5/30/2015

RBI
RISK BASED INSPECTION
Presented by:
Mohammad Javad Ranjbar
5 May 2014

Outline

Introduction to RBI
•what is RBI
•what are the key elements of RBI
•how to implement an RBI program
•how to sustain an RBI program

RBI Softwares
• TWI - RISKWISE
• ReliaSoft – RBI

1
 5/30/2015

What is RBI?
Risk-based Inspection (RBI) is a methodology for
identification of high-risk equipment by review of
active/potential damage mechanisms and the suitability of
mitigation methods
RBI allows inspection/maintenance RBI systematical
evaluated both the probability of failure and the
associated consequence of failure.
Risk is the combination of the probability of some event
occurring during a time period of interest and the
consequences,(generally negative) associated with the
event. In mathematical terms, risk can be calculated by
the equation:
Risk = Probability × Consequence

RBI vs. Other Inspection Methods

Fixed Interval Condition Risk Based

Based
• STANDARD • TREND Analysis • RISK Analysis
Inspection
• Service Interval • Consequences • Probability &
not considered Consequences
• Backward Looking • Proactive
• Forward Looking

2
 5/30/2015

Objectives of RBI
Increase Availability
1 (reducing unplanned outages )

CATASROPHIC
FAILURE OF Improve Safety
STEAMLINE 2 )Ensure Safe Operation)
(JAPAN 2004)

Optimise Inspection
3 Costs

3
 5/30/2015

RBI Benefits and Limitations

• a) an overall reduction in risk for the facilities and
equipment assessed,
• b) an acceptance/understanding of the current risk.
RBI will not compensate:
• c) inaccurate or missing information,
• d) Design errors or faulty equipment installation,
• e) External events (e.g. Collisions or falling object)
• f) not effectively executing the plans,
• g) Secondary effects from nearby units
• h) lack of qualified personnel or teamwork,

Outcome of an RBI?

• Types of • Appropriate
damage Inspection
expected Technique

What? How?

When? Where?

• Inspection • Hotspot
Frequency locations

4
 5/30/2015

International Standards

API 580 / API 581 ASME PCC-3

CWA 15740 DNV-RP-G101

(Offshore topsides)

Type of RBI Assessment

Qualitative: Provides a broad-based risk assessment of
an operating unit or a part of an operating unit, required
less detail information about the facility. In this
assessment using engineering judgement and experience
for the analysis of probability and consequences of failure.
Quantitative: Provides risk values for each equipment
item and pipe segment in a operating unit, required
comprehensive detail information about the facility and
equipment. In this assessment using logic models,
likelihood and probability data to calculate the risk of
failure.
Semi-quantitative: Some were between either approach.

5
 5/30/2015

RBI planning process overview

1. Data Collection
 design and construction records/drawings:
— P&IDs, process flow diagrams, material selection diagrams (MSDs), etc.,
— piping isometric drawings,
— engineering specification sheets,
— materials of construction records,
— construction QA/QC records,
— codes and standards used,
— protective instrument systems,
— leak detection and monitoring systems,
— isolation systems,
— inventory records
— emergency depressurizing and relief systems,
— safety systems,
— fire-proofing and fire-fighting systems,
— layout;

6
 5/30/2015

1. Data Collection
 inspection records
— schedules and frequency,
— amount and types of inspection,
— repairs and alterations
— inspection results

 process data
— fluid composition analysis including contaminants or trace
components,
— distributed control system data,
— operating procedures,
— start-up and shutdown procedures,
— emergency procedures,
— operating logs and process records,

1. Data Collection
 Off-site data and information
— if consequence may affect off-site areas;
 Failure data
— generic failure frequency data
— industry specific failure data,
— plant and equipment specific failure data,
— reliability and condition monitoring records,
— leak data;
 Site conditions
— climate/weather records,
— seismic activity records;
 Equipment replacement costs
— project cost reports,
— industry databases;

