Risk Based Inspection API 580/581

4 - 8 December 2017, Kuala Lumpur

S. Nadeem Ahmed has more than 20 years of industrial experience with career as a Mechanical Engineer with Manufacturing and Engineering MRO Industry. He is experienced in Maintenance, Repair & Overhaul (MRO), Testing and Evaluation of Turbo Machinery including Aero and Aero derivative Gas Turbine Power Plants. He has worked with various concerns on life extension and evaluation of 1400 MW+, combined cycle power plants and 1600MW+, Thermal Power Plants.

Nadeem has also provisioned Process companies (Power Generation, Oil and Gas etc) on Effective Reliability Improvement Programs, Maintenance Management Strategies, Lean Maintenance and Six Sigma Process Improvement Strategies integrating the same with reliability solutions.

He holds a Masters in Mechanical Engineering with Major in Thermal Power Systems Engineering, is a Certified Six Sigma Master Black Belt from USA & is well versed with the Quality, Six Sigma and Power Plant Equipment Reliability Analysis Software’s. He has also conducted training for the following companies: PTT Global Chemical Public Company Limited, HMC Polymers Company Limited, Teknik Janakuasa SDN BHD, Petrochina International (Bermuda) Ltd, Abu Dhabi Marine Operating Company, Abu Dhabi Company for Onshore Petroleum Operations, Dubai-Water and Power, Alstom Malaysia, Belzona Indonesia, PPTEP Thailand and Johar Coal Fired Power Malaysia.

Tel: +65 6524 4973 Fax: +65 6271 9029 Email: marylen@ctsolutionsglobal.com Online: www.tun.sg

The Trainer: S. Nadeem Ahmed

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Risk Based Inspection 4 - 8 December 2017, Kuala Lumpur

Course DescriptionRBI methodology is an approach that is used for optimization of inspection efforts in a plant by identifying most critical process equipment and piping and thus focusing the inspection effort on the equipment with the highest risk. By applying the RBI approach, a solid basis for decisionmaking on inspection frequency, the extent of inspection, and the most suitable type of inspection can be established. The knowledge about the state of the plant and management of the corresponding risks can be further integrated in the overall plant asset (integrity) management.This course will provide inspectors and analysts withadvanced knowledge and skills in Risk-Based Inspection(RBI) based on the framework defined in API RP 580 andin-depth understanding of the calculations performed according to the API RP 581 for fixed equipment and piping.The course covers both the principles and guidelines for developing an RBI program, as per API RP 580, as well as details of quantitative methods and calculation details as given in API RP 581. Other than that, this enables the participants to understand the safety and economic benefits of RBI implementation in refining and process industries. It enables the participants to understand the calculation background and principles and help them use the results of an RBI analysis in optimal way. It also covers the standards development and technology improvements and help understand the links to other topics that are dealing with risk and safety in the plant operation.The course has been updated and from ground-up reviewed to the latest editions of both API RP 580 and API 581, editions 2016 (3rd edition).

Tel: +65 6524 4973 Fax: +65 6271 9029 Email: marylen@ctsolutionsglobal.com Online: www.tun.sg

Who should attend• Refining and Petrochemical Engineers & Inspectors • Individuals who are responsible for implementing risk-based inspection programs within the company or plant facility• Plant Engineers, Non-Destructive Testing Engineers, Materials & Corrosion Engineers• Plant Inspectors responsible for managing the integrity of ageing process equipment, pipelines, boilers and storage tanks;• Maintenance personnel, operations supervisors, and process specialists who are expected to make decisions regarding the suitability of equipment for continued service• Engineers and inspection personnel from the pulp and paper, oil and natural gas, and chemical industries may also find the course beneficial.

A working knowledge of basic equipment is recommended.

Course Objective• Provide basic understanding of the RBI process for the fixed equipment and piping in refining and process industries, as well as approaches to its implementation. • Provide in-depth, in-detail knowledge and understanding of the both qualitative and quantitative approaches in the RBI• Know how to utilize this knowledge for inspection planning and as input for condition assessment of the equipment.

Course OutlineDay OneModule 1: Introduction• API Standard/ RP 580• API RP 581• ASME PCC-3• Editions, differences in implementation

Module 2: Risk Based Inspection framework (API 580)• API 580, purpose and scope• API 580, normative reference, link to other standards• Basic terms, definitions, acronyms and abbreviations• Basic Risk Assessment Concepts• Key elements of an RBI program• Types of RBI assessments and how to select them• RBI and operating risks management• RBI planning• Screening• Operating boundaries and limitations• RBI Study - Estimating resources and time• Data sources, data quality, data needs• Damage mechanisms and failure modes, overview, link to IOW• NDT methods and applicability

Day TwoModule 3: Risk Assessment Process (API 580)• Accessing probability of failure• Accessing consequences of failure• Risk determination, assessment and management• Risk management with inspection activities• Risk management with other mitigation activities („4R” concept)• Reasessment and update of RBI• RBI Documentation and record keeping• Common RBI problems and pitfalls

Module 4: Introduction to API 581 (RBI) Part 1 - InspectionPlanning Methodology• Scope and definitions• Probability of Failure• Consequence of Failure• Risk analysis and inspection planning• RBI on Pressure vessels and piping• RBI on Atmospheric storage tanks• RBI on Pressure relief devices• RBI on Heat exchanger tube bundles

