risk based inspection mechanical integrity...inspection (rbi)program. • it is a generic,...

Copyright PSRG Inc. 2016

Risk Based InspectionMechanical Integrity

Mr. Robert J. Weber, P.E. – President/CEO/FounderMs. Annie Nguyen – Director PSRG APAC

16 May 2016

JTC Summit8 Jurong Town Hall road #24-05

609434 SINGAPORETel: +65 6818 0967 - Fax: +65 6818 0801Email: [email protected]

Web: www.psrg.com


• Established, 1997 (Houston)• Established, 2015 (Singapore), as

PTE. LTD. Company• More than 100 technical

professionals worldwide averaging 29+ years experience

• Diverse industry experience on 1,000+ projects with more than 750 customers in 78 countries

• Hands-on plant operations experience

• Single source, one stop shop for comprehensive PSM/RMP, HSSE consulting and field services

• Registered & Approved “QRA Consultant” by NEA

PSRG Overview


Outline of Presentation

• Definition of RISK• What is Risk Based Inspection (RBI)• Codes and Standards for RBI• Key Elements of RBI• Approach for RBI• Implementing RBI• Summary


PLANTS WANT AND NEED

Plants want Increased reliability Reduced downtime Higher production rates Lower costs Safer operations

Plants need Methods to combine ALL OF THE ABOVE and keep risk at an

acceptably low level


Evolution of Maintenance Management

ConditionBased

RiskBased

FixedInterval

Trend Analysis

Consequencesnot Considered

Reactive!

(Backward Looking)

Standardinspection orservice interval

Risk Analysis

Probability andConsequences

Proactive!

(Forward Looking)


TRADITIONAL MECHANICAL INTEGRITY

• Maintenance and inspection tasks are done on time or condition-based.

• Time basis may be from OEM recommendations, plant operating history, and/or regulatory requirements.


RISK-BASED MECHANICAL INTEGRITY

The use of a more proactive, risk-based approach based on good engineering practices (RAGAGEP) to manage maintenance and inspection tasks to help reduce costs and manage risks.

RBI = Risk Based Inspection


WHAT IS RISK?

RISK is the chance of something bad happening.

Risk assessment asks three (3) questions:1. What could go wrong?2. How often could it happen?3. What are the consequences?


WHAT IS RISK and RISK ANALYSIS?

• Risk is the combination of the probability of an event and its consequences.

• Results can be viewed in a Risk Matrix.

RISK = PROBABILITYOF FAILURE

X CONSEQUENCES OF FAILURE


EXAMPLE RISK

RANKING MATRIX


WHAT IS RBI?• An integrated methodology that uses “risk” as a basis for

prioritizing and managing an in-service equipment inspection program by analyzing both the likelihood of failure and the consequence of failure.

• Involves quantitative assessment of the probability of failure (PoF) and the consequence of failure (CoF) associated with each equipment item in a particular process unit.

• A properly-implemented RBI program categorizes individual pieces of equipment by their risks and prioritizes inspection efforts based on this categorization.


WHAT IS RBI?• An RBI program has three (3) major goals:

1. To allow risks for process equipment failure to be better defined and quantified.

2. To reduce both the chances of failure and the consequences of that failure, should it occur.

3. To allow management to review these risks effectively and make decisions.


DRIVERS TOWARD RBI

• Risk is not uniform [80/20 Rule]• Historical data suggests that 80% of the total risk exists in 20%

of equipment items.


Mechanical Failure

Operational Error

Process Upset

Natural Hazard

Design Error

Sabotage/Arson

Others/Unknown

0 10 20 30 40 50Percent of Losses

Causes of Major Property Losses in the Oil Refining andPetrochemical Industries, 1970-2010


Equipment Involved in Major Property Losses in the OilRefining and Petrochemical Industries, 1970-2010

ReactorsDrumsPumps/ CompressorsHeat Exchangers

Towers

Heaters/Boilers

Others/Unknown

Percent of Losses

Piping Systems

Tanks

0 5 10 15 20 25 30 35


DRIVERS TOWARD RBI


of equipment items.

• Costs of inspection• The need to keep and maintain equipment fit-for-service at a

reasonable cost while minimizing releases.


DRIVERS TOWARD RBI


of equipment items.



• Not all “damage mechanisms” the same.


DRIVERS TOWARD RBI


of equipment items.



• Not all “damage mechanisms” the same.

• Costs of downtime


EUROPEAN UNION

• RBI accepted in the European Union.• 1997 Pressurized Equipment Directive.


RAGAGEP FOR RBI

• American Petroleum Institute (API)• API RP 580, Recommended Practice for Risk Based Inspection (1st

Edition – May 2002; 3rd Edition – February 2016)• API RP 581, Risk Based Inspection Technology (3rd Edition, April

2016)• API 510, Pressure Vessel Inspection Code: In-service, Rating,

Repair and Alteration (10th Edition, May 2014)• API 570, Piping Inspection code: In-service Inspection, Repair

and Alteration of piping system (4th Edition, February 2016)• API 653, Tank Inspection, Repair, Alteration and Reconstruction

(5th Edition, November 2014)


API RISK-BASED INSPECTION

• API RP 580 identifies the basic elements for developing, implementing and maintaining a risk-based inspection (RBI) program.

