Risk Based Inspection (RBI)

DEFINITION OF RISK BASED INSPECTION (RBI)

Risk Based Inspection (RBI) is a risk assessment that focus on loss containment of pressurized equipment
on process facilities due to material deterioration. It is a methodology that uses relative risk as a basis
for prioritizing and managing the efforts of an inspection program, including recommendations for
monitoring and testing. It provides focus for inspection activity to specifically address threats to the
integrity of the asset and the equipment’s capacity to operate as intended. The POF and COF are
assessed separately and then combined to determine risk of failure. Risk is compared and prioritized for
inspection planning and risk mitigation. Risk mitigation plans may include options in addition to or other
than inspection such as changes in materials of construction, the use of corrosion inhibitors, changes in
operating conditions and fluids, and/or installation of liners and coatings. RBI is proactive, it utilize the
information available to manage risk.

A RBI program includes following:

a) Systems or processes within an operation prioritized by risk.

b) Determined risk value or category associated with an equipment item within a system or process
based on a consistent methodology.

c) Prioritized equipment ranking based on risk.

d) Development of an appropriate inspection program to address key risk drivers. A method to

systematically manage risks associated with the operation of process equipment.

KEY ELEMENTS OF A RBI PROGRAM

Key elements that should exist in a RBI program are:

- Management Systems for maintaining documentation, personnel qualifications, data

requirements and analysis updates.
- Documented method for probability of failure determination (POF)
- Documented method for consequence of failure determination (COF)
- Documented methodology for managing risk through inspection and other mitigation activities
TYPES OF RBI PROGRAM

Since RBI is based on relative risk, it is imperative that analyses are performed consistently. RBI
programs can be qualitative, quantitative, or semi-quantitative.

A. Qualitative Approaches

This approach requires data inputs based on descriptive information using engineering judgment,
subject matter expertise, and experience as the basis for the analysis of probability and COF. Inputs are
often given in data ranges instead of discrete values. Results are typically given in qualitative terms such
as high, medium, and low, although numerical values may also be associated with these categories. The
value of this type of analysis is that it enables completion of a risk assessment in the absence of detailed
quantitative data. The accuracy of results from a qualitative analysis is dependent on the background
and expertise of the risk analysts and team members. Although the qualitative approach is less precise
than more quantitative approaches, it is effective in screening out units and equipment with low risk.
However, qualitative assessments generally are not as repeatable as quantitative assessments. The
qualitative approach may be used for any aspect of inspection plan development; however, the
conservatism generally associated with the more qualitative approach should be considered when
making final mitigation and inspection plan decisions.

B. Quantitative Approaches

Quantitative programs are model-based approaches where numerical values are calculated and more
discreet input data used. The advantages of a quantitative approach are:

a) calculates, with some precision, when the risk acceptance limit is reached or exceeded;
b) discrimination between equipment risk allowing prioritization of mitigation;
c) trending and monitoring risk exposure over time as well as other metrics;
d) benchmarking of reliability management such as POF trending and comparisons.

Quantitative methods are more systematic, consistent, and documented, and they are easier to update
with inspection results than qualitative approaches. A quantitative approach generally uses a software
program to calculate risk and develop inspection program recommendations. The models are initially
data-intensive, but use of models removes repetitive, detailed work from the traditional inspection
planning process. Quantitative RBI outlines a methodology for prioritizing equipment risk in a risk matrix
or ISO-risk plot in addition to calculating discrete risk values for prioritization from higher to lower risk.
POF and COF are combined to produce an estimate of risk for equipment. Equipment items are ranked
based on risk with POF, COF, and risk calculated and reported separately to aid identification of major
contributors to risk, or risk drivers.
 C. Semi-Quantitative Approaches

Semi-quantitative is a term that describes any approach that has aspects derived from both the
qualitative and quantitative approaches. It is geared to obtain the major benefits of the previous two
approaches (e.g. speed of the qualitative and rigor of the quantitative). Typically, most of the data used
in a quantitative approach is needed for this approach, but in less detail. The models may not be as
rigorous as those used for the quantitative approach. The results are usually given in consequence and
probability categories or as risk numbers, but numerical values may be associated with each category to
permit the calculation of risk and the application of appropriate risk acceptance criteria.

EQUIPMENT COVERED AND NOT COVERED OF A RBI PROGRAM

Equipment list that is covered in RBI program:

 Pressure Vessel (All pressure containing components).

 Process Piping (Pipe and piping components).
 Storage tanks (Atmospheric and pressurized).
 Boilers and heaters (Pressurized Components).
 Heat Exchangers (Shells, Heads, Channels, and Bundles).
 Pressure Relief Devices.

Equipment list that is not covered in RBI program:

 Instrument Control System.

 Electrical Systems.
 Structural Systems.
 Machinery Components (except pump and compressor casings).
RBI ASSESMENT PLANNING

A RBI assessment is a team based process. At the beginning of the exercise, it is important to define:

- Why the assessment is being done

- How the RBI assessment will be carried out
- What knowledge and skills are required for the assessment
- Who is on the team
- What are their roles in the RBI process
- Who is responsible and accountable for what actions
- Which facilities, assets, and components will be included
- What data is to be used in the assessment
- What codes and standards are applicable
- When the assessment will be completed
- How long it will remain in effect and when it will be updated
- How the results will be used

After that, we move to steps in applying RBI principles within the framework:

1. Planning the RBI assessment

2. Define the scope
3. Establish the team
4. Roles, Responsibilities, Training and Qualifications
5. Create an Equipment list
6. Equipment data and information collection
7. Identifying deterioration mechanisms and failure modes.
8. Assessing POF ( Probability of Failure)
9. Assessing COF (Consequence of Failure)
10. Risk Determination, Assessment and Management
11. Risk Management with Inspection Activities and Risk Benefit
12. Other Risk Mitigation activities
13. Reassessment and Updating
 14. Documentation and Record Keeping

BENEFITS OF USING RBI

Several benefits by using RBI:

- An understanding of the current risk

- An overall reduction in risk for the facilities and equipment assessed
- A ranking by risk of all equipment evaluated
- A description of any other risk mitigation activities
- Avoiding unnecessary inspection ( inspection intervals are based on the risk associated
with the equipment and therefore inspection personnel can spend most of their time on
the high risk area and less time in the low risk areas)
- Cost saving ( Equipment with no history of problems and no anticipated problems is
inspected on longer intervals rather than just inspecting every few years as is the case
with a time-based inspection program
- Extended plant and equipment life
- Increasing plant availability and optimum repair and replacement scheduling