GLOBAL

INDUSTRIES
INTELLIGENCE

ADVANCED RISK
BASED INSPECTION

13TH - 17TH MAY, 2024

GRAND HYATT HOTEL AL KHOBAR SAUDI ARABIA

+44 2080 508 945 www.giintelligence.com [email protected]

COURSE OVERVIEW
Risk-Based Inspection (RBI) is an analysis methodology and process that requires qualitative or
quantitative assessment of the probability of failure (PoF) and the consequence of failure (CoF)
associated with each equipment item, piping circuits included, in a process unit. The risk-based
approach requires a systematic and integrated use of expertise from the different disciplines that
impact plant integrity. Risk-based methodologies enable the assessment of the likelihood and
potential consequences of equipment failures. Risk-Based Inspection (RBI) provides companies
the opportunity to prioritize their equipment for inspection; optimize inspection methods, frequen-
cies, and resources; and develop specific equipment inspection plans. This results in improved
safety, lower failure risk, fewer forced shutdowns, and reduced operational costs.

A properly implemented RBI program categorizes individual pieces of equipment by their risks and
prioritizes inspection efforts based on this categorization.

RBI can be used to prioritize inspection-related activities, usually by means of non-destructive

examination (NDE), to reduce the uncertainties around the true damage state of the equipment and
the dynamics leading to such. The resulting inspection plan may outline the type and scheduling
of inspection for an asset. In addition to NDE, additional risk mitigation activities identified by an
RBI assessment might include a change in material of construction, installation of corrosion resis-
tant liners, operating condition changes, injection of corrosion inhibition chemicals, etc.

Consistency and repeatability of analysis are critical to producing an effective RBI program, as RBI
is based on relative risks.

COURSE OBJECTIVES:
Upon completion of this Workshop, the delegates will be aware and understanding
of the following:
Fundamental principles of Risk Analysis

The Quantitative determination of probability of failure

Analysis of consequence of failure methodology

Fundamental principles of component integrity through Oil and Gas industries

Understanding of API recommended practice API/ASME 579 standard "Fitness-for-Service"

API/580/1 – Risk Based Inspection Program

Purpose, scope and examination of critical steps within the RBI process

Using Risk Based Inspection assessment and exercises

Overview of deterioration mechanisms and failure modes affecting plant equipment

Using risk determination, risk assessment and risk management

+44 2080 508 945 www.giintelligence.com [email protected]

Team roles and responsibilities within RBI assessment(s)

Personnel training and qualifications required

Documenting and record keeping requirements, Learn the latest World Class Maintenance Best
Practices and Benchmarking Metrics to assure you stay current with the industry and ahead of
your competition.

WHO SHOULD ATTEND?

Individuals responsible for implementation of Risk Based Inspection programs within their com-
panies or plant facility. Mechanical integrity, equipment reliability and inspection personnel that
are responsible for maintaining and servicing process plant equipment for a cost-effective inspec-
tion program. Plus, maintenance personnel, operations supervisors and process specialists that
are involved with making decisions regarding suitability of equipment for continued service.

+44 2080 508 945 www.giintelligence.com [email protected]

Day 1
Fundamental principles of Risk Analysis

In simple terms, risk management is an approach used by organizations to control losses. It

involves identifying hazardous situations in the work environment and assessing the associated
risks; then acting to minimize the possible consequences of these situations.
Case Study in Practical Safety Risk Management
Exercise Spot the Hazards

Definitions and acronyms used in RBI assessments.

Basic concepts of risk acceptance, perception of risk
and using event tree analysis

ETA is a primary tool of Probabilistic Risk Assessment. In technical risk assessment, the initial
state, or “initiating event,” is generally a hazard or failure, the intermediate events are potential
propagation paths, and the final states are either conditions of loss (degradation, damage,
destruction, death) or successful loss mitigation.