Risk Based Inspection 4 - 8 December 2017, Kuala Lumpur

Course Outline

Day ThreeModule 5: API 581 (RBI) Part 2 - Probability of FailureMethodology• Probability of failure methodology• Management systems factor, link to PSM (Process Safety Management) and AIM (Asset Integrity Management)• Thinning damage factor and inspection effectiveness• Component lining damage factor and inspection effectiveness• External corrosion damage factor, ferritic component and inspection effectiveness• Corrosion under insulation (CUI) damage factor, ferritic component and inspection effectiveness• SCC Damage factor and inspection effectiveness• External SCC damage factor and inspection effectiveness• External CUI damage factor and inspection effectiveness• High temperature hydrogen attack damage factor and inspection effectiveness• Brittle Fracture damage and inspection effectiveness factor• Pipingmechanicalfatiguedamagefactorandinspection effectiveness• Furnace tube probability of failure calculation (API 581:2000)• Buried components and inspection effectiveness• Atmospheric storage tanks and inspection effectiveness

Module 6: API 581 (RBI) Part 3 - Consequence of FailureMethodology• Consequence of failure types• Consequence of failure methodology• Consequence of failure calculation levels• Consequence of failure – level 1 – representative fluid• Consequence of failure – level 1/2 – hole size selection• Consequence of failure – level 1 – Release rate calculation• Consequence of failure – level 1/2 – Fluid inventory estimations• Consequence of failure – level 1/2 – release type determination• Consequence of failure – level 1/2 – impact of detection, isolation and mitigation systems

Day FourModule 6: API (RBI) Part 3 - Consequence of Failure-Methodology (continued)• Consequence of failure – level 1 – release rate and mass for consequence of failure• Consequence of failure – level 1 – Flammable and explosive consequences• Consequence of failure – level 1 – Toxic consequences

• Consequence of failure – level 1 – Non-flammable and non-toxic consequences• Consequence of failure – level 1/2 – Component damage and personnel injury consequence area• Consequence of failure – level 1/2 – Financial consequences• Consequence of failure – level 2 – fluid composition and properties• Consequence of failure – level 2 – release rate calculation• Consequence of failure – level 2 – release rate and mass for consequence of failure• Consequence of failure – level 2 – Flammable and explosive consequences• Consequence of failure – level 2 – Toxic consequences• Consequence of failure – level 2 – Non-flammable and non-toxic consequences• Atmospheric Storage tanks consequence of failure calculation

Module 7: API 581 - Wrapping It All; case studies andcalculation examples• Risk analysis, time horizon and inspection planning• Pressure vessel PoF calculation example• Pressure vessel CoF Level 1 calculation example• Pressure vessel CoF Level 2 calculation example• Inspection planning examples• Optional: own examples

Day FiveModule 8: API 581 - Wrapping It All; real-life case studiesand calculation examples• FCC unit, gas pressure vessel• Hydrogen unit, vessel or piping• Vacuum distiller, column top• Hydrogen recovery, pump or compressor• Heat exchanger bundle example• Pressure relief Valve example (PRV) Module 9: Repetitorium, focus on RBI methodology (API 580)• RBI Methodology review• RBI - linking methodology and implementation• Other tools and methodologies related to RBI and inspection planning – how and when to use them• Limits and extensions of the RBI methodology – from RBI towards Asset Integrity• RBI key points and topics review and joint discussion• Final Exam preparation – typical questions, formats, answers

Risk Based Inspection4 - 8 December 2017, Kuala Lumpur

Phone : +65 6524 4973

Fax : +65 6271 9029

Email : marylen@ctsolutionsglobal.com

Online : www.tun.sg

Concorde Hotel Kuala Lumpur2, Jalan Sultan Ismail, Kuala Lumpur, 50250 Kuala Lumpur, Wilayah Persekutuan Kuala Lumpur, MalaysiaPhone: +60 3-2144 2200

http://kualalumpur.concordehotelsresorts.com/

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Risk Based Inspection 4 - 8 December 2017, Kuala Lumpur

SGD 5, 499

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Redhill Forum, 16 Jalan Kilang Timor

#03-07, Singapore 159308

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Hotel accommodation & travel costs are not included in the registration fee. A reduced corporate room rate has been arranged at the hotel for attendees at this conference. To take advantage of this special rate, please process the hotel room reservation form provided upon confirmation of your attendance.

Payment PolicyFull payment of course fee to be received by the stipulated date of training, failing which T.U.N INTERNATIONAL will exercise the right to refuse entry to the delegate. Any late payment will be subjected to a 5% late payment fee.

Program Change PolicyT.U.N INTERNATIONAL reserves the right to replace or modify the advertised speakers/topics should there be circumstances beyond the control of the organizers before the event. Any changes will be updated on our website as soon as possible

CancellationsIf you are unable to attend the training course for which you have registered, you may send a substitute free of charge. If you cannot send a substitute or otherwise need to cancel your class registration, please provide written notice to us via e-mail at admin@tun.sg. Cancellation requests received by T.U.N INTERNATIONAL seven (7) days or more prior to the course start date will receive full credit for use in another future course with no time limit. Credit is not available for cancellation requests received by T.U.N INTERNATIONAL seven (7) or fewer days before the course start date. T.U.N INTERNATIONAL reserves the right to alter or change any part of the course. In the event T.U.N INTERNATIONAL cancel a course due to inclement weather, or other events beyond our control, the fees will be credited to a future seminar of the registrants choice. Upon registration, the registrants acknowledges that T.U.N INTERNATIONAL will not be held liable for any charges or fees incurred due to the cancellation of travel or accommodation reservations.

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