Rbi masterclass fleming summit_ss

Saudi Aramco: Company General Use
Risk Based Inspection or RBI
1
Ganesh Smart
Ganesh.smart@outlook.com
Australia

2
AGENDA
 Introduction of RBI
 Workflow
 Data Analysis
 Assessments
 Reporting
RISK BASED INSPECTION

3
WHY DO WE NEED RBI?
 Many codes/standards based on LOF, not COF
 Reduce risk of high consequence failures
 Cost effective inspection and maintenance resources
 Shifts resources from lower to higher risk equipment
 Measure and understand the risks
 Measure risk reduction as a result of inspection practices

4
OBJECTIVES
 Determine the purpose of RBI
 Appreciate the benefits of RBI
 Understand the workflow and process
 Manage and execute an RBI program
 Analyze, interpret and report results
 Create inspection/equipment plans
 Influence maintenance and turnarounds

5
TEAM OBJECTIVES
•Tailor to plant operations
•RBI (Risk Based Inspection) of Pressure
Equipment to Avoid
 Failure of Plant
 Endangering personnel
 Environmental damage
 Business interruption losses
 Property damage

6
WHAT IS RBI?
•Risk Based Inspection (API RP 580)
• 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.
•Other Definitions:
 Strategic process for lowering risk and costs
 Manages equipment integrity
 Establishes risk levels for equipment
 Addresses life cycle value of equipment
 Time based to condition based inspection
 Optimizes inspection/maintenance

7
RISK BASED INSPECTIONS
IDENTIFY AND QUANTIFY THE RISK:
Risks considered are:
* Safety
* Environmental
* Business
The inspection is planned to reduce the risk based on
the factors creating the risk.
LIKELIHOOD
OF EVENT
X CONSEQUENCE = RISK

How RBI Works
• The LOF assessment indicates the damage mechanism, typical
locations and rate of development. The damage mechanism indicates
what inspection techniques should be used.
8

RBI Deliverable
9
Being risk based, the method requires consideration of both the probability of failure as well
as the consequences associated with failure. The methodology can be applied to process
equipment, structures and pipelines.
The main deliverable of an RBI study is an “ Inspection Programme” describing:

RBI Planning Process
10

11
INDUSTRY TRENDS TROUBLING
 Capacity creep in most process facilities
 Operating older plants without major replacements.
 Major losses are now dominated by mechanical (also
includes corrosion) failures.
 Move towards legislation based on risk criteria.

12
RBI Motivator
 A large percent of the total
unit risk is concentrated in a
small percent of the
equipment items.

13
STEPS
 Screen operating units to identify critical areas
 Estimate risk value for each equipment
 Prioritize equipment based on risk
 Create useful equipment inspection plans.
 Design an optimum inspection program
 Manage risk of equipment failures
 Reduce likelihood of failures
 Review consequences of failures
 Demonstrate cost benefit to the plants
 RBI Ever greening

14
WHAT IS RISK?
 Dictionaries define risk as the chance of a loss. This portrays risk as a
probability.
 Chronic risk is ongoing, long term, low level doses of a potentially
hazardous substance.
 Acute risk is short term, high intensity events that can cause severe
consequences.
 RBI focuses on acute risk.
•API 580 defines:
Risk: Combination of the probability of an event and its consequence. In
some situations, risk is a deviation from the expected. When
probability and consequence are expressed numerically, risk is the
product.

15
WHERE RBI / INSPECTION HELPS
Mechanical
Failure
41%
Process Upset
8%
Sabotage/Arson
3%
Unknown
18%Operational
Error
20%
Design Error
4%
Natural Hazard
6%
About half of the
containment
losses in a
typical
petrrochemical
process plant
can be
influenced by
inspection
activities

16
RISK MEASUREMENT
Eg. For Quantitative

17
RISK ACCEPTABILITY
 ACCEPTABLE – No requirement for additional activities based on current
inspection strategy.
 ACCEPTABLE WITH CONTROLS – Although risk is acceptable, additional/more
effective controls may be required.
 UNDESIRABLE – Additional controls must be implemented and their effect on
reducing risk evaluated.
 UNACCEPTABLE – Additional and more effective controls must be
implemented at the earliest opportunity.

18
RISK MEASURE Eg. of Quantitative
L
i
k
e
l
i
h
o
o
d
Consequence
10-5
10-3
10-1
10-7
103 104 105
10 102
Risk = 10
Risk = 1

19
RISK MATRIX
High Risk
Medium Risk
5
4
3
2
1
LIKELIHOOD
CATEGORY
A B C D E
CONSEQUENCE CATEGORY
Low Risk
Medium Risk
Medium High Risk
High RiskMedium high Risk

Risk Assessment Tasks
20

21

22

23
RISK MANAGEMENT
RISKLEVEL
AMOUNT OF INSPECTION
Uninspectable risk
Risk with typical inspection program
Risk using RBI

24
RISK CONTROLS
Losses($)Exp.
Quantify annual expenditure spent to avoid losses
 Inspection
 Maintenance
 Training
 Procedure
 Insurance

25
REDUCE RISKS
Losses($)
Exp.
Optimise expenses to reduce loss

26
RISK AND INSPECTION
 Inspection modifies risk by control
 Inspection optimization requires cost/risk analysis
 Risk evaluates value of information
 New technologies allow practical application of risk analysis
 Probabilistic modeling
 Computer simulation
 Computerized databases

27
INSPECTION COSTS & RISKS
 Equipment risk is a major factor contributing to operational risk, and the maintenance strategy adopted.
 Increase in inspection or maintenance intervals generally imply lower maintenance costs, but increased
“failure cost” because of higher associated probability of failure.
Optimum inspection interval defined as the having the lowest sum of maintenance and failure costs.