7

1. Identification of Damage Mechanisms
2. Probability of Failure
Probability Information
1. Number of units and type of plant:
pressure vessel, tank, column,
pipework, heat exchanger etc.
2. Plant function: distillation unit, cat
cracker, storage etc
3. Plant processes: gas, hydrocarbon,
steam etc, number of planned and
unplanned interruptions per year
4. Process stability: rate stability from
a) very stable no known upset
conditions known to exist to b) loss of
control is inherent in process
5. Plant maintenance history: repairs,
modifications, quality of maintenance,
painting & insulation maintenance
5/30/2015
6. Material of construction: steel,
stainless steel, cast steel, aluminium
etc, any coatings
7. Damage mechanisms: what damage
mechanisms are known to occur or
have the potential to occur in the
plant. eg stress corrosion, brittle
failure, temper embrittlement, fatigue,
localised or general corrosion, creep,
others,
8. Inspection: dates, type (visual,
thickness, MPI, UT etc) and extent of
inspection, inspectability, inspection
results, corrosion allowance.
Effectiveness and management of the
inspection programme.
8

2. Consequence of Failure
Consequence Information
1. Fire: are external fire fighting
resources required for the most
serious event
2. Incident mitigation: which one:
i) gas detection systems,
ii) plant operated under inert atmosphere,
iii) secure fire fighting system,
iv) automatic or manual isolation systems
v) blast walls around high pressure
equipment,
vi) drain, dump or blowdown systems that
will deinventory plant
vii) fire proofing of plant strct. and cables
viii) available supply of fire water, hour?
ix) foam system or water curtain
3. Risk Analysis
RISK MATRIX: The LoF value is plotted on the
vertical axis, and the CoF value is plotted on
the horizontal axis, of the dimensionless 5×5
5/30/2015
3. Chemical data: relates to the
chemical’s tendency to ignite. What is
the flash point of the material, rate its
stability when unconfined.
4. Quantity: how much material could
be released in a single event
5. Chemical state: what is the process
temperature,what is the boiling point?
6. Commercial damage potential: what
is the value of plant within a 30m
radius, within 150m?
7. Toxicity: rate the toxicity from: a) no
hazard to b) death or major injury on
very short exposure
8. Population: number of people, on site
and off site, within 500m of release
point
9
 5/30/2015

4. Inspection Planning
When or before the risk target is reached, an inspection of the
equipment is recommended based on a ranking of the
component damage mechanisms that have the highest
calculated damage factors.

An inspection program is the combination of NDE methods

(i.e. visual, ultrasonic, radiographic etc.), frequency of
inspection, and the location and coverage of an inspection.

Inspection programs vary in their effectiveness for locating

and sizing damage, and thus for determining damage rates.

4. Inspection Effectiveness
Lack of coverage of an area subject to deterioration,
Inherent limitations of some inspection methods to detect and
quantify certain types of deterioration,
Selection of inappropriate inspection methods and tools,
Application of methods and tools by inadequately trained
inspection personnel,
Inadequate inspection procedures,
The damage rate under some conditions (e.g. start-up, shut-
down, or process upsets) may increase the likelihood or
probability that failure may occur within a very short time.
Inaccurate analysis of results leading to inaccurate trending of
individual components, and Probability of detection of the applied
NDE technique for a given component type, metallurgy,
temperature and geometry .

10
 5/30/2015

5. Mitigation
Reducing the POF, Primary source of consequence,
magnitude of consequence:
• Equipment Replacement and Repair
• Evaluating Flaws for Fitness-For-Service
• Equipment Modification, Redesign, and Rerating
• Emergency Isolation
• Emergency Depressurizing/Deinventorying
• Modify Process
• Water Spray/Deluge
• Blast-resistant Construction
• spill detector
• Fireproofing
• …….;

