rbi - inspection management-orbit onshore_w_tcm144-512440
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8/9/2019 RBI - Inspection Management-Orbit Onshore_W_tcm144-512440
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Inspection Management –ORBIT RBI Software
Panos Topalis
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Version Slide 8
Process Plants-Objectives and Challenges
Objective: Operate safely and profitably
- Prevent/reduce leaks.
- Meet HSE Requirements
- Maintain high availability and throughput.
- Minimize shut downs.
- Extending shut down intervals
- Reduce Insurance Costs
Challenges
- Old Plants- Large, complex units
- Integrated Feed Systems
- Many degradation mechanisms
- Raw material price
- Massive amount of data
Need to manage in a proactive and systematic way
Guiding Principle: Maintenance on the basis of risk
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Version Slide 12
RISK MANAGEMENT
Software Offering For the Process Industry
Performance
Forecasting
/ RAMAnalysis
FrequencyAnalysis
ConsequenceAnalysis
Impact andRisk Analysis
AssetIntegrity
ManagementSoftware
PHAST RiskPHASTLEAK
RiskSpectrum
•ORBIT+IDS
•Silverpipe
•ORBIT RBI
•AIMS Structures
MAROS
TARO
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Version Slide 1313
DNV Integrity Management for Onshore andOffshore Facilities
Satellite Topsides
Sub sea
Onshore & Subsea Pipeline
SilverPipe
Offshore
Structure
Sesam
StructureIntegrity
Offshore
Topside
ORBIT+
IDS+RBI
• Refineries
• Gas Plants• Petrochemicals
• Chemicals
• LNG Plants
• Terminals
• Others
ORBIT+ IDS+RBI
Process Facility
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• RBI on Web or offline
• Combining risk-based and regular inspection scheduling
• Flexible work packaging and task assignment
IntegrityEngineer
• Risk and job overview for all types of equipment
• Traffic lights on facility hierarchy and integrity barriers
• Managing risk by KPIManagers
Benefits of using ORBIT+ IDS
17
• Easy inspection preparation
• Easy inspection result recording and reporting
• Generate and monitor maintenance notifications
Inspectors andContractors
• Fully web-based system, easy deployment and support
• Open web-services for integration
• Logical data views and report templates for external enhancements
ITSupport
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Version Slide 23
RBI History
Probabilistic risk analysis techniques
- Started in the nuclear industry (1970s)
Quantitative risk assessment (QRA) in the Process Industries
- Canvey Island and the Rijnmond Report (1980s)
Software tools for QRA
- Eg DNV-Technica develops SAFETI and PHAST risk assessment tools (1980s)
ASME RBI principles overview document in 1991
API develops Risk Based Inspection Methodology (mid-1990’s)- DNV main API sub-contractror
- API Base Resource Document 581 (2000)
- API RBI software
- API RP 580 (2002)
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Version Slide 24
Risk Based Inspection “Driving Factor”
% of Total Risk Vs % of Equipment ItemsPlant Unit, ~500 Total Items
0%
10%
20%30%
40%
50%
60%
70%
80%
90%
100%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
% of Equipment
% o
f T o t a l R i s k
•Risk is not equally distributed among the individual pieces of
process equipment.
•A large percent of the total unit risk is concentrated in a small
percent of the equipment.
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Version Slide 25
Managing Risk Using RBI
Risk, RBI Strategy (more effective)
Risk, Traditional Strategy
Inherent Risk
EFFORT = EURO, USD, RUB, RMB,NOK
Risk
Reduction
Cost
reduction
Both
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© Det Norske Veritas AS. All rights reserved.Slide 26
So what are the real Benefits of RBI Implementation ?