Video Event Tree

Video Fault Tree
Exercise using the Event Tree and Fault Tree

Understanding Risk Based Asset Management (RBAM)

and Risk Based Management (RBM)

Fundamentally, a risk-based asset-management system collects relevant information based on

the importance to the value stream and uses this information to make fiscally responsible deci-
sions that will, in turn, create greater value to the organization. There are four phases in the
risk-based asset-management model that are critical for the success in deployment of this strate-
gy. The four phases are: Classify, Analyse, Control, and Measure.

Video Asset Integrity Management

Asset life cycle and life cycle cost management implications to RBI

A key process within asset management is the understanding of asset life cycle. There are four key
stages of the asset lifecycle, which this section will classify and describe. The four key stages of
the asset lifecycle are: Planning – Acquisition – Operation and Maintenance – Disposal
Organisations need to implement a Risk-Based Maintenance strategy if the risk of consequence
far outweighs the cost of equipment.

Video Lifecycle Costing

+44 2080 508 945 www.giintelligence.com [email protected]

Day Two:
Assessment of probability of failure (PoF) and consequence of failure (CoF)

Probability of Failure (POF) is likelihood that a piece of equipment will fail at a given time and an
important part of effective risk analyses. POF is half of the equation when determining risk as part
of Risk Based Inspection (RBI) methodology. The POF, calculated together with the Consequence
of Failure (COF), helps operators establish the risk level for a particular piece of equipment and set
inspection intervals based on the calculated risk.

POF is calculated for individual pieces of equipment by looking at the potential damage mecha-
nisms it could be susceptible to, a general frequency of failures, and management system factors.
More details on POF are provided in the American Petroleum Institute's Recommended Practice
580 - Risk Based Inspection (RBI), which contains directions on developing, implementing, and
maintaining an effective RBI program.

Video Bathtub Curve

Exercise Numbers Game
Case Study Human Factors in Maintenance

Using data and knowledge in QRA as a useful decision-support tool

A Quantitative Risk Assessment (QRA) is the systematic development of the safety and risk man-
agement tool through engineering, procurement, construction and operation for oil, gas, chemical
and petrochemical plants. The QRA is the identifying risks and evaluating possible accidental
events (frequency and fatality), and calculation of the risks for leaks and explosions of the plant.

Case Study - CSB Safety Video

Video Quantitative Risk Assessmen

Principles and main steps of risk analysis

Risk analysis is the methodical study of uncertainties and risks we encounter in business,
engineering, public policy, amongst other areas. Risk Analysis an essential tool when your work
involves risk. It can help you identify and understand the risks.

Exercise Principles and main steps of Risk Analysis

Video Hazard and Risk

Qualitative, semi-quantitative, and quantitative approaches

Qualitative Risk Assessments and Quantitative Risk Assessments are specialised methods for
calculating risks to individuals, public (societal risk), the environment and/or assets. As part of the
formal safety assessment required in the project HSE management, a QRA is highly demanded by
clients to identify major accident hazards and reduce the significant risk contributor according to
the As Low As Reasonably Practicable (ALARP) principle.

+44 2080 508 945 www.giintelligence.com [email protected]

Day Three:
Nature of Risk and its definition

According to ISO 31000, risk is the “effect of uncertainty on objectives” and an effect is a positive
or negative deviation from what is expected.

Case Study Maintenance Management

Video ISO 31000 Risk management process

Complying with Global Processes and Minium Standards

Risk probability and impact.

The Risk Impact/Probability Chart is based on the principle that a risk has two primary dimen-
sions: Probability – A risk is an event that "may" occur.

Video What is a Risk Assessment? 4 Key Elements & How To Perform a Risk Assessment Safety
Culture
Case Study Case Study Structural Deviation

Probability impact matrix

Low impact/low probability - Low impact/high probability - High impact/low probability - High
impact/high probability

With the Risk Impact/Probability Chart, you map out each risk – and its position determines its
priority. High-probability/high-impact risks are the most critical, and you should put a great deal
of effort into managing these. The low-probability/high-impact risks and high-probabili-
ty/low-impact risks are next in priority, though you may want to adopt different strategies for each.

Exercises using Corrective Maintenance Prioritisation tools.

