II
Asset/Plant Oriented Risk Management

Short description

Objectives

The main goal of the module is to provide deeper insight and knowledge into the three main areas relevant for the main topic of the module. These are

• the principles of asset and plant oriented risk management,
• application details of the asset and plant oriented risks management.

This si done for the topics of

• Risk Based Inspection (RBI) in petrochemical and power generation industries dealing with the most important risk-based approaches in line with the main standard documents, such as API RP 580 and API 581. The courses about RBI offer a state-of-the-art knowledge on methods and tools applied.
• Reliability Centered Maintenance (RCM) and Root Cause Failure Analysis (RCFA) as methodologies used for logical decision-making process for analysis and definition of the equipment maintenance requirements, as well as for accident prevention. The focus of the course is on the damage mechanisms appearing in different industries. A large number of well elaborated examples is included. Finally, the module discusses methodologies for decision-making processes in maintenance and accident prevention. These are well illustrated by a number of instances from different industries.

The skill which the participants will master by the end of the course are primarily related to the use of the modern tools for performing the RBI/RCM/RCFA analysis in the daily practice of industrial plants, primarily in power and petrochemical industry, with the final goal to optimize asset management decisions related to:

• Run
• Repair
• Replace

i.s. the so-called 3R-decision. The ability and qualification to make this decision will be the main competence acquired by the successful attendees of this module.

Course Content by Units

Petrochemical plants

Unit 1: Risk, sources of risk, risk identification, risk perception
Unit 2: Introduction to the qualitative assessment approach
Workshop: Application of expert assessment and AHP on risk assessment of refinery components
Unit 3: API 581 Qualitative approach
Unit 4: Modeling of consequences and Release modeling
Unit 5: Likelihood assessment –statistical and API581 approach
Unit 6: Inspections and inspection effectiveness
Unit 7: Risk Based Inspection planning and inspection results evaluation
Case Study: Application of the results of RBI analysis on decision-making

Unit 1: Risk, sources of risk, risk identification, risk perception
Unit 2: Introduction to the qualitative assessment approach
Workshop: Application of expert assessment and AHP on risk assessment of power plant components
Unit 3: Introduction to the quantitative and semi-quantitative risk assessment
Unit 4: Modeling of consequences – qualitative and expert approach
Workshop: Assessment of different scenarios for power plant components
Unit 5: Modeling of consequences – quantitative approaches
Unit 6: Likelihood assessment –statistical and API581 approach
Unit 7: Likelihood assessment – physical modeling based on damage mechanisms
Unit 8: Basic Damage mechanisms
Unit 9: Inspections and inspection effectiveness
Unit 10: Defects and their probability of detection
Unit 11: Risk Based Inspection planning and inspection results evaluation

Specific areas of the RCM/RCF analysis.

Teaching Methods

Each course includes the following materials distributed to the participants:

• introductory note explaining aim and structure of the course, and used methodology as well
• ex cathedra lecturing illustrated by number of examples
• presentation of commonly used software tools
• collective and/or individual exercises
• preparation for final exam by repetition of all course units and main issues
• final exam

Literature

1. Textbook:
   RBI Risk Based Inspection - Power
2. Transparencies
   Risk Based Inspection - Power
3. HAZOP example

1. Risk Based Inspection - Petro
2. Transparencies
   EU RBI Guide document CEN CWA 15740:2008 (Risk-Based Inspection and Maintenance Procedures for European Industry)
3. Additional materials
   API 581 Appendix C Workbook for quantitative RBI
   API 581 Cosequences Analysis
   API 581 Likelihood Analysis
   NFPA 49 - Hazardous Chemicals Data

1. Textbook:
   Reliability Centered Maintenance and Root Cause Failure Analysis
2. Transparencies
   
   • Failure and damage mechanisms and reliability of ageing industrial plants
   • Reliability Centered Maintenance (RCM) and Root Cause Failure Analysis
   • EU RBI Guide document CEN CWA 15740:2008 (Risk-Based Inspection and Maintenance Procedures for European Industry
   • Root Cause Analysis
3. Additional material
   • CWA 15740, April 2008: Risk-Based Inspection and Maintenance Procedure for European Industry (RIMAP)