CCS355 Neural Network & Deep Learning UNIT III notes and Question bank .pdf
Introduction to The Augustus Group and RBI
1. 1
Risk Based Inspection Plan
for MI Enhancement and
Optimization
A Cost Effective Solution for
Asset Preservation
2. The Augustus Group (TAG or Augustus)
Mission Statement
• Problem Solving
– Assist with Problem Definition and
Strategy for Solution
– Work with You as Part of Your Team
• Provide Project Management and
Engineering Consulting in our
Specialized Technologies
3. Huntsman
Chemical
BHP Refinery
Aimvenca &
Sincor
Jose Cryogenics
(PDVSA)
ENGEN Refinery
Altura Energy
Marathon
Ashland
HB Fuller
Condea Vista
Minh Foods
ABB Lummus
Global Santa Fe
NCRA
CVR Refining
Aristech
Chemical
AKZONobel
NASA
Chemical
Manufacturer’s
Association
Electric Power
Research Institute
BP Refining &
Chemicals
BP Upstream
Arco Chemicals
Engen Refinery
DSM CoPolymer
Orion Refinery
SK Chemical
Yukong Refinery
Eastman Chemical
Company
Transworld Pipeline
Williams Refining
Products and
Industrial Projects
Carghill Fertilizer
Services and Experience
Industries
Petroleum and Chemical Downstream
Oil and Gas Upstream, on-shore and off-
shore
Food and Pharmaceutical
Nuclear and Fossil Power
Waste Water Treatment
Principle Services
Risk-Based Inspection of Facilities,
Equipment, and Pipelines
Tank and Pipe line Integrity Management
and Risk Analysis
Incident Investigation &
Insurance/Litigation Support
Metallurgy, Corrosion Engineering &
Fitness for Service
Fire & Explosion Hazard Analysis and
Management
Environmental Impact and Remediation
Studies and Plans
Security Planning and Emergency
Response
Audits, Seminars, and Training
Regulatory Support
4. RBI & TA Planning, Petroleum and Chemical
Industry Examples on TAG’s Resume
Risk Analysis of Oman to India $6B Deep-water
Pipeline, Circa 1994
RBI Analysis of 650 Pressure Vessels, BHP Refinery,
Circa 1995
About 30 RBI Implementations Worldwide, 1995 - Present
Pre-TA Analysis of About 300 Pressure Vessels
Previously Not Inspected, 3 Mo. Prior to TA, $14M
Savings, Circa 2006
Risk Based Bolting QC Program, Two Mo. Prior to TA,
$MM no Leak Startup, Circa 2006
5. Most Companies Have or/are Making the
Transition
NFPA Diamond
Conventional
MI Program
API 570 Piping
Classes:
I – Highest potential
of immediate
emergency on leak
II – Not included in
other classes,
majority of lines
III – Flammable, but
do not significantly
vaporize on leak, and
not in high activity
area.
6. Most Companies Have or/are
Making the Transition
NFPA Diamond Discrimination
Engineering
Analysis
RBI
Expert
Opinion
High
Low
High
RCM
Risk Based Mechanical
Integrity Using FFS and
Advanced NDE When
Needed
Conventional
MI Program
API 570 Piping
Classes:
I – Highest potential
of immediate
emergency on leak
II – Not included in
other classes,
majority of lines
III – Flammable, but
do not significantly
vaporize on leak, and
not in high activity
area.
7. Most Companies Have or/are
Making the Transition
NFPA Diamond Discrimination
Engineering
Analysis
RBI
Expert
Opinion
High
Low
High
RCM
Consequence Ranking
ABCDE
1
2
3
4
5
ProbabilityRanking
HIGH
MED HIGH
MEDIUM
LOW
Risk Based Mechanical
Integrity Using FFS and
Advanced NDE When
Needed
Conventional
MI Program
API 570 Piping
Classes:
I – Highest potential
of immediate
emergency on leak
II – Not included in
other classes,
majority of lines
III – Flammable, but
do not significantly
vaporize on leak, and
not in high activity
area.
