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ASME PCC-3–2007

Inspection
Planning Using
Risk-Based
Methods

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A N A M E R I C A N N AT I O N A L STA N DA R D

`..````````.``.`...`.`.`--- A N A M E R I C A N N AT I O N A L S TA N D A R D .`.ASME PCC-3–2007 Inspection Planning Using Risk-Based Methods --`.`..`.-`-`..`...

New York. --`. This code or standard was developed under procedures accredited as meeting the criteria for American National Standards.. The proposed code or standard was made available for public review and comment that provides an opportunity for additional public input from industry.`--- . and the public-at-large.. ASME issues written replies to inquiries concerning interpretations of technical aspects of this Standard. proprietary device. Participation by federal agency representative(s) or person(s) affiliated with industry is not to be interpreted as government or industry endorsement of this code or standard. ASME is the registered trademark of The American Society of Mechanical Engineers. ASME does not take any position with respect to the validity of any patent rights asserted in connection with any items mentioned in this document. and the risk of infringement of such rights. and does not undertake to insure anyone utilizing a standard against liability for infringement of any applicable letters patent..`.`. NY 10016-5990 Copyright © 2008 by THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS All rights reserved Printed in U. which precludes the issuance of interpretations by individuals..`. ASME accepts responsibility for only those interpretations of this document issued in accordance with the established ASME procedures and policies..” “rate. The interpretations will be included with the above addenda service. Users of a code or standard are expressly advised that determination of the validity of any such patent rights. No part of this document may be reproduced in any form.`. 2008 The 2007 edition of this Standard is being issued with an automatic addenda subscription service. is entirely their own responsibility.`. The use of addenda allows revisions made in response to public review comments or committee actions to be published as necessary.-`-`. ASME does not “approve.” or “endorse” any item.A. regulatory agencies.S. The American Society of Mechanical Engineers Three Park Avenue.. construction. This Standard will be revised when the Society approves the issuance of a new edition.`. nor assumes any such liability. without the prior written permission of the publisher. revisions published in addenda will become effective 6 months after the Date of Issuance of the addenda. The Standards Committee that approved the code or standard was balanced to assure that individuals from competent and concerned interests have had an opportunity to participate.````````.`. academia.. or activity.`.``.Date of Issuance: June 30. in an electronic retrieval system or otherwise.

`.`. the interpretations will be published on the ASME Web site under the Committee Pages at http://cstools.````````.``.org as they are issued.... New York.`..`.`..`. Also. THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS Three Park Avenue.asme.`--- There will be no automatic addenda subscription service issued to ASME PCC-3–2007..ERRATA to ASME PCC-3–2007 Inspection Planning Using Risk-Based Methods --`.-`-`.`.`. NY 10016-5990 August 2008 A0168E ..

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. . . . .5-1 8. . . . 39 16 References . . . . . . . . . . . . . .`. . . Six-Level Table . . . . .2. . . . . . . . . . . . . 36 14 Documentation and Record Keeping . . . . . . . . . . . . . 1 2 Basic Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and Purpose. . . . Three-Level Safety. . . . . . . . . . . . . . .7 16 Factors Contributing to Loss of Containment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Risk-Based Inspection Planning Process . . . . . . . . . . . . . . . . .4 4. . . . . . . . . . . . . . . . . . Responsibilities. . . . . . . . . . . . . .. . . . . . . . . . . . 35 13 Roles. . . . . . . . . 34 12 Reanalysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . . . . . . . .3. . . . . . . . . . . . . Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example of Calculating the Probability of a Specific Consequence . . . . . 32 11 Other Risk Mitigation Activities . . . . . . . . . . . . . . . . . . . . . ..````````. . . . . . . . . . . . . . . 47 58 65 71 79 Figures 2. . . . . . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . Health. . . . . . Relationship Among Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example Risk Matrix Using Probability and Consequence Categories . . . . . . .4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 2 3 5 7 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Committee Roster . . . . . . . . . . . . . . . . . . . 1 3 Introduction to Risk-Based Inspection. . . . . . . . . . . . and Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System. .`. . . . . . . . . . .`. . . . . . . . . . .`--- Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3. . . . 13 6 Damage Mechanisms and Failure Modes . . . . . . . . . . . . .1 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . .1 Risk Plot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 26 29 31 Tables 2. . . . . . . . . . . . . . . . . . . Six-Level Safety. . . . . . . . . . . . . . Health. . . . . . . . . . . . . . . . . . . . . . . . Introduction. . .. . . . . . . . .. . Management of Risk Using RBI . . . . . . . . . . . . . . . . . .1 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Quantitative Methods Including Expert Opinion Elicitation . . . . . . . .3.`. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 iii --`. . . . . . . . . . . .. . . . . . . . .``. . . . . . . . . Determination of Consequence of Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and Qualifications . . . . . . . . . . . . . . . . B Damage Mechanism and Defects Screening Tables . . . . . . . . . . . . . . . . . . .-`-`. . .`. . . . . . . . . . . . . . . . . and Environmental Consequence Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E Examples of Risk-Based Inspection Program Audit Questions . . . . . . . . . . . . . . . . . . . . . . . . C Table of Inspection/Monitoring Methods . . . . . . . . and Environmental Consequence Categories . . . . . . . . . . . . . . .`. . . . . . . . 38 15 Definitions and Acronyms . . . . . . . . . . . Process Unit. . . . . .`. . . . . . . . . . . . . . . . 20 9 Risk Determination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 8 Determining Consequence of Failure . . . . . . Equipment. . . . . .`. . 9 5 Data and Information Collection . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 4 22 22 23 41 Nonmandatory Appendices A Damage Mechanism Definitions . Continuum of RBI Approaches . . . . . . . . . .3 3. . .CONTENTS iv v 1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 Planning the Risk Analysis . . . . . . . . . . . . . . . . . . . . . . .3 8. . . . . . . . . . . . . . . . . . . .5-2 8. . . .5 9. . . . . . . . . . . . . . and Management . . . . . . . . . . . . . . . . . . . 15 7 Determining Probability of Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 10 Risk Management With Inspection Activities . . .

