The asset integrity assurance techniques in relation to physical assets (i.e. static process equipment, e.g. piping, pipelines and structures; and rotating machinery, e.g. pumps, turbines, etc.) will be discussed in relation to design, operational and technical integrity perspective.
The importance of minimizing human factor related challenges and role of asset performance variability minimization methodologies with relevant case studies will be explained. Risk based analysis principles and development risk matrices with special consideration to probability of failure (PoF) and consequence of failure (CoF) assessment will be presented.
Operational efficiency (OE) improvement via lean thinking and use of digitalization & artificial intelligence (AI) will be explained. Basic corrosion and erosion mechanisms that need to be considered in a risk-based inspection (RBI) program development will be explained. Reliability centered maintenance (RCM) analysis together with failure mode effects analysis (FMEA) and criticality analysis (FMECA) will be presented.
Also, the functional failure consequence classification approach for rotating machinery will be presented. Use of conventional inventory control approaches for spare parts assessment and control as well as consequence classification based on functional hierarchy and risk based spare parts assessment and control will be discussed.
Course Agenda (Day 1 – 5)
The lecures will be held on Zoom following dates:
From 09.00 to 15.00
Day 1: Overview of onshore/offshore physical assets and other critical kinds of assets, asset management, integrity, asset integrity management.
- Relationship among human factor, offshore physical assets and asset performance variability.
- Typical failures’ rates among organizational, human and technical factors.
- Role of barriers preventing unwanted events.
- Case histories of unwanted events vs lessons learned.
- Need for statistical and empirical science’ in integrity assessment and control:
- Role of ‘risk/reliability assessments, risk based inspection, risk based maintenance and reliability centered maintenance (RCM).
- Asset Performance Management (APM) vs. Asset integrity management AIM
- Augmenting conventional ad hoc assessments, control and prioritizations (AC&Ps) with systematic and formal AC&Ps.
- Importance of alignment, measuring alignment gaps.
- minimizing negative performance durations in the projects’ delivery.
- Risk based technology qualification and use of artificial intelligence to minimize the variability.
Day 2: Fundamentals of Risk Based Inspection and Maintenance
- General requirements RBIM: risk based inspection and maintenance.
- Requirements for performing PoF analysis.
- Requirements for performing CoF analysis.
- Barrier management system: barrier function, sub-function, and elements .
- Risk based inspection and maintenance within the overall management system.
- Data quality on aging offshore topside system: industrial case study findings.
- Requirements for data collection.
- Prioritization of flowline’s flanges to inspect during shutdowns.
- Input to RBIM process ( Documented and Non-documented data).
- Risk analysis requirements at screening level.
- Detailed risk Assessment requirements.
- Decision making and action plans: example framework.
- Detailed planning and reporting key performance indicators.
Day 3: In service inspection/risk-based inspection of static process equipment.
- Overview of onshore/offshore production and/or process facility.
- Risk assessment due to corrosion and erosion.
- Corrosion/erosion mechanisms on different construction materials and geometric locations of mechanical/structural systems.
- Containment failure consequence (CFC) classification.
- Inspection planning process of piping systems: engineering contractor and assets owner’s perspective.
- In service Inspection/RBI standards and regulatory requirements.
- Strategies for maintenance of ‘aging structures’.
- Case study: Prioritization of piping flanges for CVI in a PM-shutdown.
- Lean Maintenance: Asset owner (operator) and engineering contractor perspective.
- Case study: Values requisition process improvement.
Day 4: Prioritization of maintenance activities: consequence classification and reliability based.
- Rotating machinery and maintenance requirements.
- Measuring and designing for reliability and maintainability.
- Concept technical and functional hierarchy.
- Consequence classification approach for prioritization of maintenance activities.
- Reliability centered maintenance (RCM) and Failure mode effect and criticality analysis (FMECA) of offshore systems
- FMEA and FMECA analysis:
- Case study: FMEA
- Case study: FMECA
Day 5: Spare parts assessment and control for onshore/offshore industrial plants’ integrity assurance:
- Current approach with Spare Parts Interchangeability Record (SPIR).
- Spare parts classification in the petroleum industry and other major projects.
- Spare parts assessment and control workflow: standard recommended approach for spare parts evaluation.
- Generic workflow for evaluation of spare parts
- Workflow when an engineering contractor and assets’ owner involved.
- Consequence classes for spare parts.
- Development and use of a risk matrix for spare parts evaluation.
- Typical challenges pertaining to equipment tags and spare parts assessment & control
- Use of conventional inventory control approach for spare parts assessment and control with certainty and uncertainty (probabilistic approach).
- Use of EOQ model
- Use of backorder model
- Calculation of safety stocks under uncertain demand.
- Case studies and example calculations.
Who Should Attend?
This training course is suitable to a wide range of technical professionals within mechanical, process, structural, construction/manufacturing and chemical/process engineering/technical disciplines. Also, those who want to gain further knowledge within:
- Operation, inspection, maintenance, repair and modification professionals in mechanical, process, structural and chemical engineering disciplines.
- Key operations’ supervisors/leaders in mechanical, structural, construction/manufacturing and chemical/process engineering disciplines.
The course is held by Professor R. M. Chandima Ratnayake.
Read more about him here.