6. Reassessment and
Updating RBI Assessments
Why Conduct an RBI Reassessment?
• Damage Mechanisms and Inspection Activities
• Process and Hardware Changes
• RBI Assessment Premise Change
• The Effect of Mitigation Strategies
When to Conduct an RBI Reassessment?
• After Significant Changes
• After a Set Time Period
• After Implementation of Risk Mitigation Strategies
• Before and After Maintenance Turnarounds

11
 5/30/2015

RBI Softwares
RBI™ ORBIT™ S.RBI

RiskWISE™ RB.Eye
RB.QEye
FAME+

RBI Credo™ RDMIP™

RISKWISE™
Risk Based Inspection / Risk Based
Maintenance software

12
 5/30/2015

Demonstrator Contents
TWI Ltd is the sole owner of this software
demonstration show and may change this  System Overview
demonstration without issuing notice. No  Introduction
person or entity may reproduce or transmit  Ease of Use
 Access Controls
any part of the demonstration without written
 Knowledge-base
permission from TWI Ltd.
 Options and Settings
 Fluid Properties
 Nameplate Information
 Inspection History
 Damage Mechanisms
 Risk Factors
 Risk Summary
 Risk Profile
 Record Data Tables
 Record Properties
 Risk Mitigation
 Risk Comparison
 Inspection Plans
 Management Reporting
 Contact TWI

RISKWISE™ has a friendly Microsoft® style graphical user interface )GUI),

developed in Visual Basic using object-oriented design tools.
Microsoft®
Toolbar

Folder
Tree

Drag „n Drop
Table Sorting

Intuitive
Interface

Graphical
Navigation

13
 5/30/2015

RISKWISE™ is an API RP580 compliant risk- Features

based inspection (RBI) planning tool for use with Integration
RISKWISE™ is a second
pressure equipment, pipelines, power boilers generation client-server
and storage tanks. The risk model is semi- product, using the ODBC
quantitative, so it can be easily learned and is (Open DataBase
convenient to use. Connectivity) protocol for
SQL databases (eg
FoxPro, SQL Server,
RBI management systems are applied to: Oracle and Access).
Multi-lingual
 Improve the safety of critical plant RISKWISE™ is designed
to provide complete
 Reduce the duration of inspection outages multi-lingual capability
 Extend the interval between major for rapid native language
inspections implementation.
 Reduce direct inspection and maintenance
costs

RISKWISE™ enables the system administrator Features

Access Control
to control user access, tailoring it to the specific Three main levels:
needs of the inspection and maintenance  Read-Only
organisation. This allows simple control and  Proposal Write
auditability of previous assessment records.  Item Write Access
Auditability
The name of the
assessor undertaking the
RBI evaluations for each
item of equipment is
recorded, in compliance
with best practice
auditing principles.
Record Hierarchy
Proposed inspection
plans
RBI assessment results
which cannot be
changed or deleted

14
 5/30/2015

RISKWISE™ stores equipment nameplate Features

information in the Item Properties and Materials Item Properties
Captures general
screens. This information can be easily information about the
integrated with asset information in other equipment including
applications, via the in-built RISKWISE™ ‘Import drawings, design and
Wizard’. operating parameters.
Materials
Captures information
about the materials of
construction
components within
equipment or pressure
system.

RISKWISE™ contains an inspection knowledge- Features

base covering non-destructive testing (NDT) NDT
methods and comprehensive descriptions of The knowledge-base
covers visual, magnetic,
over 30 damage mechanisms (DM), including 20 ultrasonic, eddy current,
corrosive species leading to general and metallurgical,
localised corrosion and 10 species leading to radiographic,
thermographic, acoustic
stress corrosion cracking. emission and other non-
intrusive methods.
Damage Mechanisms
The common
mechanisms are
categorised in terms of
leading to „Metal loss‟,
„Environmental‟ or
„Metallurgical and
mechanical‟ damage.

