Upon completion of this course, participants will be able to:

• Explain the core methodologies of RBI and RCM and their interrelation within AIM.
• Quantitatively assess the probability of failure (POF) and consequence of failure (COF).
• Apply the API 580 and API 581 methodologies for RBI implementation on pressure equipment.
• Develop optimized inspection and maintenance task lists based on quantified risk and remaining life.
• Identify critical equipment functions and functional failures for a systematic RCM analysis.
• Implement a Failure Modes and Effects Analysis (FMEA) to determine maintenance strategy effectiveness.
• Calculate the financial benefits and cost-effectiveness of implementing risk-based strategies.
• Integrate RBI and RCM into a cohesive Asset Integrity Management (AIM) system.
• Select appropriate NDT (Non-Destructive Testing) techniques based on the identified damage mechanism.

• Asset Integrity Managers and Engineers
• Maintenance and Reliability Engineers
• Inspection Specialists (API 510/570/653 certified)
• Process Safety and HSE Personnel
• Plant Managers and Operations Supervisors
• Technical Auditors and Consultants
• Mechanical and Piping Engineers

• Scenario-based risk assessment and risk matrix development for a facility unit.
• Group activities applying FMEA to a critical equipment failure and selecting a strategy.
• Case studies on successful implementation of RBI and RCM programs.
• Individual exercises in calculating POF and COF (quantitative RBI).
• Discussions on API 580/581 compliance and audit preparation.

Unit 1: Introduction to Risk-Based Asset Management

• Limitations of traditional time-based and reactive maintenance programs
• Defining risk in the context of asset integrity (Risk = POF × COF)
• Overview of RBI (API 580) and RCM methodologies and their benefits
• Regulatory and financial drivers for adopting risk-based strategies (PSM requirements)

Unit 2: Risk-Based Inspection (RBI) Methodology

• Identifying relevant damage mechanisms (e.g., corrosion, creep, fatigue, brittle fracture)
• Calculating POF based on damage rates, effectiveness of inspection, and remaining life
• Use of API 581 tables and quantitative methodologies for equipment analysis
• Impact of operating conditions, materials of construction, and inspection history on POF

• Assessing safety, environmental, and financial consequences of failure scenarios
• Defining consequence areas, fluid properties, and injury/fatality models
• Calculating risk ranking and visualization using risk matrices (qualitative vs. quantitative)
• Determining the target risk level, risk mitigation options, and tolerance boundaries

Unit 3: Reliability-Centered Maintenance (RCM)

• Defining equipment functions, functional failures, and performance standards
• Conducting Failure Modes and Effects Analysis (FMEA) for each functional failure
• Determining the dominant failure modes and their root causes (RCA)
• Selecting the appropriate maintenance strategy (e.g., PM, PdM, Failure Finding Tasks)

Unit 4: RBI and RCM Implementation

• Prioritizing inspection efforts and optimizing inspection intervals based on risk reduction
• Selecting the optimal NDT technique (e.g., PAUT, MFL, AE) for specific damage
• Integrating RBI and RCM findings with Computerized Maintenance Management Systems (CMMS)
• Measuring the effectiveness and continuous improvement of the AIM system

Unit 5: Case Studies and Regulatory Compliance

• Real-world case studies of RBI implementation and the resulting cost savings
• Auditing and validation of RBI analysis and documentation
• Fitness-For-Service (FFS) assessments (API 579) as a risk mitigation option
• Compliance with regulatory requirements and PSM programs