Introducing Inspectioneering Training

This course addresses the breadth and depth of an asset (mechanical) integrity program. It starts with an understanding of why an AI program is so important to a company’s success. The course addresses how to determine what equipment should be included in an AI program and the many roles responsible for an effective AI program. It focuses on details associated with aligning practices with recognized and generally accepted good engineering practices (RAGAGEPs) for each category of equipment. Several modules focus on fixed equipment (pressure vessels, storage tanks, piping, relief devices). Rotating, instrumentation, and mitigation equipment are addressed as well. The course also discusses holistic, field-proven techniques for procedure development; AI-related training; inspection, testing, and preventive/predictive maintenance (ITPM) implementation; quality assurance/quality control; and equipment deficiency management. Finally, the course wraps up with a discussion on continuously improving your AI program.

Whether you are developing an AI program, or you are responsible for updating/auditing an existing program, this course is packed full of practical, proven techniques for an effective AI program.

Learning Goals and Objectives

By the end of this course, you will understand and appreciate:

• The elements of a comprehensive asset integrity (AI) program
• The various roles and responsibilities associated with an AI program
• The different equipment types and associated RAGAGEPs, key ITPM activities, and intervals for those activities
• The importance of AI-related procedures and training
• Equipment deficiency management
• AI program-related quality assurance
• AI program auditing, KPIs, and learning from others’ mistakes

After taking this course, you should be able to:

• Apply these principles to developing or improving AI programs at your facility.
• Use the information provided in this course to assess/audit existing AI programs.
• Have a better understanding of applicable RAGAGEPs, roles/responsibilities, types of equipment to include and what key ITPM activities should be applied to equipment types.

Who is this course intended for?

Roles/Titles

• Maintenance managers/supervisors
• Process safety personnel
• Reliability managers
• Anyone and everyone currently involved in mechanical/asset integrity
• Anyone interested in advancing into a mechanical integrity career

Industries

• Oil Refining
• Midstream (Gas Processing and Terminals)
• Petrochemicals / Chemicals
• Ammonia
• Fertilizer
• Pharmaceuticals

About the Instructor

Chad Patschke has over 27 years of experience in maintenance; mechanical integrity; and process safety management. He has held the positions of plant engineer, materials engineer, project manager, engineering manager, operations manager, plant manager, and North America PSM Manager. He has both domestic and international experience in a variety of industries including refining, oil and gas production (both onshore and offshore), petrochemical, LNG, and specialty chemicals. Mr. Patschke is an active member of the American Petroleum Institute (API) Subcommittee on Inspection. He previously held inspector certifications for API 510 Pressure Vessels, API 653 Atmospheric Storage Tanks, and API 570 Process Piping, and has developed and managed MI programs for a variety of companies.

Risk-Based Inspection (RBI) is a holistic process that requires strategic thinking about how equipment is degrading and the potential consequences in the event of a release. API RP 581 is the most widely used risk assessment methodology in the refining and petrochemical industries, and is becoming more popular with midstream gas plants. This recommended practice is an ANSI-accredited document and represents industry best practices. It is likely the most quantitative RBI methodology available.

In order to maximize the benefits of the API RP 581 technology, it is important for stakeholders to understand the models and relative sensitivities of the inputs, as well as their impact on the calculations/outputs.

Learning Goals and Objectives

By the end of this course, you will understand and appreciate:

• The API RP 581 models
• How to use API RP 581 technology to its maximum potential
• How to deal with special situations that inevitably arise (e.g., CUI special emphasis programs)
• The value of a structured vetting process, and how it can be used to overcome hurdles (e.g., lack of insulation data)
• How to use API RP 581 quantitatively and qualitatively
• How to use the results of the analyses to manage risk most effectively
• How to identify risk drivers
• How to determine the best cost vs. risk reduction strategies
• How to create an inspection strategy using RBI outputs

About the Instructor

Greg Alvarado possesses over 40 years of experience in the chemical, petrochemical and oil and gas industries. His roles have included positions as an owner-operator, consultant, Chief Chemist, and Corrosion/Materials/NDE applications engineer. He has specialized in risk-based inspection consulting, training, mentoring, RBI program gap assessment and project management since 1996. He is a 30+ year member of the API Sub-Committee on Inspection, an original working member of the API group that created the recommended practices (RP 580 and RP 581, all editions) for Risk-Based Inspection. Mr. Alvarado currently provides risk management, NDE technical consulting, and equipment lifecycle/fixed equipment reliability program gap assessments and consulting as a Principal Consultant with Trinity Bridge Consulting LLC. He is also the founder and Chief Editor of Inspectioneering Journal.

This course addresses the top ten opportunities for improvement in fixed equipment mechanical integrity (FEMI) programs as identified by John Reynolds. These areas for improvement are based upon his 50+ years of experience in the refining & petrochemical industry as well as his participation in over 100 separate site assessments of FEMI programs.

Learning Goals and Objectives

By the end of this course, you will understand and appreciate:

• The importance of tracking your top FEMI risks
• The benefits of understanding all of the potential damage mechanisms in each process unit
• The work process for identification and implementation of IOWs
• How to learn from industry FEMI incidents and near-misses
• Opportunities for improvement in piping inspection programs
• The importance of proper application of industry in-service inspection codes and standards
• The importance of using the best available inspection technologies
• The need for documentation of FEMI management systems
• The importance in pursuing qualified FEMI personnel
• The importance of FEMI data analysis

About the Instructor

John Reynolds is a Principal Consultant with Intertek Asset Integrity Management, Inc. Prior to this he was a Master Engineering Consultant with Shell Oil's Westhollow Technology Center in Houston. After graduating from the University of Wisconsin with degrees in Mechanical and Metallurgical Engineering, John joined Shell in 1968 and retired from Shell in 2006. Over the 37+ years of employment with a number of the Shell companies, John held various engineering and management positions at Shell's refining and chemical processing sites, as well as central offices in the United States and Europe. Along the way, one of John's favorite activities was providing leadership for Shell's intranet communities of interest dealing with the 101 Essential Elements of Fixed Equipment Mechanical Integrity (FEMI). The focus of John's entire 50+ year career has been on establishing and improving FEMI programs in the petroleum and petrochemical industries. As part of that continuing goal, another of his favorite activities is continuing participation in the API/AFPM Process Safety Site Assessment Program (PSSAP) as one of the FEMI specialists providing feedback to operating sites that seek to improve their FEMI programs.

Since retiring from Shell, John has remained active in FEMI activities serving as an industry consultant and expert witness for numerous refining and petrochemical companies. He has been and is currently the master editor for several API Standards on Inspection and FEMI-related topics, and remains active in both the API Subcommittee on Inspection and Mechanical Integrity (SCIMI) and the ASME Post-Construction Committee (PCC). John is the past Chairman of the API Subcommittee on Inspection, the API Task Group on Inspection Codes, the API Task Group on NDE Technology, the API Task Group on API 580 RBI, and the API User Group on Risk-Based Inspection. He has also been the Downstream Business Sector Lead for the Planning Committee of the API Inspection Summit since its inception in 2007. Over the years, John has authored more than 90 articles and/or presentations on FEMI subjects, many of which have been published with Inspectioneering Journal and are summarized in his book "101 Essential Elements in a Pressure Equipment Integrity Management Program."