Applying mitigation methodology

Risk mitigation strategies are action plans you conceptualize after making a thorough evaluation
of the possible threats, hazards or detriments that can affect a project, a business operation, or
any form of venture. The purpose of such strategies is to lessen or reduce, if not totally eliminate
the adverse impacts of the known or perceived risks inherent in a particular undertaking, even
before any damage or disaster takes place.

Day Four:
Deviation Analysis, Hazard and Operability Studies, Energy Analysis
The Hazard and Operability (HAZOP) study is the most widely used Process Hazards Analysis
(PHA) technique in the chemical, pharmaceutical, food, oil and gas, nuclear, and other process
industries worldwide. HAZOP is used during the design stages of a new process or project, for
major process modifications, and for periodic review of existing operations.

+44 2080 508 945 www.giintelligence.com [email protected]

 Video How to Calculate Standard Deviation
Case study What is HAZOP?

Failure Modes, Effects Analysis, HAZOP’s (Hazard and Operability Studies)

Failure Mode and Effect Analysis (FMEA) is an alternative method of hazard identification: it is less
formalized than Hazop and involves the consideration of the possible outcomes from all discerned
failure modes or deviations within a system.

Exercises using the Failure Mode and Effect Analysis

(FMEA) tool.
Video What is FMECA
Case study FMEA RCA
Video 5-Why’s

Day Five:
Failure Logic – Fault Trees, Event Trees & Cause – Consequence
Identifying areas for improvement.

Video Fault Tree Introduction

Exercises Fault Tree and Line of Sight tools.

RBI Data Needs, Analysis of Equipment Failure Data

Video What is Risk-Based Inspection

When to Conduct an RBI Reassessment

RBI assessment team roles and responsibilities

+44 2080 508 945 www.giintelligence.com [email protected]

 TRAINER’S BIO
JOHN HAY

John Hay has 30 years’ experience in Maintenance and Reliability training worldwide, having suc-
cessfully delivered training throughout Europe, Africa, Asia and the Middle East.

John has worked with many of the major companies worldwide such as Shell, Marathon Oil,
Conoco Phillips, Dolphin Drilling, Chevron, Total, and DONG Energy managing and delivering Main-
tenance and Reliability training in key areas such as Total Productive Maintenance TPM Reliability
Centred Maintenance RCM, Life Cycle Management LCM, Root Cause Analysis RCA, Risk Based
Inspection RBI, Criticality Analysis, KPI Management/analysis and Maintenance Planning and
Scheduling including many other related areas.

John is also an accredited Operational Excellence Auditor within Shell and an International Main-
tenance & Reliability Trainer and has specialist knowledge within SAP Plant Maintenance interfac-
ing within all other SAP modules.

+44 2080 508 945 www.giintelligence.com [email protected]

Course Methodology
Practical Learner Friendly Training

Presentations

Games

Case Studies Audio – Video

Interactive Exercises

Learning by Doing

If I listen, I forget If I see, I remember.

If I do, I understand.

If I teach, I learn.

TRAINING METHODOLOGY:
The course is interactive and is comprised of lectures, case studies, technical process learning,
and supplemental discussions related to various industries and the challenges of implementation.

TESTIMONIALS
RICHARD GROGAN
UK IT/SAP Team Manager at Amoria Bond
Since working with John at ConocoPhillips we have had nothing but good feedback on his perfor-
mance. He has made an impact from his first day on site both in terms of process improvement
and in terms of building relationships within the business.

He is punctual, professional and has been an absolute pleasure to work with. I would highly rec-
ommend John as a true expert within the SAP arena.

Scott Fraser
Vice President OIM Energy Group
John provides an excellent service, in his chosen field. John is professional & a pleasure
to work with

+44 2080 508 945 www.giintelligence.com [email protected]

 ADVANCED RISK BASED INSPECTION
13th - 17th May, 2024
Grand Hayat Al Khobar Saudia Arabia
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MUHAMMAD SAAD
EMAIL: [email protected] | TEL : +44 2080 508 945

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