Plant Integrity Management – Plant Defect Assessment & Risk-Based Inspection

Plant Integrity Management by Defect Assessment / Serviceability and Risk-Based Inspection & Maintenance

1. Introduction to Plant Integrity.

2. Improving plant integrity
o Hardware options – standby technique
o Improved / high-efficiency Components
o Reliability of system / subsystem / components.
o Examples
o Plant Integrity and Productivity / Line of balance

3. Overall Equipment Effectiveness concept
o Developing historical OEE models / Example
o Predicting equipment failure from OEE model
o Improving OEE

4. Life cycle assessment of Equipment/components.
o Parameters for enhancing life cycle of plant and machinery and productivity
o Operation severity impact – high temperature/pressure operation / cyclic operation – examples
o Shut down / startup procedures - impact on equipment life cycle
o Standard operating procedures.

5. Defects identification from
o Equipment performance parameters
o Failure rates/maintenance history
o Corrosion / erosion / wear out of components / sections

6. Continuum Damage mechanics
o Damage mechanics
o Behavioral pattern of equipment
o Analysis of equipment behavior.
o Developing damage models and damage prediction

7. Equipment fractures
o Fracture theory
o Material influences
o Elastic/ plastic fracture mechanics models
o Fully plastic and creep fracture mechanics concepts.

8. Defect Assessment Procedures
o Standard methods
o Visual / non-destructive tests / microanalysis
o Selection of materials of construction from historical fatigue, and creep-fatigue analysis

9. Creep, Fatigue, and Crack Growth
o Basics of Creep / Fatigue in equipment
o High-temperature cracks / Stress corrosion cracking
o Thermally induced cracks
o The behavior of a cracked / defective components
o Reliability of cracked reactors – case studies Reformer
o Thermally induced cracking in a reactor – case study – coker unit reactor
o Reliability Assessment using quantitative methods.
o Inspection for Serviceability

10. Equipment maintenance / replacement decisions.
o Operation/maintenance‘ failure data analysis.
o Fitness for service using KPIs
o Under rating service parameters.
o Case studies/examples.
o Exercise

11. Summing up
Learning objectives :
This program covers the basics of
  • Risk-based Inspection & Maintenance
  • Reliability theory
  • Preventive and Predictive Maintenance
  • Evaluation of failure rates / Risk Priority Number concept
  • Fault tree analysis and
  • Application of these concepts in actual operation and maintenance practices for achieving an Integrated Plant Management System. 
This program is intended for all operations/ maintenance/production planning/inspection and safety and project personnel from petroleum, petrochemical, fertilizer, power plants and equipment intensive industries.
The specific advantage of this training program is the hands-on training with group exercises and case studies. After participation in this program shall be able to assess the reliability/risk of their industries and carry out predictive maintenance of their plant, which could save substantial maintenance costs and avert costly equipment failures.
For Training and Consultancy Services Contact us on 022-62210100 or Email us on
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