Inspections based on risks

1. INTRODUCTION TO RBI
& API 580
RBI Training Course
Module 01

2. Scope of the Training
Introduction to RBI
RBI Methodology Theory + with hands on exercises
Likelihood calculation
Consequence calculation
Case Study with the RBI software: refinery unit
Data preparation
Screening analysis
Detailed analysis

3. Agenda
Start End
1 09:00 12:30
12:30 13:30
2 13:30 15:00
3 15:00 17:00
4 09:00 10:30
5 10:30 12:30
12:30 13:30
6 13:30 17:00
7 09:00 11:00
8 11:00 12:30
12:30 13:30
8 13:30 17:00
9 09:00 11:00
10 11:00 12:00
11 12:00 12:30
12:30 13:30
12 Other Features 13:30 16:00
Lunch
Plant inspection plans Creating inspection plans from the RBI guidelines.
Reporting features / information output Extracting information from software
Model creation and data entry issues.
Detailed analysis - Data entry
Day 1
Introductions - Installations, Introduction to RBI
Detailed analysis - Data entry
Day 4
Lunch
Project Start up and Data Organization. Inventory groups and Corr circuits
Module
Other limit states
Day 2
Consequence theory and exercises
RBI Training Program. Breaks assumed during the day but not shown. Timing approximate.
Item Objectives
Lunch
Likelihood theory 2
Likelihood theory 3 Other likelihood models
Thinning: calculation principles and inspection updating
Likelihood theory 1
Other features
Establishing criteria and using the IP tool Inspection Planning using risk criteria
Consequence theory
Model creation and data entry issues.
Screening Analysis Introduction Using the screening tool
Lunch
Day 3

4. INTRODUCTIONS
(Name,
Organisation
type of work,
why interested in RBI,
English )

5. Presentation Topics - This Session
RBI History – API Standards
General Introduction
The benefits of RBI
What RBI is
How RBI fits within existing plant systems
Implementing RBI
Some case studies

6. RBI History
Probabilistic risk analysis techniques
Started in the nuclear industry (1970s)
Quantitative risk assessment (QRA) in the Process Industries
Canvey Island and the Rijnmond Report (1980s)
Software tools for QRA
Eg DNV-Technica develops SAFETI and PHAST risk assessment
tools (1980s)
ASME RBI principles overview document in 1991
API develops Risk Based Inspection Methodology (1990’s)
DNV main API sub-contractror
API Base Resource Document 581 (2000)
API RBI software
API RP 580 (2002)

7. RBI History
DNV develops ORBIT Onshore 1997-now
Some Reasons:
Need for a RBI software for all onshore installations
– API 581 focuses on refineries
Improved consequence calculations with PHAST link
Enhancements in likelihood calculation
– ORBIT uses equations for limit state implementation
Need for a robust software architecture professional
software development and maintenance
ORBIT is consistent with the API 580 RBI standard
ORBIT and API 581 share philosophy/technology
API RBI development by Equity Eng. (2002-now)
API RP 581 Update (2008)
API RP 580 Update (2009)

8. API Inspection and FFS Standards
Existing RBI FFS documents
API
750
API
510
API
570
API
653
API - BRD P 581
RISK BASED
INSPECTION
MPC
FITNESS FOR
SERVICE
RBI
API RP 581
FFS
API RP 579
Working
Documents
Research reference
Documents
New
Documents
ASME
RBI
API RP 580

9. Presentation Topics - This Session
RBI History
General Introduction
The benefits of RBI
What RBI is
How RBI fits within existing plant systems
Implementing RBI
Some case studies

10. A Typical Plant
Loading facilities
Processing to give
added value.
Storage and
export

11. Typical Operating Objectives
Operate safely and profitably
Maintain high availability and throughput.
Minimize shut downs.
Extending shut down intervals
Prevent/reduce leaks.

12. Class question?
What are the typical plant objectives here?

13. Typical Plant Issues
Challenges
Old Plants
Large, complex units
Integrated Feed Systems
Many degradation mechanisms
Raw material price

14. PROCESS CORROSION
- Continuously degrading integrity

15. