Professional Documents
Culture Documents
API 580 provide users with basic elements for develop and implementation RBI program and specifically targeted at
the application in hydrocarbon and chemical process industry
1- RBI
* Program Requirements (Key elements)
Management system for documntation-personnal-data-analysis
Documented method for P.O.F
Documented method for PC.O.F
Documented method for managing risks through mitigation or inspection
* Outcomes of process
Ranking by risk all equipments evaluated
Inspection plan (method -time-extent- coverage)
Risk mitigation activates (repair-replacement—0)
Expected Risk levels
* Uses
1-Continuous improvement tool
As new data becomes available or changes occur reassessment made which refreshed view of risk
Guide to the direction of inspection technology development
4- basic concepts
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Weather condition
15-the accuracy of output is function of method used as well as quantity and quality of data available for this it
Benefit to use quantitative and qualitative complementary
The accuracy of any RBI analysis depends on using sound method—quality data and knowledgably personnel (5.3)
16- Equipment integrity and function performance depends on suitability of equipment to operate safety and reliable under
normal and abnormal conditions (5.4)
17-the susceptibility of equipment for deterioration and operating current conditions (process fluid containments +desired run
length between scheduled shutdown + upset operating conditions)
18- the suitability and current condition of equipment within the current operating envelope will determine the P.O.F
19---inspection influences of risk associated with pressure equipment by improving knowledge of deterioration state and
P.D.F
P.D.F for in service deterioration depends on( 5.5.1)
Deterioration type + mechanism + rate+
Probability of identifying and detecting the deterioration
Equipment tolerance
22- some risks cannot managed by inspection and need non-inspection mitigation action as (5.5.2)
Equipment nearing retirement
Failure mocha. As brittle and fatigue
Consequence does minted risks
And need non-inspection mitigation action as
Repair—replacement—update—redesign or upgrade
23-the current used specification for process safety management is OSHA 29 CFR 1910.119 or API RP 750
RBI Limitation
Will not compensate o
Missing or inaccurate information
Inadequate design or faulty installation
Operating outside the acceptable design envelope
Not effectively executing plans
Lack of qualified personnel
Lack of sound engineering or operation
How the RBI assessment will be carried out
By gathering data and information
Calculate the P.O.F AND C.O.F for each equipment
Calculate risk—ranking –identified the high risk –inspection plan
Mitigation system –reassessment
What knowledge and skills are required for the assessment?
Correct updated and valid information about current condition for all facilities included in RBI
Who is on the RBI TEAM?
Team leader who is responsible for formation of the staff and verifying the skill and knowledge
and prepare report and distributed it to the design makers
Follow up the mitigation action
What are their roles in the RBI process?
The RBI STEPSAS
Introduction to RBI
Planning to RBI assessment
Data and information collection
Identifying deterioration mechanism and failure modes
Assessing P.O.F and C.O.F
Risk determination and management
Risk management with inspection activates
Other risk mitigation activates
Reassessment and updated
Roles and responsibilities
RBI documents
Who is responsible and accountable for what actions?
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Management
Which facilities and assets and components will be included?
all the oil and gas plants—chemical and hydrocarbon plants--pressure vessels
Pipelines and pipeline stations –boilers and heaters -valves –
What data is to be used in the assessment?
Design –construction –quality –operating data
When the assessment will be completed
After identified high risk and making inspection plan
How long the assessment will remain in effect and when it will be updated
During the specific period of operating conditions without any change in RBI input data
How the results will be used
To avoid risk
RBI planning and assessment
A--Establish the goals and objectives of RBI—6.2
1- Understand risks in plant operation
2- Defined risk criteria (the team and management judge it for associated items)
3- Management of risks (identified-inspection-mitigation to acceptable level)
4- Reducing cost (reducing all unnecessary inspection)
5- Safety and environmental requirements (
6- Sort mitigation alternatives by non inspection methods (modification of process—operating conditions-change the
construction material or fluids to less flammable – remove unnecessary insulation –reduce inventories) .
7- Making RBI assessment for new project (change design –material)
8- Making strategies foe end of life (retirement) facilities by calculate FOS –API RP579
b- Establish physical bounders for RBI assessment (facilities-process units-system within process units—equipments
items –utilities, emergency and off plot system)
c- Establish operating boundaries ( start up and shut down-normal –upset and cyclic operation-operation time period)
d- Select type of RBI ASSESSMENT 9(qualitative –quantitative -semi-)
Small risk can use qualitative and high risk can used quantitative risk method.
