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RBIRISK BASED INSPECTION

Presented by:

Mohammad Javad Ranjbar

5 May 2014

Introduction to RBI

what is RBI

what are the key elements of RBI

how to implement an RBI program

how to sustain an RBI program

RBI Softwares

TWI - RISKWISE

ReliaSoftRBI

Outline

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What is RBI?

Risk-based Inspection (RBI) is a methodology foridentification of high-risk equipment by review ofactive/potential damage mechanisms and the suitability ofmitigation methods

RBI allows inspection/maintenance RBI systematicalevaluated both the probability of failure and theassociated consequence of failure.

Risk is the combination of the probability of some eventoccurring during a time period of interest and theconsequences,(generally negative) associated with theevent. In mathematical terms, risk can be calculated bythe equation:

Risk = Probability Consequence

RBI vs. Other Inspection Methods

Fixed Interval

STANDARDInspection

Service Interval

ConditionBased

TREND Analysis

Consequencesnot considered

Backward Looking

Risk Based

RISK Analysis

Probability &Consequences

Proactive

Forward Looking

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Increase Availability

(reducing unplanned outages )

Improve Safety

)Ensure Safe Operation)

Optimise InspectionCosts

Objectives of RBI

CATASROPHIC

FAILURE OF

STEAMLINE

(JAPAN 2004)

1

2

3

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RBI Benefits and Limitations

a) an overall reduction in risk for the facilities and

equipment assessed,

b) an acceptance/understanding of the current risk.

RBI will not compensate:

c) inaccurate or missing information,

d) Design errors or faulty equipment installation,

e) External events (e.g. Collisions or falling object)

f) not effectively executing the plans,

g) Secondary effects from nearby units

h) lack of qualified personnel or teamwork,

Outcome of an RBI?

Hotspotlocations

InspectionFrequency

AppropriateInspectionTechnique

Types ofdamageexpected

What? How?

Where?When?

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International Standards

API 580 / API 581 ASME PCC-3

CWA 15740 DNV-RP-G101(Offshore topsides)

Type of RBI Assessment

Qualitative: Provides a broad-based risk assessment of

an operating unit or a part of an operating unit, required

less detail information about the facility. In this

assessment using engineering judgement and experience

for the analysis of probability and consequences of failure.

Quantitative: Provides risk values for each equipment

item and pipe segment in a operating unit, requiredcomprehensive detail information about the facility and

equipment. In this assessment using logic models,

likelihood and probability data to calculate the risk of

failure.

Semi-quantitative: Some were between either approach.

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RBI planning process overview

1. Data Collection

design and construction records/drawings:P&IDs, process flow diagrams, material selection diagrams (MSDs), etc.,

piping isometric drawings,

engineering specification sheets,

materials of construction records,

construction QA/QC records,

codes and standards used,

protective instrument systems,leak detection and monitoring systems,

isolation systems,

inventory records

emergency depressurizing and relief systems,

safety systems,

fire-proofing and fire-fighting systems,

layout;

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1. Data Collection

inspection recordsschedules and frequency,

amount and types of inspection,

repairs and alterations

inspection results

process datafluid composition analysis including contaminants or tracecomponents,

distributed control system data,

operating procedures,

start-up and shutdown procedures,emergency procedures,

operating logs and process records,

1. Data Collection

Off-site data and information

ifconsequence may affect off-site areas;

Failure datageneric failure frequency data

industry specific failure data,

plant and equipment specific failure data,

reliability and condition monitoring records,

leak data;Site conditionsclimate/weather records,

seismic activity records;

Equipment replacement costsproject cost reports,

industry databases;

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1. Identification of Damage Mechanisms

2. Probability of Failure

6. Material of construction: steel,

stainless steel, cast steel, aluminium

etc, any coatings

7. Damage mechanisms: what damage

mechanisms are known to occur or

have the potential to occur in theplant. eg stress corrosion, brittle

failure, temper embrittlement, fatigue,

localised or general corrosion, creep,

others,

8. Inspection: dates, type (visual,

thickness, MPI, UT etc) and extent of

inspection, inspectability, inspection

results, corrosion allowance.

Effectiveness and management of the

inspection programme.

1. Number of units and type of plant:

pressure vessel, tank, column,

pipework, heat exchanger etc.

2. Plant function: distillation unit, cat

cracker, storage etc

3. Plant processes: gas, hydrocarbon,steam etc, number of planned and

unplanned interruptions per year

4. Process stability: rate stability from

a) very stable no known upset

conditions known to exist to b) loss of

control is inherent in process

5. Plant maintenance history: repairs,

modifications, quality of maintenance,

painting & insulation maintenance

Probability Information

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2. Consequence of Failure

3. Chemical data: relates to the

chemicals tendency to ignite. What is

the flash point of the material, rate its

stability when unconfined.