Risk ranking and prioritization of inspection and maintenance activities
Optimise spending on maintenance and inspection
May significantly alter the inspection strategies to become more “efficient”
May provide substantial cost savings
May contribute to reducing operational risks
Improved communication between operations, inspection and maintenance
Provides RBI database for easy future inspection scheduling, updating andrisk control
Improves the mechanical integrity system and provides means to measure
the effectiveness of inspection
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Version Slide 28
ORBIT Onshore Features
Suitable for RBI of chemical plants, refineries, onshoreinstallations
Semi-qualitative screening analysis enables rapid identificationof high risk items
Detailed likelihood calculation as a function of time, using limitstate equations
State-of-the-art consequence modelling using PHAST models Extensive database of more than 1700 construction materials
(ASME)
Incorporates database of more than 1500 chemicals (DIPPR),100 chemicals with detailed data
Easy addition of new materials or chemicals for detailed RBI orscreening RBI
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Version Slide 29
Modules
Qualitative-Screening Approach
Internal Thinning
Stress Corrosion Cracking (SCC)
External Damage
Brittle Fracture
Fatigue
High Temperature Hydrogen Attack (HTHA)
Linings
Pressure Relief Valves
Consequences with PHAST lookup tables or direct input
Inspection Planning, Optimisation, Cost Benefit Analysis and Final Approval
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Version Slide 31
Typical Reports
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Version Slide 32
Typical Reports
Risk matrices for
- Current Date
- Future prior to inspection
- Future post inspection
Executive summary with risks per equipment type and damage mechanism, riskvariation with time with / without inspection
Inspection plans showing what equipment items to inspect, for what type ofdamage, when to inspect and what approach to use
Cost Benefit Analysis/ Risk benefit analysis
Equipment summary sheet
Detailed risk breakdown including business interruption, equipment damage and
personnel safety contributions
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Version Slide 36
Success Stories
Dow Chemicals
- Using ORBIT in 16 sites
- User group and technical steering group
Total Petrochemicals (former Atofina)- Selected ORBIT in competition with other RBI software
- Deployed already in 4 sites, planned for more sites
Borealis
- Deployment in 6 sites: Austria, Belgium, Germany, Sweden, Norway,Finland
Equate, RBI implemented in Kuwait petrochemical installation
Kuwait Oil Company
- RBI and Inspection Software (ORBIT Onshore and ORBIT+IDS)- Inspections conducted/managed for 5000 equip. & 50000 pipes
- 21 Gathering Centres and 3 Booster stations,
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Evidence of Benefits from the Use of ORBIT
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Version Slide 38
ORBIT Onshore Worldwide Continuous Success Story:Dow Chemicals
http://www.dnv.com/resources/publications/dnv_forum/archive/DowChemicalCo.asp
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Version Slide 39
Dow Chemicals
Chemical company with sites / joint ventures worldwide
RBI Implementation in more than 15 sites
- Europe, US, South America, Asia Use of ORBIT Onshore & DMI since 2000
- In-house RBI experts
- Currently operating with minimum DNV assistance
Risk based inspection instead of periodic inspection Quoted(*) Benefits of the RBI program:
- Improved reliability
- Eliminated low-value work
- 40% inspection cost reduction
Dow quote 100 million USD savings/year
* http://www.dnv.com/resources/publications/dnv_forum/archive/DowChemicalCo.asp
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Version Slide 42
RBI – Risk in Detailed Analysis
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Version Slide 46
Undesirable Consequences in RBI
HEAT from flames destroys equipment, injures people
PRESSURE WAVE from explosions knocks down structures andpeople, causes flying objects
TOXIC cloud, for some duration, causes toxic exposure injuries
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Version Slide 50
Risk Target and Inspection Planning
InspectionTarget
R i s k / D a m a g e F a c t
o r ( D F )
Predicted Risk
Increase
Now
Time to next
inspection
Highly Effective
Risk / DF
1st
Turnaround
Fairly Effective
2nd
Turnaround
Time
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Version Slide 55
API and ORBIT
DNV develops successive versions of API 581 and API-RBI, 1993-2002
DNV develops ORBIT RBI 1997-now
- Some Reasons:
- Need for a RBI software for other than refineries
- Improved consequence calculations with PHAST link- Need for a robust software architecture & professional software
development and maintenance
ORBIT is consistent with the API 580 RBI standard
ORBIT and API 581 share a lot of technology
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Software Demonstration
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Version Slide 63
ORBIT Overview
•Screening or
•Detailed
Analysis
•Designed for All Types of Process Plants.
•Designed to Be Subdivided Easily IntoPlant Units, Areas, Zones, Corrosion
Circuits Etc.