Based on object of assessment –
Data availability and quality –
Resources –
Time constrains—
Previous evaluated risk
e--Estimatimating resources and required time
What’s available for what required
Implementer’s skill and knowledge training time for implementer’s
plan and data necessary number if units to be evaluated
Data and information required required time and resources
Degree accurately needed time and resources for evaluate assessment
1- The important document for RBI approach is base of study, assumptions and any devotions from prescribed standards
procedures
2- The RBI data quality has to the ---- relative accuracy of RBI analysis
Direct relation –indirect relation —no relation
6- the data requirement is ---------- for the various types of RBI analysis
Completely different -quite different-similar
7- the team leader checking the integrity of RBI analysis by checking the -------- quality data
Updating and validity---quantity and validity—quality and validity
8- failure data and incident investigations required for RBI analysis. POF.COF
9- the potential sources of input data errors in RBI are
Inspector //clerical error- old drawing –inaccurate instruments
8-the nelson curves used for using carbon –low alloy steels without deterioration in partial hydrogen HTHA API RP-941-
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(8.3.3)
9-the susceptibility of C.S and low alloys steels to HTHA based on
Material of construction –operating conditions-hydrogen partial pressure and exposure time
10- the four deterioration mechanisms (8.3)
Thinning-stress corrosion cracks -mechanical –metallurgical – and environmental
11-the thinning can be determined by thickness measurement—corrosion rate- corrosion tolerance—equipment ego—
Operating conditions- inspections types and numbers
5-Thinning deterioration mech. includes general /local/pitting corrosion and other metal loss mech. from internal or external surface -
8.3.1
12- S.S.C includes
Caustic cracks –sulfide stress cracks
Hydrogen induced cracks
Chloride cracks in S.S
13-The equip.susciptability to SCC includes to Probability for initiating cracks and also cracks resulting in a leak or rupture
8.3.2
9-Assessing probability of failure
Probability
Qualitative description for specific out comes or
Extent of event to occur with time frame under consideration
Number of occurrences of an event in given time
Range from min.is zero—0 –(impossible –rare) to max one –1 I high degree of belief
1- The probability of specific consequence will occur = P.O.F * probability of scenario under consideration assuming
Failure has occurred (9.1)
2- the causes of loss of containment by
Deterioration mechanisms
Seism tic activity
Design or human errors
Overpressure
Sabotage
Wrong material used
3- The probability is frequency = number of events occurring during specific time frame (9.2)
The probability units are event per interval (failure/year) or event per occasion (failure /run) (9.2)
The most probability assessment used blend of qualitative and quantitative approaches (9.3)
4-- When insufficient data available for the quantitative probability of failure analysis the specific failure data taken and
Modified and adjusted for each equipment case by case (9.3.2)
5-to calculate the probability of failure by
a** Deterioration mechanisms and rates from its material and operation conditions
b-** Effectiveness of Inspection program to monitor deterioration and repaired before failure
6-if operation conditions changed the deterioration rates based on previous inspection data may be not be valid .(9.4)
3- The in service deterioration effect on POF steps
Determined the deterioration mechanism and rates
Quantify the effectiveness of past inspection
Calculate POF
9-to determined the deterioration susceptibility and rates by used same components from same material and exposed to same
internal and external environmental
10- the links between the deterioration and mechanical result failure modes ( 9.4.2)
For each deterioration mechanism has its own characteristic failure models.
Pitting cause small hole
Thinning cause leak through big area or rupture
SCC cause cracks
Metallurgical and mechanical cause small holes or rupture
10-Assessing consequence of failure
Consequence
Outcome of an event expressed qualitatively or quantatively --positive or
Negative
1- The object of consequence analysis performed to provide decimation between the equipment items on basis of potential failure.
the analysis method chosen should have ability to provide the required level of discrimination between higher and lower
consequence equipments items
2- Plant inspector or inspector engineer manage risks by managing the probability of failure with inspection and maintenance
planning
3- In RBI consequences analysis should be simplified. Repeatable and credible estimate
4- The consequence failure can be determined by qualitative and /or quantative consequence analysis approaches (10.2).
12- The consequence analysis magnitude can be determined by the volume of released fluid (10.3.4).
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5- The calculation of quantitative consequence of failure based on
Type of process
State of fluid inside equipment and also after released
Process operating variables
Mass of inventory
Failure mode
6-What are the major factors in evaluating the consequence of failure?
a- Flammable events
b- Toxic events
c- Releases of other hazardous fluids
d- Environmental consequence
e- Production consequence
Maintenance and reconstruction impact
6- The units used in measuring consequence analysis are cost, safety, affected areas and environmental damage (10.3).