4. Quantity: how much material could

be released in a single event

5. Chemical state: what is the process

temperature,what is the boiling point?

6. Commercial damage potential: what

is the value of plant within a 30m

radius, within 150m?7. Toxicity: rate the toxicity from: a) no

hazard to b) death or major injury on

very short exposure

8. Population: number of people, on site

and off site, within 500m of releasepoint

1. Fire: are external fire fighting

resources required for the most

serious event

2. Incident mitigation: which one:

i) gas detection systems,

ii) plant operated under inert atmosphere,

iii) secure fire fighting system,

iv) automatic or manual isolation systems

v) blast walls around high pressure

equipment,

vi) drain, dump or blowdown systems thatwill deinventory plant

vii) fire proofing of plant strct. and cables

viii) available supply of fire water, hour?

ix) foam system or water curtain

Consequence Information

3. Risk Analysis

RISK MATRIX: The LoF value is plotted on the

vertical axis, and the CoF value is plotted on

the horizontal axis, of the dimensionless 55

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4. Inspection Planning

When or before the risk target is reached, an inspection of the

equipment is recommended based on a ranking of the

component damage mechanisms that have the highest

calculated damage factors.

An inspection program is the combination of NDE methods

(i.e. visual, ultrasonic, radiographic etc.), frequency of

inspection, and the location and coverage of an inspection.

Inspection programs vary in their effectiveness for locating

and sizing damage, and thus for determining damage rates.

4. Inspection Effectiveness

Lack of coverage of an area subject to deterioration,

Inherent limitations of some inspection methods to detect and

quantify certain types of deterioration,

Selection of inappropriate inspection methods and tools,

Application of methods and tools by inadequately trained

inspection personnel,

Inadequate inspection procedures,

The damage rate under some conditions (e.g. start-up, shut-down, or process upsets) may increase the likelihood or

probability that failure may occur within a very short time.

Inaccurate analysis of results leading to inaccurate trending of

individual components, and Probability of detection of the applied

NDE technique for a given component type, metallurgy,

temperature and geometry .

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5. Mitigation

Reducing the POF, Primary source of consequence,

magnitude of consequence:

Equipment Replacement and Repair

Evaluating Flaws for Fitness-For-Service

Equipment Modification, Redesign, and Rerating

Emergency Isolation

Emergency Depressurizing/Deinventorying

Modify Process

Water Spray/Deluge

Blast-resistant Construction

spill detector

Fireproofing

.;

6. Reassessment and

Updating RBI Assessments

Why Conduct an RBI Reassessment?

Damage Mechanisms and Inspection Activities

Process and Hardware Changes

RBI Assessment Premise Change

The Effect of Mitigation StrategiesWhen to Conduct an RBI Reassessment?

After Significant Changes

After a Set Time Period

After Implementation of Risk Mitigation Strategies

Before and After Maintenance Turnarounds

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RBI Softwares

RiskWISE

ORBITRBI

Credo RDMIP

RB.Eye

RB.QEye

FAME+

S.RBI

RBI

RISKWISERisk Based Inspection / Risk Based

Maintenance software

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Demonstrator Contents

System Overview

Introduction Ease of Use

Access Controls

Knowledge-base

Options and Settings

Fluid Properties

Nameplate Information

Inspection History

Damage Mechanisms

Risk Factors

Risk Summary

Risk Profile

Record Data Tables

Record Properties

Risk Mitigation

Risk Comparison

Inspection Plans

Management Reporting

Contact TWI

TWI Ltd is the sole owner of this software

demonstration show and may change this

demonstration without issuing notice. Noperson or entity may reproduce or transmit

any part of the demonstration without written

permission from TWI Ltd.

RISKWISE has a friendly Microsoft style graphical user interface )GUI,

developed in Visual Basic using object-oriented design tools.

Graphical

Navigation

Microsoft

Toolbar

Folder

Tree

Intuitive

Interface

Drag n Drop

Table Sorting

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RISKWISE is an API RP580 compliant risk-

based inspection (RBI) planning tool for use with

pressure equipment, pipelines, power boilersand storage tanks. The risk model is semi-

quantitative, so it can be easily learned and is

convenient to use.

RBI management systems are applied to:

Improve the safety of critical plant

Reduce the duration of inspection outages

Extend the interval between major

inspections

Reduce direct inspection and maintenance

costs

FeaturesIntegrationRISKWISE is a second

generation client-server

product, using the ODBC

(Open DataBase

Connectivity) protocol for

SQL databases (eg

FoxPro, SQL Server,

Oracle and Access).