• Looks Like Microsoft
Outlook.
• Intuitive To Use.
• Online Help.• Menus Or Buttons.
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Version Slide 64
ORBIT List Views
Allows Easy Sorting andEditing of Large Amounts
of Data
A List-view: one of the
possible views of the
same study Database
ORBIT Li Vi
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Version Slide 65
ORBIT List Views
“Drag and Drop” Facilities
for Sorting
Seven Pre-Installed List
Views
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Version Slide 66
User List Views
Facility to Create User
Defined Views
Screening Analysis
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Version Slide 67
Screening Analysis
Screening Analysis is a
semi-Quantitative
Method for Rapidlyidentifying high-risk
items from a large set of
Equipment Items.
NFPA
Ratings for
1600
Chemicals.
S i A l i
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Version Slide 68
Screening Analysis
Likelihood By:
DamageMechanism
Method (for Long
Life Expectancy
Items) or -
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Version Slide 69
Screening Analysis
Results Calculated Immediately As
•Likelihood rating (1 to 5)
•Consequence Rating (A to E)
•Overall Risk Ranking (Low to High).
- Statistical
Method (for
Shorter LifeItems).
Recommendat
ions Made.
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Version Slide 71
Detailed Analysis
Extensive
Database of
Materials.
Select Exact Material
or Generic Type (E.G.
Carbon Steel)
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Version Slide 72
Consequence Analysis
PHAST Is
DNV’s Widely
Used Software
for ConsequenceModelling
In Consequence Module
Define:
Consequence Method
(PHAST-Lookup or
Direct Input),
Chemical,
Vessel Shape.
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Version Slide 73
Consequence Analysis
Database of 1600
Chemicals. A subset
have lookup tables
Consequence Results
Determined:
Business Interruption Cost
Equipment Damage Cost
Safety Cost
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Version Slide 74
Consequence Analysis
SI, English, Metric or
User Defined Units of
Measure
C A l i
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Version Slide 75
Consequence Analysis
LinkEquipment
Items Into
Inventory
Groups
-
Automatically
Calculated or
Manual Input
Thinning Calculation
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Version Slide 76
Thinning Calculation
Choice of Corrosion Rates:Measured,
Expert Opinion
Inspection History - Number
and Type: Used to Calculate
Probability That Corrosion
Rate Is Worse Than Measured,
or Estimated Rate.
Program Considers the Chance
of Corrosion Rate Being Higher
Than Measured or Estimated.
Localised or General
Corrosion
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Version Slide 77
Thinning
Likelihood Factor = How many
times the Equipment Item Is More
Likely to Fail Than Generic.
Likelihood Factor for
Thinning Projected for a 5
Year Period.
Thi i
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Version Slide 78
Thinning
Results Include:
Equipment Item Remaining
Life and Confidence in
Corrosion Rate (Based on
Inspections Undertaken).
E l D
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Version Slide 79
External Damage
Estimated or Calculated
Corrosion Rates
Choice of Corrosion
Rates:
Measured,
Expert Opinion or
Calculated
SCC M d lli
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Version Slide 80
SCC Modelling
In-built SCC
Causes:
•Caustic
•Amine•Carbonate
•SSC
•HIC/SOHIC
•Chloride
•PTA•HSC
•Ammonia
Calculated or
expert SCC
Susceptibilities
Results:•SCC Factor
SCC Modelling
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Version Slide 81
g
SCC Factor Projected for a
5 Year Period.
Inspections
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Version Slide 82
Inspections
Inspection History for Each
Equipment Item
Effectiveness Is Highly,
Fairly, Usually or Poorly -
DNV Templates Definitions
- Modified for Each Client
Inspection ImprovesConfidence in the
Estimated, Measured or
Calculated Corrosion Rate
or SCC Susceptibility
Other Modules
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Version Slide 83
Other Modules
Other Modules:
•Brittle Fracture•Piping Fatigue
•HTHA
•Liners
•PRVs
Results: Risk Matrix Report
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Version Slide 84
Results: Risk Matrix Report
Results: Equipment Summary Sheet
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Version Slide 85
Results: Equipment Summary Sheet
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