By agreement with the American Petroleum Institute. which is oriented toward the hydrocarbon and chemical process industries. The BPTCS covers non-nuclear boilers. The PCC formed the Subcommittee on Inspection Planning and the Subcommittee on Flaw Evaluations in 1995..`. the Board on Pressure Technology Codes and Standards (BPTCS) formed the Post Construction Committee (PCC) in 1995.FOREWORD ASME formed an Ad Hoc Task Group on Post Construction in 1993 in response to an identified need for recognized and generally accepted engineering standards for the inspection and maintenance of pressure equipment after it has been placed in service. iv --`. piping and piping components.. The scope of this committee was to develop and maintain standards addressing common issues and technologies related to post-construction activities. The subcommittees were charged with preparing standards dealing with several aspects of the inservice inspection and maintenance of pressure equipment and piping. This Standard provides guidance on the preparation and implementation of a risk-based inspection plan. Repair of Pressure Equipment and Piping. and improvements to the text of API 580 were made. Risk-Based Inspection. In 1998.``. a Task Group under the PCC began preparation of Guidelines for Pressure Boundary Bolted Flange Joint Assembly. pressure vessels (including heat exchangers).. In the standards development process that led to the publication of this Standard.````````. and storage tanks. product-specific codes and standards addressing issues encountered after initial construction for equipment and piping covered by Pressure Technology Codes and Standards. additions. this Standard is closely aligned with the RBI process in API 580.`. and in 1999 the Subcommittee on Repair and Testing was formed. 2007. pipelines. At the recommendation of this Task Group.`. If it is determined that repairs are required. This Standard provides recognized and generally accepted good practices that may be used in conjunction with Post-Construction Codes.. Other topics are under consideration and may possibly be developed into future guideline documents. when appropriate.. This Standard is based on API 580.. and NB-23. API 570.`. Fitness for Service.`--- .`. guidance on repair procedures is provided in ASME PCC-2. such as API 510. ASME PCC-3–2007 was approved as an American National Standard on October 4.`.`. numerous changes.. using the procedures provided in the API 579-1/ASME FFS-1. The PCC selects standards to be developed based on identified needs and the availability of volunteers.`.-`-`. Flaws that are identified during inspection plan implementation are then evaluated. many of which are intended to generalize the RBI process to enhance applicability to a broader spectrum of industries. and to work with other consensus committees in the development of separate.

Sims. Inc. E. P. Cowfer. L. The National Board of Boiler and Pressure Vessel Inspectors J. Jr. Peters. R. Chair. Inc. Structural Integrity Associates J. The Dow Chemical Co.. Contributing Member. Contributing Member. W. S. D. E. N. Becht Engineering Co.. Rossi. Becht Engineering Co. R.`--- . Jr.`. The National Board of Boiler and Pressure Vessel Inspectors v --`. Fluor Daniel J. Consultant F. R.. Roberts. Secretary. G. Consultant E.. Duvic III. Rossi. Lang. M. Sr. Life Cycle Engineering D.. Inc. Structural Integrity Associates J. Brown. Titer. T. Neely. Jr. Sr. FM Global D. Mirant Mid-Atlantic C. C.`. Batey.. Sims. R. Secretary STANDARDS COMMITTEE PERSONNEL T. BP North American Products. Tanner... L. J. Mokhtarian. E. D. J. R. ABB Lummus Global. Progress Energy Fossil Generation C. C. Chaku.. N. Lang. C. L. Rowley.. Vessel Statistics G. The Dow Chemical Co. ABB Lummus Global. Schmidt. D. Berger. Consultant S. Becht Engineering Co. Vice Chair. Montgomery. Rodery. Antalffy.-`-`. Inc. D. Batey.. PPL Generation LLC P.`. M. L. Vice Chair S. D. Sims. J. Becht Nuclear Services J. Arnold.. FM Global C. POST CONSTRUCTION SUBCOMMITTEE ON INSPECTION PLANNING P. Neely. Chair J. Inc. The Wesley Corp. A. Antaki. M & M Engineering H. Inc. C. C. C.`. Consultant J. Sr. Leonard. R..`. T. Reynolds. Leonard. E. N.. UOP LLC D.`. Hackford.. The American Society of Mechanical Engineers L.. Utah Labor Commission W. Cowfer.) STANDARDS COMMITTEE OFFICERS D. Inc. Berger. Lang. G. Life Cycle Engineering K. P. Parks. D. PPL Generation LLC F.. Chaku.`. R. City of Kozani. A. M. Becht Engineering Co. Consultant C.. Becht IV. Koves. A. T. Michalopoulos. G. A. Jr. Becht Engineering Co. Consultant J. Reynolds. Sharp.``. Inc. Shell Global Solutions US.. A. Inc.````````.ASME COMMITTEE ON PRESSURE TECHNOLOGY POST CONSTRUCTION (The following is the roster of the Committee at the time of approval of this Standard. Consultant M. C. Greece G. The American Society of Mechanical Engineers C.`. Schmidt.