Multi-lingualRISKWISE is designed

to provide complete

multi-lingual capability

for rapid native language

implementation.

RISKWISE enables the system administrator

to control user access, tailoring it to the specific

needs of the inspection and maintenance

organisation. This allows simple control and

auditability of previous assessment records.

FeaturesAccess ControlThree main levels:

Read-Only

Proposal Write

Item Write Access

AuditabilityThe name of the

assessor undertaking the

RBI evaluations for each

item of equipment is

recorded, in compliance

with best practice

auditing principles.Record HierarchyProposed inspectionplans

RBI assessment results

which cannot be

changed or deleted

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RISKWISE stores equipment nameplate

information in the Item Properties and Materials

screens. This information can be easilyintegrated with asset information in other

applications, via the in-built RISKWISE Import

Wizard.

FeaturesItem PropertiesCaptures general

information about the

equipment including

drawings, design and

operating parameters.

MaterialsCaptures information

about the materials of

construction

components within

equipment or pressure

system.

RISKWISE contains an inspection knowledge-

base covering non-destructive testing (NDT)

methods and comprehensive descriptions of

over 30 damage mechanisms (DM), including 20

corrosive species leading to general and

localised corrosion and 10 species leading to

stress corrosion cracking.

FeaturesNDTThe knowledge-base

covers visual, magnetic,

ultrasonic, eddy current,

metallurgical,

radiographic,

thermographic, acoustic

emission and other non-

intrusive methods.

Damage MechanismsThe common

mechanisms are

categorised in terms of

leading to Metal loss,

Environmental or

Metallurgical and

mechanical damage.

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RISKWISE allows users complete freedom to

undertake assessments in European, US

Customary units or User-defined units. Systemadministrators have the ability to define safety

factors based on assessment consequence

categories, for direct use in the derivation of

equipment inspection intervals.

FeaturesUnitsDefine system wide

defaults for assessment,

such as engineering

units of measure.

Factors of SafetyModify configuration of

safety factors, that are

linked to the

consequence categories,

in the calculation of

remaining life indicators

for all damage

mechanisms.

RISKWISE assesses consequence of failure

generally in accordance with guidance provided

in API BRD581 based on the fluid property

classifications presented by National Fire

Protection Association (NFPA).

FeaturesChemical FactorA Flammability Factor is

used by RISKWISE, in

combination with a

Reactivity Factor, to derive

a Chemical Factor,

representing a fluids

inherent tendency to ignite.

Explosion and FireRISKWISE assesses a

State Factor and the

Chemical Factor, in

accordance with theprocedure in publication

API BRD581.

ToxicityRISKWISE employs the

NFPA ranking of the

probable severity of the

effects of a fluid on

exposure to personnel, in

the event of a release and a

fire.

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RISKWISE captures all relevant historical

inspection and maintenance history in the

Inspection Methods screen for subsequent use

in the identification of equipment damage

mechanism prior to the risk assessment.

FeaturesInspection MethodsCaptures relevant

historical information

including coverage and

findings, that will be

regularly updated

following future

inspections.

Inspection PlansRISKWISE transfers

historical findings as well

as the proposedinspection activities, to

the Written Scheme of

Examination.

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RISKWISE captures the location of all active

and potentially active damage mechanisms

within each item of pressure equipment.

FeaturesChecklistRISKWISE deals with

damage mechanisms

relevant to oil, gas and

petrochemical process

equipment, storage

tanks, pipelines, and

fossil fuel power boilers.

Remaining Life

IndicatorsThe estimated remaining

life of each damage

mechanism is assessed

within RISKWISE, to

establish equipment

inspection intervals.

RISKWISE assesses seven likelihood

(probability) of failure factors and nine

consequence of failure factors, for each item of

equipment.

FeaturesTime-based Risk

AnalysisRISKWISE assesses

failure probability over

three forward periods of

time, for each active or

potentially active damage

mechanism.

Inspection

EffectivenessRISKWISE assesses

the effectiveness of thecurrent inspection

program for each

damage mechanism

separately.

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RISKWISE presents the results of the risk

analysis for each of the damage mechanisms,

over the three forward time intervals, as well asthe resulting remaining life indicator (RLI) which

defines a safe inspection interval.

FeaturesRisk Matrix

RISKWISE plots eachassessment point on an

API RP580 five-by-five

risk matrix for risk

regions ranging from

Favourable to Critical.

Limiting Damage

MechanismsThe lowest RLI out of all

damage mechanisms

equates to the maximum

allowable inspection

interval for the

equipment.

RISKWISE provides a risk profile of all

equipment within the facility for the identification

of critical and non-critical equipment.