15
 5/30/2015

RISKWISE™ allows users complete freedom to Features

undertake assessments in European, US Units
Define system wide
Customary units or User-defined units. System defaults for assessment,
administrators have the ability to define safety such as engineering
factors based on assessment consequence units of measure.
categories, for direct use in the derivation of Factors of Safety
Modify configuration of
equipment inspection intervals.
safety factors, that are
linked to the
consequence categories,
in the calculation of
remaining life indicators
for all damage
mechanisms.

RISKWISE™ assesses consequence of failure Features

generally in accordance with guidance provided Chemical Factor
A Flammability Factor is
in API BRD581 based on the fluid property used by RISKWISE™, in
classifications presented by National Fire combination with a
Protection Association (NFPA). Reactivity Factor, to derive
a Chemical Factor,
representing a fluid‟s
inherent tendency to ignite.
Explosion and Fire
RISKWISE™ assesses a
State Factor and the
Chemical Factor, in
accordance with the
procedure in publication
API BRD581.
Toxicity
RISKWISE™ employs the
NFPA ranking of the
probable severity of the
effects of a fluid on
exposure to personnel, in
the event of a release and a
fire.

16
 5/30/2015

RISKWISE™ captures all relevant historical Features

inspection and maintenance history in the Inspection Methods
Inspection Methods screen for subsequent use Captures relevant
in the identification of equipment damage historical information
including coverage and
mechanism prior to the risk assessment. findings, that will be
regularly updated
following future
inspections.
Inspection Plans
RISKWISE™ transfers
historical findings as well
as the proposed
inspection activities, to
the „Written Scheme of
Examination‟.

17
 5/30/2015

RISKWISE™ captures the location of all active Features

and potentially active damage mechanisms Checklist
within each item of pressure equipment. RISKWISE™ deals with
damage mechanisms
relevant to oil, gas and
petrochemical process
equipment, storage
tanks, pipelines, and
fossil fuel power boilers.
Remaining Life
Indicators
The estimated remaining
life of each damage
mechanism is assessed
within RISKWISE™, to
establish equipment
inspection intervals.

RISKWISE™ assesses seven likelihood Features

(probability) of failure factors and nine Time-based Risk
consequence of failure factors, for each item of Analysis
RISKWISE™ assesses
equipment. failure probability over
three forward periods of
time, for each active or
potentially active damage
mechanism.
Inspection
Effectiveness
RISKWISE™ assesses
the effectiveness of the
current inspection
program for each
damage mechanism
separately.

18
 5/30/2015

RISKWISE™ presents the results of the risk Features

analysis for each of the damage mechanisms, Risk Matrix
over the three forward time intervals, as well as RISKWISE™ plots each
the resulting remaining life indicator (RLI) which assessment point on an
API RP580 five-by-five
defines a safe inspection interval. risk matrix for risk
regions ranging from
„Favourable‟ to „Critical‟.
Limiting Damage
Mechanisms
The lowest RLI out of all
damage mechanisms
equates to the maximum
allowable inspection
interval for the
equipment.

RISKWISE™ provides a risk profile of all Features

equipment within the facility for the identification Summary
of critical and non-critical equipment. The distribution of risk
can be presented using a
risk matrix, pie charts or
bar charts as well as
comparatively, ie for
subsequent post-
assessment cost-benefit
analysis.

19
 5/30/2015

RISKWISE™ simply identifies critical equipment Features

as those items where the RLI is less than Table Sorting
current inspection period, and non-critical The results of the RBI
assessment are
equipment as those items where the RLI is presented in the
greater than the current inspection period! RISKWISE™ data tables,
which can be easily
sorted using the „drag „n
drop‟ column titles.

RISKWISE™ ensures that the individual authors Features

of each equipment RBI assessment are fully Auditability
traceable. RISKWISE™ enables
comprehensive tracking
of assessment results
and input assumptions,
in accordance with the
requirements of API
RP580.
Record Notes
RISKWISE™ includes a
simple “catch-all” free
text field for any other
information relevant to
the likelihood of
consequence of failure of
the equipment under
consideration.

