Risk-Based Inspection, Fitness-For-Service & Reliability Integration

Risk-Based Inspection, Fitness-For-Service & Reliability Integration

Location

Duration

Online /In-Class

1 week

Contact with our Team

Sector:

Industrial & Energy – Mechanical Systems

Technical Focus Area:

Operational Excellence & Performance (OPEX)

About the Course

Risk-based strategies prioritize where inspection and maintenance matter most by combining credible damage mechanisms with consequence modeling. This course demystifies risk methods (qualitative → quantitative), shows how to apply API 580/581, and connects RBI to RCM so inspection, monitoring, and maintenance tasks reinforce each other.
Through worked examples, you’ll identify active damage mechanisms, estimate PoF and CoF, set inspection plans and intervals, and apply Fitness-For-Service (API 579) when components fall short of original code criteria. You’ll leave with a deployable playbook, templates, and governance model to sustain a living RBI/RBM program.

Objectives

By the end of this course, participants will be able to:

- Explain RBI/RBM concepts, definitions, benefits, limitations, and implementation steps.
- Apply probability/consequence analysis using qualitative, semi-quantitative, and quantitative tools.
- Map and evaluate damage mechanisms per API 571 and identify active vs. unlikely mechanisms.
- Use API 580/581 to risk-rank equipment and determine inspection scope and methods.
- Perform corrosion/remaining life calculations and set risk-based inspection intervals.
- Conduct Fitness-For-Service screenings and assessments (API 579) to support run/repair/replace.
- Integrate RBI with RCM to align inspection/maintenance and optimize resources.
- Build and govern an RBI/RBM program (team, data, software, KPIs, revalidation cadence).
- Communicate risk effectively to stakeholders and drive risk reduction actions.

Who Should Attend

- Operations & Maintenance Engineers
- Reliability/Integrity Engineers and Inspectors
- Engineering Managers & Supervisors
- Project/Turnaround & Asset Integrity Staff
- Technical staff responsible for degradation assessment and RBI deployment

Course Program

Risk Fundamentals, Inspection’s Role & Assessment Methods

- Why inspection matters to integrity, uptime, and cost

- Risk basics: probability of failure (PoF) & consequence of failure (CoF)

- Risk management: avoidance, mitigation, acceptance; risk communication

- Assessment levels: qualitative, semi-quantitative, quantitative—when to use each

- Common inspection strategies vs. RBI—strengths and limitations

- Inspection KPIs and governance for integrity programs

- **Activity/Workshop:** Build a simple PoF/CoF matrix for a sample equipment set

Implementing RBI per API 580/581 & Links to Codes/Standards

- API 580 scope, terminology, and program elements; evolution of RBI

- API 581 methodology: data needs, damage factor, PoF/CoF models, risk plots

- Economic case for RBI and limits/assumptions

- Interfaces with API 510/570/650 (in-service), and API 579 (FFS)

- Software considerations and data structures for RBI models

- RBI within plant integrity management; benefits & pitfalls

- **Exercise:** Populate a minimal API 581 dataset and generate a risk ranking

Damage Mechanisms (API 571) & RCM Integration

- Overview of >60 mechanisms; focus on common ones: general/localized corrosion, SCC, HIC/H2S damage, fatigue, brittle fracture, CUI/ECM

- Identifying active mechanisms vs. unlikely; simultaneous mechanisms and interactions

- Selecting materials and process controls to mitigate risk

- Linking RBI and RCM: functions, failure modes, consequences, and task selection

- Integrated asset management: monitoring, inspection, and maintenance workflows

- **Case Study:** Determine active mechanisms for a crude unit circuit and propose inspection/monitoring tasks

Inspection Planning, Data Quality & Program Build

- Developing the equipment/circuit inventory and criticality ratings

- Inspection planning guidance: methods, coverage, effectiveness & sampling

- When speculative/exploratory inspections are justified

- Data quality: histories, thickness readings, NDE results; shared RBI–RCM database

- CMMS alignment: tags, tasks, intervals, and feedback loops

- Team structure, roles, and mandates; essentials for successful RBI rollout

- **Group Activity:** Draft an RBI plan (methods, scope, due dates) for a high-risk circuit

Interval Optimization, FFS & Risk Reduction Roadmap

- Corrosion rate and remaining life calculations; re-inspection intervals

- Fitness-For-Service (API 579): screening and selected assessment paths

- Consequence refinement (toxic/flammable releases, environmental, business impact)

- Re-ranking after findings; updating risk and intervals—living program management

- KPIs, revalidation cadence, and management reporting

- Building the 12-month risk reduction plan: monitoring, mitigations, repairs, and projects

- **Capstone:** Set optimized inspection intervals and a risk reduction roadmap for two critical assets

Course Dates & Prices

Location	Starting Date	Price
Online	19/10/2025	1799 $
Dubai (UAE)	20/10/2025	2549 $
Dubai (UAE)	20/10/2025	2799$
Cairo (Egypt)	27/10/2025	2549 $
Online	27/10/2025	1799 $
Online	03/11/2025	1799 $
Dubai (UAE)	10/11/2025	2799 $
Muscat (Oman)	10/11/2025	2799 $
Dubai (UAE)	17/11/2025	2799 $
Online	17/11/2025	1799 $
Muscat (Oman)	24/11/2025	2799 $
Online	24/11/2025	1799 $
Online	24/11/2025	1799 $
Dubai (UAE)	01/12/2025	2799 $
Online	01/12/2025	1799 $
Online	01/12/2025	1799 $
London (UK)	01/12/2025	3299 $
Dubai (UAE)	08/12/2025	2799$
Online	08/12/2025	1699 $
Istanbul (Turkey)	15/12/2025	2799 $
Dubai (UAE)	15/12/2025	2799 $
Online	15/12/2025	1799 $
Kuala Lumpur (Malaysia)	22/12/2025	3899$
Doha (Qatar)	22/12/2025	2799 $
Kuala Lumpur (Malaysia)	22/12/2025	3899$
Online	29/12/2025	1799 $
Dubai (UAE)	29/12/2025	2799$
Istanbul	29/12/2025	2549 $
Online	29/12/2025	1799 $