28
UNINSPECTABLE RISKS
 Human error
 Natural disasters
 External events like collisions
 Secondary effects from nearby units
 Deliberate acts like sabotage
 Hazardous materials handling
 Inspection method detectability

29
API 580 RBI COVERS
 Reactors
 Pressure Vessels
 Piping
 Furnaces
 Pumps
 Compressors
 Heat Exchangers
 Storage Tanks

30
API 580 RBI DOES NOT COVER
 Individual Components
 Instrument systems
 Control systems
 Electrical gear
 Machinery components
 Non-pressurized equipment

31
RBI Methodologies
 DNV-API 580, 581
 Shell RBI
 TWI – RISKWISE software
 AEA Technology – Operational Critical Assessment (OCA) software
 Aptech Engineering –Risk Directed Mechanical Integrity Program
(RDMIP) software
 WGIM – Nexus Integrity Centre
 GL Noble Denton Galiom software
 Meridium APM (Asset Performance Management) Software
 API RBI
 BV RBeye

32
RBI ISSUES
 Resistance to Change
 Inadequate Records
 Lack of Resources
 Risk Acceptance
 KPI data
 Internal versus Contractor
 RBI Validation

How do we measure Risk?
Acceptable Risk
Area
Very Low Risk
Area
High Risk
Medium-
High Risk
Medium
Risk
Low Risk
Probability
Consequence

Sq. ft / year
 PoF is expressed in frequency of occurrence
 or
 PoF = Number of Possible event / total number of events
 or
 Gff of 3.06x10-5 = 1 in 306,000 per year
Definition:
 Extent to which an event is likely to occur within the time
frame under consideration.

LOF or POF
 Introduction to Probability analysis
 Units of measure in POF analysis
• Definition:
 Extent to which an event is likely to occur within the time frame
under consideration.
 The chance that a given event will occur.
 Probability = Number of Possible event / total number of events
The probability of failure used in API RBI is computed as:
Pf (t)=gff. Df(t) .Fms
35

LOF or POF
• Generic Failure Frequency: A probability of failure developed
for specific component types based on a large population
of component data that does not include the effects of
specific damage mechanisms.
• Damage Factor: is the equipment specific adjustment factor
• Management Systems Factor: Adjusts the generic failure
frequencies for differences in process safety management
systems. The factor is derived from the results of an
evaluation of a facility or operating unit’s management
systems that affect plant risk.
36

Generic Failure Frequency
37

Damage Factor
38
• Definition:
• An adjustment factor applied to the generic
failure frequency to account for damage
mechanisms that are active in a component.
• The damage factor is determined based on the
applicable damage mechanisms.

Damage Factor
39

Management System Factor
40
• The API RBI procedure includes an evaluation
tool to assess the portions of the facility’s
management system that most directly impact the
probability of failure of a component.
• This evaluation consists of a series of interviews
with plant management, operations, inspection,
maintenance, engineering, training, and safety
personnel.
• A listing of the subjects covered in the
management systems evaluation and the weight
given to each subject is presented in next slide.

Probability Analysis
41
The Key Concepts of RBI
RISK = Probability of Failure X
Consequence of
Failure
GFF Item DFX
Age
Damage
type/rate
Insp.
effective.
Damage area
Item repair
Other repairs
Injury
Business int.
Env. clean up
The probability of failure used in API RBI is computed as:
Pf (t)=gff. Df(t) .Fms

Inspection and POF
42
The probability of failure can be managed....
By recognizing the types of damage that
different environments cause.
AND
By using the right inspection method at the right
location and right frequency.
AND
Addressing the mechanism before failure.

Probability Analysis
43
It should be noted that damage mechanisms are not the
only causes of loss of containment. Other causes of loss
of containment include but are not limited to:
seismic activity,
weather extremes,
overpressure due to pressure-relief device failure,
operator error,
inadvertent substitution of materials of
construction,
design error,
Sabotage.

Units of measure in POF analysis
• POF is typically expressed in terms of frequency.
• The time frame is typically expressed as a fixed interval.
• The frequency is expressed as events per interval.
• For a quantitative analysis, the POF may be categorized as one
through five.

Continuous Improvement in Asset
Operations
8
Developing Maintenance,
Inspection/ Monitoring
Program

S-RBI Process Flow – Examples
46

• Thank You
47

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