An optimized plant-level inspection program, that takes the human element into account in the RBI Assessment and creates an ongoing process for maintaining the availability and performance maxima, is essential to managing risks over the long term.  RBI Assessment of a plant provides a “snapshot” of plant condition, operations and systems from the perspective of a plant manager seeking to maximize reliability, availability and maintainability (RAM) of key equipment, while maximizing throughput of that equipment and minimizing uncertainties.  RBI Assessment does not address the plant’s inspection program practices, or the execution of recommendations following the assessment results.

Quest Reliability offers a consulting service in inspection program optimization and plant reliability management systems that is centered on the hands-on, detailed knowledge of our skilled and experienced senior reliability engineers.  Whether as a one-off system development task or a long-term retainer engagement, this work typically includes:

• Evaluation of plant operations, organization and procedures in terms of Reliability, Availability and Maintainability
• Establishment of a risk and reliability baseline (see RBI Assessment)
• Benchmarking of the plant against past condition and performance of the plant, its corporate siblings’ plants, and the broader industry
• Resources for reliability management at the plant:
  • Inspection data management system
  • Maintenance data management system
  • Safety data management system
  • Operating data management system
  • Data systems integration capabilities (e.g., SAP)
  • Risk management system
  • Human resources for RAM and risk management
  • Procedures and protocols for RAM-related systems
  • Manuals and other guidelines for these systems
  • Turnaround planning and management procedures and protocols
• Review of RBI data and management of critical equipment and maintenance issues identified therein
• Development of organizational recommendations for management of RAM and risk management, and preparation of a human resources development plan for those activities
• Development or revision of procedures and protocols for optimizing the cost and effect of RAM-related systems, in particular the inspection program
• Preparation of manuals and guidelines as needed
• Preparation of limited specific recommendations for maintenance, inspection, repair or replacement strategies considered critical to attainment of reliability management objectives

The consulting service of inspection program optimization is often bundled with implementation of Quest’s proprietary RMS or Signal RBI™ Software, which incorporates an inspection data management system, an API 581 risk calculator, and report writing capabilities.  Signal RBI™ software links to SAP, as well as to external data files of several formats.

For further information about Inspection Program Optimization please contact us.