and petroleum sectors. API RP 691 provides a structured framework for evaluating equipment integrity by integrating risk assessment with inspection strategies, emphasizing proactive maintenance and safety enhancement. Delegates will explore the intricacies of RBI methodologies, including risk assessment techniques, inspection planning, and mitigation strategies for various asset types, such as pressure vessels, piping systems, and storage tanks.

Delegates will examine case studies and real-world examples that illustrate the application of API RP 691 principles in diverse operational contexts. This experiential learning approach enables delegates to grasp and apply complex concepts effectively in their professional roles. Moreover, it underscores the importance of aligning RBI practices with regulatory requirements and industry standards, ensuring compliance, and fostering a culture of continuous improvement in asset management. They will have acquired the expertise to develop robust RBI programs, optimise inspection intervals based on risk profiles, and make informed decisions regarding maintenance prioritisation and resource allocation. This holistic understanding empowers professionals to mitigate operational risks, reduce downtime, and extend the service life of critical assets, thereby enhancing overall operational efficiency and reliability in the dynamic environments of the refining, petrochemical, and petroleum industries.

Core Objectives

The delegates will achieve the following objectives:

• Confidently implement the risk-based machinery management framework based on API RP 691
• Master the implementation toolbox from API RP 691
• Learn various maintenance management approaches
• Optimise decision-making considering safety and economic aspects
• Optimally use risk and reliability in asset management

Training Approach

This training course employs a blended approach, integrating interactive sessions with practical case studies and real-life examples. Delegates will explore API RP 691 principles through instructor-led discussions and demonstrations. Real-world case studies illustrate the application of risk-based machinery management frameworks in diverse industrial contexts, enhancing the understanding and application of theoretical concepts. Practical exercises simulate RBI scenarios, enabling hands-on learning and skill development in risk assessment and mitigation planning. Our methodological approach combines research-backed principles with industry best practices, ensuring delegates gain actionable insights to optimise asset management decisions and achieve sustainable safety and economic benefits in their operational environments.

The Attendees

It will be suitable to the professionals but not limited to the following:

• Engineers (Mechanical, Electrical, Civil)
• Maintenance Managers
• Asset Integrity Engineers
• Safety and Reliability Engineers
• Designers and machinery manufacturers

Daily Discussion

DAY ONE: RBMM INTRODUCTION, FEASIBILITY AND DESIGN

• Machinery Risk Management Overview
• Normative References and Definitions
• Risk Assessment Methodology (Annex A)
• Feasibility and Concept Selection
• Technical Risk Categorisation
• API 691 Feasibility and Concept Selection Guidelines
• API 691 Facility Audit Guidelines (Annex G)
• Front-end Engineering Design
• Preliminary Machinery Risk Assessment
• Reliability, Availability, and Maintainability Analysis
• Machinery Design and Selection
• Process and Instrument Diagram (P&ID) Reviews
• Workshop: P&ID Review and Analysis

DAY TWO: FEED, DETAILED DESIGN, INSTALLATION AND COMMISSIONING

• Long Lead Machinery and Vendor Qualifications
• Operations, Maintenance, and Facilities Strategies
• Detailed Design and Machinery Risk Assessment
• Design Failure Mode and Effects Analysis
• Risk Mitigation-Task Selection Process
• RAM-2 Analysis and Application
• Safe Operating Limits and Integrity Operating Windows
• Qualification of Manufacturing and Design
• Start-up and Commissioning Plans
• Machinery Standard Operating Procedures
• Facilities Completion Planning and Execution
• Implementation of Risk Mitigation Tasks and Strategies
• Installation, Commissioning, Decommissioning, and Decontamination
• Pre-start-up Safety Review and Optional Tests
• Workshops: Risk-based Machinery Validation Checklists (Annex B); Machinery Failure Modes, Mechanisms, and Causes (Annex C)

DAY THREE: OPERATION, MAINTENANCE, AND MONITORING

• Field Risk Assessments and Mitigation Strategies
• Implementation of RAM-2 Analysis Results
• Safe Operating Limits and Integrity Operating Windows in Practice
• Guideline on Condition Monitoring and Diagnostic Systems (Annex E)
• Guideline on Machinery Prognostics (Annex F)
• API 691 Datasheets Utilisation (Annex H)
• API 691 FMEA Worksheet Application (Annex I)
• Workshop: FMEA Analysis - Part 1
• Workshop: FMEA Analysis - Part 2

DAY FOUR: DOCUMENTATION AND QUALIFICATION

• Documentation and Recordkeeping Best Practices
• Document Management Throughout Product Lifecycle
• Operation and Maintenance Training Programs
• Proof of Qualification Requirements and Processes
• Guideline on Risk Mitigation Task Selection (Annex D)
• Type II and Type III Evaluation Examples and Exercises
• Workshops: Pump Type II Evaluation; Gas Turbine Type II Evaluation; Combination of RBI Approach and Type II Analysis for PSV

DAY FIVE: PRACTICAL IMPLEMENTATION AND CASE STUDIES

• Real-world Applications of RBMM Principles
• Case Studies on Successful Implementation
• Review and Discussion of Practical Challenges
• Optimisation of RBMM Strategies Based on Case Studies
• Q&A Session and Course Evaluation