7- in safety consequence expressed by the severity of injury based on fatality, serious injury. Medical treatment first aid (10.3.1)
8- To compare between the various types of losses on common basis used the cost unit in measuring the consequence failure
(10.3.2).
9- the main information In consequence analysis by cost is product value, equipement costs, repair cost, pesonnal resources and
environmental damage and manpower (10.3.2).
11-n consequence analysis expressed by affected area the distribution of equipments and personnel must be event
(10.3.3)
13- When considering affected area unit in consequence analysis the surface area that experiences an effected by (toxic dose-
thermal radiation or explosion overpressure) greater than predefined limiting value (10..3.3)
14- The degrees of environmental damage in consequences analysis measured by (acres of land-miles of shoreline) affected per
year or human use resources consumed (10.3.4)
15- The effects (consequence) of loss of containment can be (10.1.1)
Safety and health impact
Production loss
Environmental impact
Maintenance and construction impact
16-the flammable events occur when both leak and ignition occurs and cause damage in ways thermal radiation and blast
Over pressure (10.5.1)
17-the thermal radiation effect to occur at close range but the blast over pressure cause damage over large distance from
The blast center (10.5.1).
18-toxic addressed only when released fluid affect personal (site and public)
19- Toxic releases don’t require an additional event (ignition) as the flammable needed and toxic cause affects greater
Distances than flammable events (10.5.2).
20- RBI program focuses on active toxic risks (create immediate danger 0 rather than chronic risks from low-level
Exposures (10.5.2)
21- Hazardous fluids in RBI program which cause thermal or chemical burns when contact with person as steam. Hot
Water. Acids and caustics (10.5.3)
22- Consequence by effected area is much smaller and magnitude of hazard is less for hazardous fluids than flammable
And toxic releases (10.5.3).
23- Consequence of environmental damage = cost clean up + fines+ other costs
24- Financial consequence value = lost process fluid + business interruption (10.5.5)
25- Business interruption = process unit daily value * downtime (days) (time required to get back into production. (10.5.5)
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5-the probability incidents decrease with the severity of the incident (probability of event from fatality less than probability of event
from first aid)
4- The probability of all consequence scenarios should equal 1
Probability of fire = P.O.F * P.O. ignition
Probability of non fire = P.O.F+ P.O.non ignition + P.O. non failure
Probability of fire +probability of non fire =1
5- Risk = probability * consequence
6- The risk = sum of individual risks for each specific consequences
7- The risk can be determined by probability and consequence as numerical values or from risk matrix (probability is associated
with consequence) 11.2.2
8- To use risk assessment in inspection and maintenance by combined the engineering /maintenance and inspection team to
Determined what to inspect –how to inspect and extent of inspection
Determined the risk value and prioritize (11.3.2)
9- The risk analysis that are more detailed (quantitative) there are specific value for each variable on risk calculation( 11.4)
10- Sensitivity analysis involves reviewing some or all input variables to the risk calculations to determine the overall influence on the
resultant risk value ( 11.4)
11- to improve the quality and accuracy of risk analysis by making sensitivity analysis and reevaluation the input variables if
additional data gathering (11.4)
12- Over estimating C.O.F AND P.O F values will unnecessary influence the calculated risk values ( 11.5)
13- Over inflated risk values mislead to
Inspection planners
Money and insures
Create lack of creditability for user of RBI
18- using risk matrix or risk plot for communicate the results of analysis to decision makers and inspection planners (11.6)
19- different size risk matrix is away to distribute the risks through plant without numerical values (11.6.1) by ranking the
consequence and probability categories and its desirable to associate numerical values with the categories to provide guidance to
assessments personal.
20- risk plot is drawn using as screening tool during the prorization process. High-risk items residing in upper right hand corner take
priority for inspection. Planning (11.6.3)
21- risk matrix –plot used to screen and initially identify ( higher –intermediate and lower ) risk equipments
22- the threholders that divide the risk plot –matrix into acceptability and UN acceptabiable regions and to be developed by
safety/financial polices
12--risk management with inspection activates
1- Inspection does not arrest or mitigate deterioration mechanism but serves to identify monitor and measured it and become
Important in case deterioration mechanism reached critical point
2- The better predictability the less uncertainty when failure occur for this (mitigation can be planned and implemented prior to the
predicated failure date ( 12.1)
3- Reduction in uncertainty &increase predictability leads to reduction P.O.F and risk
4- Risk mitigation achieved through inspection if organization will act on the inspection results in timely manner
5- in situations where risk is being driven by P.O.F there is potential for risk management thought inspection (12.1)
6- the inspection effectiveness based on
Equipment type –inspector skill
Inspection method-coverage-extent-frequency
Accessibility to deterioration mechanism. Rates susceptibility active, credible
Shut down requirements
Amount reduction in P.O.F
12- in evasive inspection which cause deterioration and increase risk as ( 12.4)
Internal lining inspection
Moisture ingress to equipment
Removal of passivity layers
Human errors.
