RISK BASED INSPECTION STRATEGY

Select Plant Unit

C&I, CTS, Opn. - Full Time

FDC, Maint., HSE - Part Time Team Formation
Based on:
Pressure, Temperature, Velocity, pH. MOC,Corrosion rate, HIC,
Define Corrosion Loops SIC, Corrossive liquid

Based on Failure Probability:

List Loop Components e.g. Column Top, Colm. Bottom, HEx Shell. HEx
Tubes

Based on:
Generic - Literature, Experience at other locations
Identify Potential Failure
Licensor's Recommendations
Mechanisms & Occurence
Past History

A Prepare Risk Ranking Matrix

Regulations Decide Inspection Frequency Decide Process Parameters for Adoption of Risk Mitigation
Monitoring, Set Limits Measures
General, Localised,
Internal, External Decide Inspection Areas Fix Schedule & Responsibility
- Reduce Process Inventory
- Modify Process
Invasive, Online Sources: - Emergency Isolation
Decide Inspection Type
DCS, IP21, LIMS, Field Monitor defined Parameters - Eqpt. Redesigning
- Eqpt. Repair / Replacement
- Any Other
Prepare Inspection Checklist
No
Deviation from Operating
Prepare Inspection Schedule Window is beyond set limits?

Yes
Any Unexpected
Carry Out Inspection Failures?
No

Yes

No
FAR required?
Are findings consistent with No Yes

predicted probability of
Yes deterioration? FAR Process Corrective Repair

Revisit Corrosion Loop

Definition
A Contd in next page

Rev-1
 Factors:
- No. of available past Insp.
Observations
Inspection Confidence Ranking
- No. of Unexpected Failures
- Accessibility for Inspection
HAZOP/ QRA / Potential Scenario:
FMEA / ETA - Size of Flaw
Factors: - Extent of Rupture
- No. of Start / Stops
Plant Operations Confidence Ranking
- No. of Operating Window violations
Estimate Spread - Personnel Safety
- Environment
- Corporate Image
- Secondary Damage
Loss (Currency terms)
- Localized failure
Service :
- Production Loss
Corrosive Fluid
Abrasives
Pressure, Temperature, Velocity Probability of Failure A Consequence Category

Risk Ranking Matrix

Corrosion Rates
External Environment:
Proximity to corrosive environment
Proximity to Cooling Towers
Exposure to Rain / Humidity Date of Last Inspection
Insulation type / condition Adoption of Risk Mitigation
Measures

Equipment Condition Confidence Ranking

Factors:
- Design Thickness for Pressure
Overdesign Factor
- Minimum Structural Thickness

Factors:
- SCC
- HIC
- Embrittlement Failure Mechanisms
- Creep
- Fatigue