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EFFECTIVE RISK BASED INSPECTION 19th – 21st October 2015

Cologne, Germany RBI stands for Risk Based Inspection and is a methodology applied in the Hydrocarbon and Chemical Processing Industry as part of their Process Safety Management. This is done in order to operate and manage assets and Equipment which is exposed to hazardous chemicals and pressure in a safe manner. The approach is one of many methodologies used to maintain assets are in a safe and reliable condition to keep the chemicals/fluids/gases inside of the pressure boundaries as per the original design criteria. In most countries around the globe, the surveillance of these pressure vessels or pipelines containing hazardous chemicals are regulated with rigid inspection programs.

YOUR FACILITATOR – DR MICHAEL RENNER Dr Michael Renner holds an Engineering degree and a Ph.D. from Teesside University, UK in Mechanical Engineering/Metallurgy and is a certified European Engineer (EUR ING). He has worked in several different industries such as the Steel, Hot Dip Galvanizing, Non-Ferrous Metal and has over 26 years in the Chemical Process Industry at Bayer and their clients. He has in total 35 years working experience, the first half of which is centred on Corrosion Prevention Strategies, Materials Optimization & Development and Root Cause Failure Analysis. Dr M Renner has worked in the metallurgical engineering and inspection management in Germany and in the US he extended his working area into the field of Mechanical Integrity (MI) including Material Engineering and strategic QA in major investment projects. Dr Renner has now centred his focus on working in the field of Asset Life Cycle Management, Risk Management (to include Risk Based Maintenance & Risk Based Inspection) and Corrosion Management in Europe, Middle East and the USA via his consultancy Asset & Corrosion Management in Germany.

WHY YOU SHOULDN’T MISS IT?- BENEFITS

• To improve risk management results. • To provide an independent approach for managing risks. • To apply a strategy of doing what is needed for safeguarding Integrity and improving reliability and availability of the asset by planning and executing those inspections that are needed. • To reduce inspections required and shutdowns needed and provide longer run length without compromising safety or reliability. • To safeguard integrity and mitigate the risk of failures. • To increase plant availability and reduce unplanned Shutdown. • To provide a flexible technique to be able to continuously improve and adopt to changing risk. • To ensure inspection techniques and methods are in line consider potential failure modes. • A more cost-effective alternative to traditional inspections by means of non -destructive testing. • More reliable equipment and plant operation. • Identification of the operational risks associated with equipment via material degradation. • Adherence to codes of compliance resulting in increased Safety.

IN CO-OPERATION WITH

• 5H+ of Networking session with other industry peers and sharing best practices. • Case study from the trainer’s experience.

CGOG 01

EFFECTIVE RISK BASED INSPECTION 19th – 21st October 2015

Cologne, Germany

WHO SHOULD ATTEND? • • • • • •

Inspection & Maintenance personnel Materials & Corrosion engineers Plant Reliability engineers Non-destructive testing engineers

•

Plant inspectors responsible for managing the integrity of ageing process equipment, pipelines, boilers and storage tanks

• •

Production and other plant engineers

Materials and corrosion engineers Unit & Maintenance superintendents/supervisors

Technicians responsible for the safe on -going operation of pressure containing equipment in oil and gas facilities and HSE personnel

TRAINER’S PROFILE Dr Michael Renner holds an Engineering degree and a Ph.D. from Teesside University, UK in Mechanical Engineering/Metallurgy and is a certified European Engineer (EUR ING). He has worked in several different industries such as the Steel, Hot Dip Galvanizing, Non-Ferrous Metal and has over 26 years in the Chemical Process Industry at Bayer and their clients. He has in total 35 years working experience, the first half of which is centred on Corrosion Prevention Strategies, Materials Optimization & Development and Root Cause Failure Analysis. Dr M Renner has worked in the metallurgical engineering and inspection management in Germany and in the US he extended his working area into the field of Mechanical Integrity (MI) including Material Engineering and strategic QA in major investment projects. Dr Renner has now centred his focus on working in the field of Asset Life Cycle Management, Risk Management (to include Risk Based Maintenance & Risk Based Inspection) and Corrosion Management in Europe, Middle East and the USA via his consultancy Asset & Corrosion Management During his established career he has written more than 80 papers which have been published in international magazines and conferences. He served twice as chairman for The Stainless Steel World Conference 2001 in Maastricht/NL and the Asset Integrity Conference in Doha/Qatar in 2009. He has been invited numerous times to be a keynote speaker for conferences in the USA and Malaysia and at times moderated conference sessions. He also provides Corrosion Management seminars to the Oil & Gas, Refinery and Chemical Industry and is an RBI Courses lecturer for a International Master's degree program called European Risk Management from The Steinbeis University in Berlin. Dr Michael Renner is a fellow of NACE International and Stainless Steel World. To add to his accomplishments he is also a co-author of a RBI book called- “Risk-Based Inspection and Maintenance Procedures for European Industry”, published in 2008.