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13- other risk mitigation activates
Mitigation
Limitation of any consequence or reduction in P.O.F event by detects. Isolate and reduce
The plant inspector –management and process safety personal can not modify the C.O.F but
the methods as following
1-The risk mitigation activates action in
a- reducing the P.O.F
b-reduce the magnitude of C.O.F
c-Enhance the survivelence of facility and people
d-Mitigate the primary source of consequence
2-This mitigation activates are
1-modified the equipments piping, redesign or rerating
2- Evaluate flaws for F.O.S
3-equipment replacement, repair
3 - Emergency action as
A-isolation capabilities by using isolation valves or remote control system
b-Depress ring or de inventory
4- Process modification to less hazardous fluids
5- Installing water system
1-Spray to reduce risk
2-Steam or air curtain
6- blast resistance construction as wall
7- Installing Spill detection and containment
8-Fire proofing, lining and isolation
9-Flow control and design improvements
10-Training
14- Reassessments and updating RBI assessments
1-RBI is dynamic tool can provide current and future risk evolutions which based on the current and knowledge. This evolution changed
with time goes and required updating for RBI assessment evolutions results
2-why conduct A RBI re assessment
the trigger key factors are
1-changes in deterioration mechanisms and inspection activates
Time base and given as rate may vary over time
2-changes in process and hardware changes
** Process as replacement the facility or modification
Example chloride stress corrosion cracks in S.S and wet H2S for C.S
** Head ware changes as change in design changes PDF
Changes n location near ignition source increased the consequence magnitude
3-RBI assessment premise changes
Change product values – revision safety –environmental laws—change material-replacement-repair facilities-population changes
4-Affect of mitigation strategies
the strategies monitoring the implantation of the desired mitigation activates and once finished to check the risk reduction by updating
the programs
1- When to conduct RBI re assessment
BEFORE
Making maintenance to use it in planning turnaround to focus the resources on high-risk items
AFTER
1- A-significant changes in process –facility-services
2-Set time period
3-Implementation of risk mitigation strategies
4-Inspection –maintenance –repair or modification
15 Roles, responsibilities, training and qualifications
1- RBI assessment is team process and required skill and background some of team full time and some part time
2-Team leader any one full time and stockholder responsible for
Formation of team and verifying the skill and knowledge of each
Assuring that study is conducted properly
Preparing study report and distribute it to decision makers and responsible for implementation of
Actions to mitigate risks
Follow up and assure that brisk mitigating has been implemented.
3-equipement inspectors or inspection specialist
Responsible for
a- gathering data for current condition and history for study
b- Implementation of inspection plan reconditions
Assessing the effectiveness of past inspection
Data unavailability and with the corrosion specialist to provide predications about current conditions.
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4- Materials and corrosion specialist.
Responsible for
a- Assessing all deterioration types and severity
b- Compare this assessment with the actual condition
c- Recommended the method for mitigation of P.O.F and methods to monitor the process
Process specialist
Responsible for
d- Documents variations in process conditions due to abnormal occurrences
e- Provide information about process condition in flow sheets
f- Descript the compos ion and variability of fluids and gases for flammability or toxicity
g- Recommended the process of mitigation
5- Operations and maintenance personnel
Responsible for
a- Provide information about occurrences when process deviated from the limits in operation envelope.
b- Verified the repair-replace-additions have been included in data
c- Recommended the process monitoring and modifications
6- Management
Responsible for.
a- give design on risk management based on RBI results
b- Provide all resources and sponsorship for RBI study
c- Follow up system to implantations of mitigation decisions
7- Risk assessment personnel
Responsible for
a-assembling data and carrying out analysis
b- defined data required and its quality
c-used the program to calculate the risks or calculate manuals
d-display the results in understanding ways and prepare the reports
9-environemental and safety personnel
Responsible for
a- Provide Data bout safety and environmental
b- Recommended ways to mitigate the consequence of failure
10- financial /business personnel
Responsible for
a- Provide data about cost
b- Recommended methods to mitigate the financial consequence of failure
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