20
 5/30/2015

RISKWISE™ presents RBI assessors with a risk Features

action plan from which the most suitable risk Action Grouping
mitigation options, for critical equipment, can be RISKWISE™ assigns the
most frequently used risk
evaluated. mitigating actions to six
groups, for ease of
evaluation during the
final inspection planning
and optimisation phase
of the RBI assessment.

RISKWISE™ allows the RBI assessor to Features

evaluate the impact of the proposed actions or Inspection Optimisation
The process of risk
inspection changes on risk and the remaining comparison within
life indicator (RLI). RISKWISE™ enables users to
systematically evaluate the
effect of actions on the risk of
failure, while considering the
constraints.
Total Savings = $1.1M
B/C Ratio = 11:1

$900k

$700k

$500k

$300k

$100k
Inspection
Savings

Production
Cost Savings
RBI

21
 5/30/2015

The final output of a RISKWISE™ assessment is Features

an optimised inspection plan )‘Written Scheme Reporting
of Examination’) which focuses on each damage RISKWISE™ presents a
detailed report of the RBI
mechanism. assessment for use by
field inspection
engineers, or in other
reports application as
necessary.

RISKWISE™ provides a post-assessment Features

analysis capability to evaluate the impact of Time Tracking
RISKWISE™ enables the
actions on the risk distribution for all equipment. user to assess the value of
RBI following successive
major inspections and
subsequent RBI updating,
eg. between Revision 0 and
Revision 1.

22
 5/30/2015

NEW
Released
Feature

RISKWISE 2014

RBI EXAMPLE
Quantitative Assessment of a Boiler

23
 5/30/2015

Application
Selection
Chosse boilers as
Oil,Gas and
Process Plant
Suite

Current Table
A table of current
revision records or a
table of all proposal
records can be
displayed by
navigating to these
screens via the
shortcut bar.
These lengthy tables
can be organised
and sorted by
dragging the column
titles to the top of the
screen, into any
ordered display
hierarchy:

24
 5/30/2015

Item Proposal
Once you have
specified the
equipment class,
(for example,
specify that a
particular pipe is a
Hot Reheat Pipe),
the list of expected
damage
mechanisms is
shortened
automatically to
display the types of
damage that might
be expected.

Item Properties
The entries on the
unit properties
screen determine
the risk associated
with various items
in boilers.

25
 5/30/2015

Item Properties
Enlarge the picture
to see the detailes
you have to enter.

Risk Factors
All of the items on
the Risk Factors
screen will be read-
only if the item
properties, damage
mechanisms and
inspection methods
screens are fully
completed. If you
need to change any
of these values you
will need to change
back to manual
mode

26
 5/30/2015

RISK Analysis
The assessment
points for each of the
three risk analysis
periods can be
toggled on or hidden
via the buttons on the
toolbar. For example,
if you wish to display
the assessment
points for the first
analysis period (1AP)
only, select the
buttons to HIDE 2AP
and HIDE 3AP. The
risk plot will then only
display 1AP ( )
assessments points.

Level 1
Assessment
The level 1
assessment is a
unit level
assessment to
assess a boiler as a
whole. To switch to
the level 1 view,
click on the
assessment level
toggle at the top of
the main screen.
When switching to
the level 1
assessment, the list
of items now only
shows units.

27
 5/30/2015

Home
You can right-click
on an existing unit
to create a
proposal, or create
a new unit or
proposal
from the links on
the home screen.

Unit
Proposal
Each unit has a set
of properties
associated with it
in a similar way
that other (level 2)
components have
an item properties
list. The proposal
record can be
viewed by double
clicking on it in the
items list.

28
 5/30/2015

Unit
Analysis

The analysis
screen shows the
business
consequence of
the major
components of the
boiler failure.

THANK YOU FOR YOUR ATTENTION

Your Questions Are Wellcomed …

mj.ranjbar@gmail.com

29