FeaturesSummaryThe distribution of risk

can be presented using a

risk matrix, pie charts or

bar charts as well as

comparatively, ie for

subsequent post-

assessment cost-benefit

analysis.

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RISKWISE simply identifies critical equipment

as those items where the RLI is less than

current inspection period, and non-criticalequipment as those items where the RLI is

greater than the current inspection period!

FeaturesTable SortingThe results of the RBI

assessment are

presented in the

RISKWISE data tables,

which can be easily

sorted using the drag n

drop column titles.

RISKWISE ensures that the individual authors

of each equipment RBI assessment are fully

traceable.

FeaturesAuditabilityRISKWISE enables

comprehensive tracking

of assessment results

and input assumptions,

in accordance with the

requirements of API

RP580.

Record NotesRISKWISE includes a

simple catch-all free

text field for any other

information relevant to

the likelihood of

consequence of failure of

the equipment under

consideration.

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RISKWISE presents RBI assessors with a risk

action plan from which the most suitable risk

mitigation options, for critical equipment, can beevaluated.

FeaturesAction GroupingRISKWISE assigns the

most frequently used risk

mitigating actions to six

groups, for ease of

evaluation during the

final inspection planning

and optimisation phase

of the RBI assessment.

RISKWISE allows the RBI assessor to

evaluate the impact of the proposed actions or

inspection changes on risk and the remaining

life indicator (RLI).

FeaturesInspection OptimisationThe process of risk

comparison within

RISKWISE enables users to

systematically evaluate the

effect of actions on the risk of

failure, while considering the

constraints.

RBI

Inspection

Savings

Production

CostSavings

$100k

$300k

$500k

$700k

$900k

Total Savings = $1.1MB/C Ratio = 11:1

RBI

Inspection

Savings

Production

CostSavings

$100k

$300k

$500k

$700k

$900k

Total Savings = $1.1MB/C Ratio = 11:1

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The final output of a RISKWISE assessment is

an optimised inspection plan )Written Scheme

of Examination which focuses on each damagemechanism.

FeaturesReportingRISKWISE presents a

detailed report of the RBI

assessment for use by

field inspection

engineers, or in other

reports application as

necessary.

RISKWISE provides a post-assessment

analysis capability to evaluate the impact of

actions on the risk distribution for all equipment.

FeaturesTime TrackingRISKWISE enables the

user to assess the value of

RBI following successive

major inspections and

subsequent RBI updating,

eg. between Revision 0 and

Revision 1.

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RISKWISE 2014

NEW

Released

Feature

RBI EXAMPLEQuantitative Assessment of a Boiler

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Application

Selection

Chosse boilers as

Oil,Gas and

Process Plant

Suite

Current Table

A table of current

revision records or a

table of all proposal

records can be

displayed by

navigating to these

screens via theshortcut bar.

These lengthy tables

can be organised

and sorted by

dragging the column

titles to the top of the

screen, into any

ordered display

hierarchy:

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Item Proposal

Once you have

specified the

equipment class,

(for example,

specify that a

particular pipe is a

Hot Reheat Pipe),

the list of expected

damage

mechanisms is

shortenedautomatically to

display the types of

damage that might

be expected.

Item Properties

The entries on the

unit properties

screen determine

the risk associated

with various items

in boilers.

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Item Properties

Enlarge the picture

to see the detailes

you have to enter.

Risk Factors

All of the items on

the Risk Factors

screen will be read-

only if the item

properties, damage

mechanisms and

inspection methodsscreens are fully

completed. If you

need to change any

of these values you

will need to change

back to manual

mode

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RISK Analysis

The assessment

points for each of the

three risk analysis

periods can be

toggled on or hidden

via the buttons on the

toolbar. For example,

if you wish to display

the assessment

points for the first

analysis period (1AP)

only, select thebuttons to HIDE 2AP

and HIDE 3AP. The

risk plot will then only

display 1AP ( )

assessments points.

Level 1

Assessment

The level 1

assessment is a

unit level

assessment to

assess a boiler as a

whole. To switch to

the level 1 view,click on the

assessment level

toggle at the top of

the main screen.

When switching to

the level 1

assessment, the list

of items now only

shows units.

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Home

You can right-click

on an existing unit

to create a

proposal, or create

a new unit or

proposal

from the links on

the home screen.

Unit

Proposal

Each unit has a set

of properties

associated with it

in a similar way

that other (level 2)

components have

an item propertieslist. The proposal

record can be

viewed by double

clicking on it in the

items list.

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Unit

Analysis

The analysis

screen shows the

business

consequence of

the major

components of the

boiler failure.

THANK YOU FOR YOUR ATTENTION

Your Questions Are Wellcomed

mj.ranjbar@gmail.com