Partial list of companies that have benefitted from Mr. Renner ’s expertise:

Ø Thai Oil Public Limited Ø PTTEP

Ø Shell

Ø Conoco Phillips

Ø Total

Ø BP

Ø Petronas

Ø ExxonMobil

CGOG 01

EFFECTIVE RISK BASED INSPECTION 19th – 21st October 2015

Cologne, Germany

Introduction Risk Management & RiskInspection Based Inspection (RBI) Introduction to RisktoManagement & Risk Based (RBI) ü Overview of the RBI Key Elements of the RBI Technology based upon API 580 & 581 such as :-

• • • • • • • • • • •

Data Collection for RBI Risk Analysis Consequence of Failure Likelihood of Failure How Inspection Affects Risk Assessing Inspection Effectiveness RBI Inspection Planning RBI Inspection and Task Management Benefit & Limitations of RBI Case Studies Example of major chemical accidents/incidents with inspection or materials & corrosion shortcomings as cause of the incidents

DAY ONE 19 TH – OCTOBER 2015 - 9:30am to 5:00pm

ASSET INTEGRITY MANAGEMENT (AIM) IN THE HYDROCARBON & CHEMICAL PROCESSING INDUSTRY q q q q q q q

Discussion: Audience perception of AIM Asset Integrity Management (AIM) – A holistic approach Asset Integrity Risk Management process Process Safety Management & Asset Integrity Management Role of Risk Based Inspection within AIM RBI benefits & limitations RBI as an Integrated Management or Continuous Improvement

RISK ASSESSMENT CONCEPTS q q q q q

Discussion: Audience perception of risk assessments What is risk? Risk management & risk reduction Inspection optimization Case Study: Case history of an AIM related refinery

PLANNING RBI ASSESSMENTS q q q q

DATA & INFORMATION COLLECTION FOR RBI ASSESSMENT q q q

q q q q q

Key elements of an RBI Program Consequence & probability for RBI Types of RBI assessments Understanding how RBI can help to manage operating risks Relationship between RBI and other Risk -Based and safety initiatives Jurisdictional requirements

Data needs & quality Sources of site specific data & information Codes & Standards – National & International

DAMAGE MECHANISMS AND FAILURE MODES q q q

INTRODUCTION TO RISK -BASED INSPECTION

Establishing objectives & goals of a RBI assessment Initial screening Establishing operating boundaries Selecting type of RBI assessment

Identification of damage mechanisms Overview damage mechanisms Introduction of Failure Modes and the relevance for POF/COF Accumulated damage Tabulating results Case Study: Case Histories of major industrial incidents Group Discussion: Cases of damage mechanisms & failure mode

CGOG 01

EFFECTIVE RISK BASED INSPECTION 19th – 21st October 2015

Cologne, Germany

DAY TWO – 20 TH OCTOBER 2015 - 9:30am to 5:00pm ASSESSING PROBABILITY OF FAILURES (POF

• Introduction to probability analysis • Types of probability analysis RISK MANAGEMENT WITH INSPECTION ACTIVITIES & OTHER RISK MITIGATION ACTIVITIES ASSESSING CONSEQUENCE OF FAILURES (COF )

• • • • • • • •

Intro to consequence analysis Units of measure Level 1 & 2 consequence analysis considerations Determination of COF Group Discussion: Assessing COF examples Corrosion management strategies Preparation of corrosion loops Establishment of Integrity Operating Window

NETWORKING SESSION

DAY THREE – 21ST OCTOBER 2015 - 9:30am to 5:00pm INSPECTION PLANNING BASED UPON RISK ANALYSIS

• • • • •

Risk target Inspection effectiveness Pressure vessels & piping Heat exchanger tube bundles Inspection planning

INSPECTION TECHNOLOGY/METHODOLOGY Discussion: INSPECTION TECHNIQUES & NDT TECHNOLOGY

• Intrusive and non-intrusive methods • Classic & advanced NDT technology • Examples regarding important damage mechanisms

REASSESSMENT & UPDATING RBI ASSESSMENTS (EVERGREENING )

• Inspection data management & RBI documentation and • • • •

recordkeeping Case Study: Relationship between RBI & a FFS assessment Examples of RBI Pitfalls Example of an Industrial RBI assessment case Q&A session NETWORKING SESSION

IN CO-OPERATION WITH

CGOG 01

EFFECTIVE RISK BASED INSPECTION 19th â€“ 21st October 2015

Cologne, Germany

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1796

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