• It is a generic, Recommended Practice document on RBI that can be used as a “measuring stick” by which the quality of any and all RBI methods and work processes cam be evaluated to determine if they meet the level of quality prescribed in the RP.

https://inspectioneering.com/tag/risk-based+inspection


API RISK-BASED INSPECTION

• API RP 580 defines RBI as:

• RBI is a risk assessment and management process that is focused on loss of containment of pressurized equipment due to material deterioration.


API RISK-BASED INSPECTION• API RP 581, Risk-Based Inspection Technology, is a

recommended practice developed and managed by the American Petroleum Institute (API).

• Originally released in 2000 (updated, April 2016), the purpose of this publication is to provide quantitative risk-based inspection (RBI) methods that support the minimum general guidelines presented by API RP 580.

https://inspectioneering.com/tag/apihttps://inspectioneering.com/tag/risk-based+inspectionhttps://inspectioneering.com/tag/api+rp+580


API RISK-BASED INSPECTION• API RP 581 is based on the knowledge and experience

of industry practitioners with extensive experience in its implementation.

• API RP 581 presents the RBI methodology in three (3) parts:• Part 1 – Inspection Planning Using API RBI Technology• Part 2 – Determination of Probability of Failure in an API RBI

Assessment• Part 3 – Consequence Analysis in an API RBI Assessment


GENERAL METHODOLOGY & APPROACH

• Prioritization of high risk components (WHERE TO INSPECT)

• Identification of dominating mechanisms (WHAT TO INSPECT)

• Assessing inspection intervals (WHEN TO INSPECT)

• Assessing inspection methods (HOW TO INSPECT)


KEY ELEMENTS OF RBI

• Management systems in place for maintaining documentation, data, and analysis updates

• Documented method• For determination of probability of failure determination• For determination of consequences of failure• Managing risk through inspection


KEY ELEMENTS OF RBI

RBI does not compensate for• Inaccurate or missing information• Inadequate designs or faulty equipment installation• Operating outside the acceptable design envelope• Not effectively executing the inspection plan• Lack of qualified personnel or teamwork• Lack of sound engineering or operational judgment


KEY ELEMENTS OF RBI

RBI covers• Pressure vessels• Process piping and components• Storage tanks• Rotating equipment• Boilers and heaters• Heat exchangers• Pressure relief devices


KEY ELEMENTS OF RBI

RBI does NOT normally cover:• Instrumentation and control systems• Electrical Systems• Structural Systems


RISK AND RBI

R I S K

Risk Using RBI

Risk with Typical Inspection Programs

Residual Risk

LEVEL OF INSPECTION ACTIVITY

LEVEL OF INSPECTION ACTIVITY

R

I

S

K

Residual Risk

Risk with Typical Inspection Programs

Risk Using RBI


MANAGING FOR RBI

Plant Integrity

Management System

Plant Design

Maintenance and

Operating Procedures

Data and Data

Analysis

Trained and Competent Staff


APPROACHES TO RBI• Qualitative (Expert judgment based on experience)

• Semi-quantitative (Rule-based analysis)

• Quantitative (Probabilistic, computer modeling, QRA)


APPROACHES TO RBI


BASIC RBI FLOW


RBI IMPLEMENTATION

Four (4) main elements:

1. Get the organization ready Establish goals and objectives Set risk tolerance criteria Determine boundaries for RBI

2. Risk assessment3. Inspection planning4. Feedback / continuous improvement


RBI IMPLEMENTATION

• Must calculate risk at equipment level• Must set tasks and frequencies appropriate to probability

and consequences for each item• Must be updated• Must be economical


RBI IMPLEMENTATION –TYPICAL DATA NEEDEDTypical data needed for an RBI analysis may include:a) type of equipmentb) materials of construction; c) inspection, repair and replacement recordsd) process fluid compositionse) inventory of fluidsf) operating conditionsg) safety systemsh) detection systemsi) corrosion damage mechanisms, rates, and severityj) personnel densitiesk) coating, cladding, and insulation datal) business interruption costm) equipment replacement costsn) environmental remediation costs


RBI IMPLEMENTATION –DAMAGE MECHANISMSPotential deterioration mechanisms to be considered:• Carbonic acid (CO2) corrosion• H2S corrosion• Preferential Weld Corrosion• Erosion and erosion-corrosion• Crevice corrosion• Flange face corrosion• Cavitation• Deadleg corrosion• Under deposit corrosion• Microbial corrosion• Oxygen corrosion• Galvanic corrosion• Corrosion under insulation (CUI)• Liquid Metal Embrittlement (LME)• Chemical concentration corrosion• Fatigue/Vibration• Thermal Fatigue• Brittle Fracture• Cracking mechanisms (e.g., Sulfination, High Temperature Hydrogen Attack (HTHA), Chloride

