Risk Based Inspection (RBI)

Reducing Planned and Unplanned

Downtime while improving safety
Ricardo Santos, CPEng NER, CAMA, CPAM
Agenda

Why RBI?
What is RBI?
RBI Case Study
Q&A

Risk Based Inspection (RBI) 2

Why RBI?
Inspecting the right equipment
at the right time

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Safety and inspection

Reports by The International

Association of Oil and Gas
Producers have shown that
Asia/Australasia has one of the
best safety performances in the
world.

Worldwide, inadequate
maintenance, inspection
and testing was the
second leading cause of
accidents.

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2008: Varanus Island, WA

What happened?

A section of pipeline at a beach crossing was not

covered by the inspection programs. That section
corroded over the years, undetected, until it leaked
and caused and explosion.

What was the consequence?

A third of energy supply affected. Gas

shortages.

$60 million in direct damage, $3 billion dollar to

the WA economy.

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2010: Northern Territory

What happened?

A storage tank containing diesel fuel leaked from

its bottom and contaminated underground water
and soil.

What was the consequence?

$160,000 fine from NT government

$3,000,000 estimated on clean-up costs

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Legislative Requirements for Integrity
Management of Pressure Equipment

The Australian Workplace Health and
Safety Act
•Places a “Primary Duty of Care on
all businesses to ensure, so far as is
reasonably practicable, the health
and safety of workers at work”.
Petroleum and Gas (P&G) Act ,
Regulation
•Lists AS 3788 as a mandatory
code for management of in-service
inspection of pressure equipment
associated with Gas facilities.

•“the person with management or

control of pressure equipment at a
workplace must ensure that the
equipment is inspected on a
regular basis by a competent
person.”

•Code of Practice for Plant identifies

AS 3788 as the minimum
standard to ensure that
operators of Pressure
Equipment meet health and
safety requirements.

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Pareto Principle and Diminishing Returns

Risk Based Inspection (RBI) 8

What is RBI?

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What is RBI?

A risk assessment and management process that is focused on loss of containment of

pressurized equipment in processing facilities, due to material deterioration. These risks are
managed primarily through equipment inspection.

Typical Risk Matrix

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Where RBI can be used?

Equipment Categories covered:

• Fired Vessels
• Unfired Pressure Vessels
• Plant Piping Systems
• Pressure-relieving devices
• Blow-down and flare systems
• Storage tanks
Oil and Gas Chemicals • Pipelines and attachments
• Pig launchers and receivers
• Flow lines and gathering systems
• Wellheads and Christmas Trees
• Closed drains & atmospheric vents,
Soil-Air interfaces

Equipment Categories not covered:

• Fire-fighting equipment and

systems
Utilities Mining • Support structures including pipe
rack and piping supports,
Processing access/egress structures

Risk Based Inspection (RBI) 11

RBI Aligned with Organisation

Asset Management Policy

Strategic Asset Management Plan

Asset Management Plans

Standards

Procedures

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RBI within the Asset Management

Stakeholder
needs
RBI

Monitor and Demand

Review Management

Ops & Systems

Maintenance Engineering

Acquisition

Risk Based Inspection (RBI) 13

RBI Case Study

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Scenarios

Refinery and
CSG Operator Mining Processing
Chemicals
• 10,000+ wellsite • 2,000 assets • 20 pressure
separators to (pressure vessels vessels requiring
inspect every 4 and piping circuits) inspection every 4
years requiring years
• 40+ compression inspection every 4 • 400 storage tanks
trains to take years requiring
offline every 4 • 100 storage tanks inspection every
years requiring 10 years.
• 10 FTEs required inspection every • More than half of
to manage 10 years inspection are
inspection program • Management overdue and the
• Dozens of constantly regulator is
inspection crews challenges the pursuing action.
constantly need for inspection
mobilized

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RBI Methodology

Assess
Criticality

Group assets
Record by corrosion
loops

Agreed
methodology
Assess
Execute and workflow degradation
mechanisms
right from the
start

Prepare or Identify and

update monitor
Inspection operating
Plans variables

Calculate
probability
and
consequence
Risk Based Inspection (RBI) 16
RBI Study

1. Qualitative assessment of
criticality
• High
• Medium
• Low

2. Group assets by corrosion loops

• Same material
• Similar process conditions

3. Assess degradation mechanisms

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RBI Study - continued

4. Identify and monitor operating

variables

5. Calculate probability and

consequence
• Models for degradation rates
• Hole/crack size estimates
• Leak rate and duration
• Gas and Liquid dispersion
models

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RBI Study - continued

6. Prepare or update Inspection

Plans
Inspection
Inspection Intrusive Inspection Non-intrusive Inspection
Effectiveness
Category Example Example
Category

50 to 100% examination of
50 to 100% ultrasonic
the
scanning
Highly surface (partial internals
A coverage (automated or
Effective removed), and
manual) or
accompanied by
profile radiography
thickness measurements

Nominally 20% ultrasonic

Nominally 20%
scanning
examination (no
coverage (automated or
internals removed), and
Usually manual), or
B spot
Effective profile radiography, or
external ultrasonic
external spot
thickness
thickness (statistically
measurements
validated)
2 to 3% examination, spot
external
Visual examination with
Screenshot of GE APM, C Fairly Effective thickness
measurements
ultrasonic thickness
measurements, and
little or no internal visual
RBI logic tree examination

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Execution

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Typical Benefits on the first 3 years

95% to 100%
Compliance with
regulations*

16%
Reduction on
maintenance costs 25% 40%
reduction on Increase in
administrative asset
30% workload availability
Cost reduction of
inspection activities

* Gap shall require approval through deviation management Risk Based Inspection (RBI) 21
Commonly used RBI Software

• GE APM

• Reliasoft

• PCMS RBI Semi-quantitative

• PIMS technologies RBI

• Nexus IC from Wood Group Integrity Management (WGIM)

• Lloyd’s Register CAPSTONE RBMI

• RB.Eye and FAME+ from Bureau Veritas

• RiskWise from TWI

• API RBI from E2G

• CIRRAS III (which is a Brunei Shell owned IDMS with RBI functionality)

• Galiom

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Risk Based Inspection (RBI)

Reducing Planned and Unplanned Downtime while improving safety

Ricardo Santos
CPEng NER (Mechanical), CAMA, CPAM
API 580, API 577

More than happy to answer more questions

and discuss further. Write me at:
ricsantos@deloitte.com.au

Level 23, 123 Eagle Street, Brisbane 4000

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