8. Risk Based Inspection (RBI) Provides
MI Program Definition
Focuses Limited
Resources on High Risk
Items
Substantially Reduces
Time & Money Spent
Compared to Traditional
Programs
Recognized & Accepted as
Good Engineering Practice
RBI Approach
Conventional Approach
9. Why Do we Do It?
Risk Based Inspection Planning For
On-stream Inspections
Optimization Of Outage or
Turnaround Scope
Risk Based Inspection Planning For New
Design Prior To Construction And
Operations
Application Of Risk Based Principals To
Management Of Degraded Equipment
Risk Based Inspection of Orphaned
Buried Piping
RBI/FFS of Bullet Tanks Suspected of
Caustic Cracking
Hazard
Screen
Risk
Benchmark
Inspection
Plans
Non-
Intrusive
Inspections
Opportunity
Inspections
Turnaround
Plan
Evergreen
Risk
Analysis
Turnaround
Inspections
10. Important Concepts
Three Parameters Define Risk
Scenario or what can go wrong
Probability of the scenario occurring or POF
Consequence if the scenario occurs or COF
Risk = POF x COF (parameters are not absolutes)
Inspections do not reduce risk, inspections:
Improve our state of knowledge of the POF
Provide information to manage potential damage that
could lead to failure
Risk-Based Inspection is Simply the Application
of Engineering Intensity to the Inspection
Function
11. Scenario - Initiation of Event and
Probability of Failure
Damage
Mechanism
Initiates, P1
Damage
Arrests
Damage
Continues,
P2
Damage is
Detected
Damage is
not
Detected or
Arrested
Damage
Continues,
P3
Damage
does not
arrest
Pressure
Boundary
is
Breached
Stressor(s)
Active
Mitigating
Factors &/or
Self Limiting
Nature of
Mechanism
Initiating Events
Effectiveness
of Non-Destructive
Examination
Damage
Continues
to Failure
(1-f2) = probability
damage will
be detected by NDE
Damage
Mechanisms are
Identified and Evaluated
Considering Process
Stream Conditions,
Metallurgy, and
Stressors
(1-f1) = probability
damage will
be mitigated
12. Scenario – Effect of Event and
Consequence of Failure
Pressure
Boundary
is
Breached
Leak is not
Arrested or
Mitigated
Leak
Continues,
P4
Leak
Disperses no
Con-
sequence
Leak Finds
Ignition
Source
Or Receptor
Destruction
Occurs,
P5
Leak
Arrests
Damage
Continues
to Failure
Effectiveness of
Detection System
Or Mitigation
Potential for
Finding
Ignition
Source or
Toxic Receptor
(1-f3) = probability
lleak will be mitigated
(1-f4) = probabability
leak will disperse
with no problems
Pinhole
or Minor Leak,
Subcritical
Defect or Leak, or
Gross Failure are
Evaluated for
Potential Damage
Mechanisms
13. How it Is Done?
For Success Will Need:
1. Management Commitment
2. Policy, Procedures
3. Tools (Management Systems,
SW, etc.)
4. Training and
5. Audit of Implementation
14. How it Is Done?
For Success Will Need:
1. Management Commitment
2. Policy & Procedures
3. Tools (Management Systems,
SW etc.)
4. Training and
5. Audit of Implementation
15. How it Is Done?
For Success Will Need:
1. Management Commitment
2. Policy & Procedures
3. Tools (Management Systems,
SW, etc.)
Management System for
Qualitative Analysis
Customized Integration
PHA Software
XLS/Access
SharePoint for Data
Management
Associated Apps
Inspection and Testing
Management System
RBI Software, e.g. Aptech,
Capstone RBMI, API,
Reliasoft, PCMS, Tischuk,
TWI, Orbit, etc.
Inspection Data
Management Software, e.g.
Ultra-pipe, 3-Rivers, etc.
Deficiency Resolution
Management System
4. Training and
5. Audit of Implementation
17. Qualitative RBI
Expert Judgment and Weighting of Qualitative Factors
Training Participants On Scope, Approach, And Details
Materials And Corrosion Analysis with Process
Segmentation
Qualitative Review With Plant Personnel
Reduction Of Data
Presentation Review Of Results and Inspection Plans
Final Report
Recommend Integration with PHA to Ensure
Continuous Improvement and Employee
Involvement
18. RBI Management System
Implementation Process
Equipment
Data
Collection
Process
System
Corrosion
Analysis
Qualitative
Analysis
Data Entry
Quantitative
Analysis
QC Audit and
Equipment
Integrity
Review
RBI Plan
Approval
Action
(Inspections
etc)
Results
Analysis
Criticality and
Plan Update
Plan
Document
Execute
Continuously
Improve
25. RESULT = 5x5 Matrix with History
Documented, For Use In Inspection Planning
Consequence Ranking
ABCDE
HIGH
MED HIGH
MEDIUM
LOW
1
2
3
4
5
ProbabilityRanking
Consequence
A-Catastrophic
B-Very Serious
C-Serious
D-Significant
E-Minor
Probability
1-Very High
2-High
3-Moderate
4-Low
5-Very Low
26. API RP 580 “Risk Based Inspection”
Supports 510, 570, and 653
with Detailed Broad Based
Guidance and Criteria
Provides Definition
What RBI is
Key Elements
How to Implement a
Program
No Preference to Single
Methodology
Further Legitimatizes RBI
Requirements for
Documentation and Record
Keeping
Training Program and
Certification in Conducting
RBI Analysis and Maintaining
the Program
QC/QA of the RBI Analysis
and Maintenance
Audits of the Program
27. Traditional MI vs RBI Implementation
Collect PFDs and P&IDs for Unit. – Identical Activity for
RBI
Create/Classify/Systems – Slight Modification to
Procedure for RBI Implementation
System Break PFD Using Traditional Methods
Collect MSDS Sheets For Each Major Stream As They Appear On
PFD
Consult With Process Engineer/Operator To Obtain Pressures And
Temperatures For Process Lines On PFD
Using Good Engineering Practices, And Accepted Procedures, Break
Major Systems At Locations That Best Achieve System Breaks IE:
Specs Break, Control Valves, Major Equipment Etc.
