Functional Area:
Risk-Based Inspection (RBI), Damage Mechanism Assessment (DMA), Inspection Planning, Condition Monitoring, Inspection Data Management, Mechanical Integrity Assessment, Fitness for Service (FFS)
Reports To:
Manager, Asset Integrity
Responsible For:
Risk-Based Inspection Management
Overall Purpose of Job:
The Lead RBI Engineer implements and manages Risk-Based Inspection (RBI) programs within the Asset Integrity Management group. This position develops and executes RBI methodologies, conducts damage mechanism assessments, and creates inspection plans for various fixed equipment projects, including pressure vessels, piping, storage tanks, and relief devices.
Responsibilities:
RBI Implementation and Management
- Develop comprehensive RBI Methodology Documents, including Management System and Technical Instructions, tailored to specific client needs and regulatory requirements.
- Design and implement RBI programs in commercially available inspection data management systems (IDMS), ensuring seamless integration with existing asset management processes.
- Conduct detailed risk analysis using advanced statistical methods and industry-standard risk matrices.
- Regularly update RBI inspection plans based on new data, operational changes, and emerging industry best practices.
- Maintain the evergreening of RBI analysis, ensuring that all risk assessments remain current and relevant.
- Perform rigorous quality audits to verify RBI data integrity, accuracy of assumptions, and consistency of application across different asset classes.
- Provide advanced RBI software support for the production system, including troubleshooting complex issues, managing software updates, and optimizing system performance.
- Develop and implement RBI performance metrics to continuously improve the effectiveness of the RBI program.
Damage Mechanism Assessment and Inspection Planning
- Lead comprehensive damage mechanism assessments/reviews, utilizing advanced modeling techniques to identify and quantify potential damage mechanisms.
- Conduct in-depth analysis of process conditions, material properties, and environmental factors to determine the likelihood and consequences of various failure modes.
- Perform and oversee fixed equipment system and circuitization, ensuring optimal grouping of equipment for efficient inspection and risk management.
- Develop risk-based inspection and test plans for fixed equipment and piping, incorporating innovative NDT techniques and emerging technologies.
- Create detailed corrosion loops and piping inspection circuits, considering factors such as material compatibility, process conditions, and historical data.
- Establish and implement condition monitoring programs, including the selection and placement of online monitoring devices.
- Develop and maintain a library of damage mechanism profiles specific to the organization's assets and operating conditions.
Technical Expertise and Innovation
- Serve as the organization's subject matter expert in RBI concepts, RRM (Risk and Reliability Management), RBI software applications, and advanced inspection technologies.
- Lead the development and refinement of corrosion prediction models and failure analysis methodologies.
- Stay at the forefront of non-destructive testing (NDT) advancements, evaluating and recommending new technologies for integration into inspection programs.
- Manage, carry out, and implement Statistical RBI (S-RBI) Studies, incorporating probabilistic approaches to enhance risk assessment accuracy.
- Develop and maintain a comprehensive database of degradation mechanisms relevant to the organization's assets, including their identification, monitoring, and mitigation strategies.
- Prepare detailed turnaround scope requirements, ensuring that all high-risk items are adequately addressed during planned outages.
- Conduct critical assessments of equipment and systems using advanced RBI tools, including Finite Element Analysis (FEA) and fracture mechanics when necessary.
- Establish, monitor, and optimize operating windows for critical equipment and systems, balancing operational flexibility with asset integrity requirements.
- Develop and implement innovative approaches to extend equipment life and optimize inspection intervals without compromising safety or reliability.
Team Leadership and Project Management
- Lead and mentor a multi-disciplinary team of technicians, specialists, and engineers, fostering a culture of continuous improvement and technical excellence.
- Develop and implement training programs to enhance the team's capabilities in RBI methodologies, damage mechanism assessment, and inspection techniques.
- Create detailed project execution plans, including resource allocation, timelines, and budget considerations for RBI implementation and evergreening projects.
- Establish and monitor key performance indicators (KPIs) for team performance and project success.
- Provide comprehensive guidelines and technical standards for team members to ensure consistency and quality in project execution.
- Implement agile project management methodologies to improve efficiency and adaptability in RBI projects.
- Conduct regular team meetings and performance reviews to ensure alignment with project goals and identify areas for improvement.
Continuous Improvement and Knowledge Management
- Establish and maintain a robust knowledge management system to capture lessons learned, best practices, and technical insights from RBI activities.
- Conduct regular benchmarking studies to compare the organization's RBI practices with industry leaders and identify areas for improvement.
- Lead post-mortem analyses of significant equipment failures or near-misses, ensuring that lessons learned are incorporated into future RBI assessments and inspection plans.
- Develop and implement a continuous improvement program for the RBI process, incorporating feedback from stakeholders and emerging industry trends.
- Collaborate with research institutions and technology providers to pilot and evaluate new asset integrity technologies and methodologies.
Compliance and Risk Management
- Ensure all RBI activities comply with relevant industry standards (e.g., API 580, API 581) and regulatory requirements.
- Develop and maintain a comprehensive risk register for fixed equipment, regularly updating it based on inspection findings and operational changes.
- Participate in internal and external audits related to asset integrity management, preparing necessary documentation and addressing findings.
- Contribute to the development and updating of corporate policies and procedures related to asset integrity and risk management.
- Provide expert testimony or technical support in legal or insurance matters related to equipment failures or integrity issues.
Key Performance Indicators:
- Successful implementation and maintenance of RBI programs
- %age Reduction in inspection-related costs while maintaining or improving asset integrity
- Accuracy and timeliness of damage mechanism assessments
- Quality and effectiveness of inspection plans
- Team productivity and adherence to project timelines
- %age Reduction in unplanned downtime related to fixed equipment failures
- Compliance rate with regulatory requirements and industry standards
- Successful completion of S-RBI studies and critical assessments
- Effectiveness of communication and collaboration with multi-disciplinary teams
Person Specification:
- Bachelor’s degree in engineering, preferably Mechanical, Chemical, or Materials Engineering. A Master's degree is desirable.
- Professional Engineer (P.Eng.) certification or equivalent
- Minimum of 10 years of experience in asset integrity, with at least 5 years specializing in RBI implementation and management
- Deep technical knowledge of RBI methodologies, damage mechanisms, and inspection techniques
- Strong understanding of ASME and API codes and standards relevant to fixed equipment
- Proficiency in RBI software and inspection data management systems
- Experience in leading and managing technical teams
- Proven track record in implementing and optimizing RBI programs
- Strong analytical and problem-solving skills
- Excellent communication and interpersonal skill
Required Competencies:
- In-depth knowledge of Risk-Based Inspection concepts and methodologies
- Expertise in damage mechanism assessment and mitigation strategies
- Strong project management and team leadership skills
- Proficiency in RBI software and data management systems
- Advanced problem-solving and decision-making capabilities
- Excellent communication and stakeholder management skills
- Ability to work effectively in multi-disciplinary and multi-cultural environments
- Strong analytical skills with the ability to interpret complex data
- Commitment to safety and asset integrity