Stress Corrosion Cracking, Amine Stress Corrosion


RBI IMPLEMENTATION – TEAM MAKEUP

• Team Leader / Facilitator• Equipment Inspector or Inspection Specialist• Corrosion & Metallurgy Specialist• Process Specialist• Operations and Maintenance Personnel• Management• Risk Analyst• Environmental and Safety Personnel• Financial/Business Personnel


TYPICAL BENEFITS/SAVINGS

• 15% saving shutdown inspection cost• Risk profiles identified/approved• Increased intervals between shutdowns• Increased production


CASE HISTORY - GAS TERMINAL

• Operating since 1974• Expanded in four (4) phases• Capacity 1.8 Billion SCF/day• RBI started being applied in 1999• 4500 lines in 143 piping systems• 530 Static equipment items• 638 Relief Valves


CASE HISTORY - RBI BENEFITS (Over 6 Years)

11869

2064

1027

1306

504248 OCA

34912

2976

1507

1766

480

MAINTENANCE COSTS

INSPECTIONCOSTS

DIRECT

COSTSINDIRECT

TOTAL $41,641,600 Conventional

TOTAL $17,017,600RBI


DOING RBI

Reducing Risk Through Inspection• Inspection, by itself, does not reduce risk• Uncertainty about the state of the equipment can be reduced• Higher confidence in continued safe operation


DOING RBI

Reducing Risk Through Inspection • Effective inspection techniques need to be established, for the type

of deterioration suspected• Risk reduction depends on Mode of failure of the deterioration mechanism Time interval between the onset of deterioration and failure Detection capability of inspection technique Scope of inspection Frequency of inspection


DOING RBI

Managing Risk Through Inspection • Frequency of inspection• How much is inspected• Inspection tools and techniques• Qualifications of inspectors• Internal versus external inspection


EFFECTIVE INSPECTIONS


OUTCOMES FROM RBI

• A detailed inspection plan for each equipment item• Plan for “evergreening” the RBI process


BENEFITS OF RBI

• Identification of high risk equipment

• What drives the risk• State of equipment• Consequence of failure

• Allow for longer operation due to improved prediction of failures

• Assess results of process changes on equipment


BENEFITS OF RBI

• Inspection Planning• Using on-stream, non-intrusive, inspections Reduced inspection costs May permit delay in internal inspections

• Improved and possible shortened turnarounds


SUMMARY of RBI• Increased plant availability due to

• Better inspection and maintenance• Fewer failures of critical plant• Use of on-line methods

• Reduced risk of failure due to• Use of methods that match failure modes

• Reduced direct costs for low risk items


SUMMARY of RBI• Increased plant availability/reliability

• Awareness of degradation mechanisms

• Increased safety due to reduced rate and severity of unexpected failures

• Reduced number & duration of planned shutdowns

• Increased production & profits


WHY ADOPT RBI?

• Make better use of process plant with increasing pressure on operating costs and reduced human resources……………..without gaining any unacceptable increase in risk exposure.


Thank You!

JTC Summit8 Jurong Town Hall road #24-05

609434 SINGAPORETel: +65 6818 0967 - Fax: +65 6818 0801

Email: [email protected] . Web: www.psrg.com

Risk Based Inspection� Mechanical IntegritySlide Number 2Outline of PresentationPLANTS WANT AND NEEDSlide Number 5TRADITIONAL MECHANICAL INTEGRITYRISK-BASED MECHANICAL INTEGRITYWHAT IS RISK?WHAT IS RISK and RISK ANALYSIS?EXAMPLE RISK RANKING MATRIXWHAT IS RBI?WHAT IS RBI?DRIVERS TOWARD RBISlide Number 14Slide Number 15DRIVERS TOWARD RBIDRIVERS TOWARD RBIDRIVERS TOWARD RBIEUROPEAN UNIONRAGAGEP FOR RBIAPI RISK-BASED INSPECTIONAPI RISK-BASED INSPECTIONAPI RISK-BASED INSPECTIONAPI RISK-BASED INSPECTIONGENERAL METHODOLOGY & APPROACHKEY ELEMENTS OF RBIKEY ELEMENTS OF RBIKEY ELEMENTS OF RBIKEY ELEMENTS OF RBIRISK AND RBIMANAGING FOR RBIAPPROACHES TO RBIAPPROACHES TO RBIBASIC RBI FLOWRBI implementationRBI implementationRBI implementation –TYPICAL DATA NEEDEDRBI implementation – DAMAGE MECHANISMSRBI implementation – team MAKEUPTypical Benefits/Savings�Case History - Gas TerminalSlide Number 42DOING RBIDOING RBIDOING RBIEFFECTIVE INSPECTIONSEFFECTIVE INSPECTIONSEFFECTIVE INSPECTIONSOUTCOMES FROM RBIBENEFITS OF RBI BENEFITS OF RBISUMMARY of RBISUMMARY of RBIWhy Adopt RBI?Thank You!�

risk based inspection mechanical integrity...inspection (rbi)program. • it is a generic,...

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