Transfer systems to P&IDs and add systems as needed
and line breaks per procedures. – Requirements
Essentially Identical for RBI Implementation
28. Risk Analysis - Qualitative Risk Analysis & Integration
with Process Hazard Analysis Using Agreed Upon Criteria
– Option to Use Quantitative Risk Based Software If
Desired on Select Items
Walk down P&IDs (redline as needed and make system
adjustments per field changes) and develop FIELD
INVENTORY LIST as it is in the field.
Develop System files for each system including MSDS
sheets and any other documentation collected to fortify
decisions made in systemizing. Classification is marked
for each system based on API 570 and MSDS /NFPA
flammability rating. – Identical Activity for RBI, Except
Potential Cost Savings and Potential to Focus on High
Risk Items if QRA is Done
Traditional MI vs RBI Implementation
29. Traditional MI vs RBI Implementation
Taking each system at a time, Develop ISOs for FE and Piping
(separate) for Visual, UT, and/or any other needed NDT. Identical
Activity for RBI; Potential Cost Savings and Potential to Focus on High
Risk Items if QRA is Done
Ensure Completeness and/or Build FE and Piping System Files –
Identical Activity for RBI
UT each FE item along with Visual (using pre-accepted Check lists) -
Identical Activity for RBI, Except Cost Savings Using Prioritization of
Assets
UT each Piping ISO including Visual (using checklists) - Identical
Activity for RBI, Except Cost Savings Using Prioritization of Assets
Enter data into data management program for review with client for
deficiencies and inspection planning. - Identical Activity for RBI, Except
Cost Savings Using Prioritization of Assets
Develop TROI list and/or NCR list for dispensation.
Analyze Data and Develop Inspection Plans for Future - Identical
Activity for RBI, Except Cost Savings Using Prioritization of Assets
31. $$-TAG Savings From FFS and RBI
Well Documented
Mid to Late 1990’s TAG Personnel Presented Cost
Savings (O&G Journal Article and NPRA)
Open Less FE Items Just For Inspection
Extend TA Interval
2009 - Well Quantified, Tesoro NPRA
TA Inspection Cost Savings Mo. 17, About $2.5M
PV Inspection,
Less RVs Maintenance
LESS UT/Year, About $600K
Safety, Environmental, and Lost Production Cost Benefits,
About $6.4M in Reduced Risk within 3 Mos Project
2012, Caustic Cracking Example, $5MM To $10MM
32. Delivered Benefits From Project
Inspection Method Current
inspections
Cost RBMI
inspection
s
Cost Projected
Savings
Delivered
savings
INSPECTION COST RECUCTIONS
Thickness reading inspection costs vessels -
annual savings
11,580 $231,600 5,790 $115,800 $115,800
Thickness reading inspection costs piping
circuits - annual savings
32,236 $644,720 8,000 $160,000 $484,720
Total projected thickness reading inspection
costs vessels and piping
43,816 $876,320 13,790 $275,800 $600,520 $600,520
(on going)
TURN AROUND SAVINGS
2006 Turn around savings from reduced
frequency of relief valve maintenance
370 $555,000 222 $333,000 $222,000 $222,000
(month 17)
2010 Turn around savings from reduced
frequency of relief valve maintenance
370 $555,000 222 $333,000 $222,000
2006 turn around savings from reducing the
number of pressure vessels to be opened for
internal inspections
261 $5,220,000 183 $3,660,000 $1,560,000 $1,543,000
(month 17)
2010 turn around savings from reducing the
number of pressure vessels to be opened for
internal inspections
261 $5,220,000 183 $3,660,000 $1,560,000
RISK REDUCTION
10 year reduced risk of equipment
failure
$13,510,000 $6,373,000
(To date!!)
34. RBI Inspection Plan
The RBI Inspection Plan must use the
risk assessment to determine:
When to Inspect (Interval)
What to Inspect (Scope)
How to Inspect (Method)
This must be done in a way that ensures that the
same risk values yield the same actions every
time.
35. Top 5 Reasons for Disappointment
with RBI
1.
2.
3.
4.
5. The consultants didn’t understand our
plant or our systems
36. 1.
2.
3.
4. RBI was too complicated for the
company team members
5. The consultants didn’t understand our
plant or our systems
Top 5 Reasons for Disappointment
with RBI
37. 1.
2.
3. Problems with basic plant data
4. RBI was too complicated for the
company team members
5. The consultants didn’t understand our
plant or our systems
Top 5 Reasons for Disappointment
with RBI
38. 1.
2. Lack of buy-in by some or all of the
organization
3. Problems with basic plant data
4. RBI was too complicated for the
company team members
5. The consultants didn’t understand our
plant or our systems
Top 5 Reasons for Disappointment
with RBI
39. 1. No measurable return on investment
2. Lack of buy-in by some or all of the
organization
3. Problems with basic plant data
4. RBI was too complicated for the
company team members
5. The consultants didn’t understand our
plant or our systems
Top 5 Reasons for Disappointment
with RBI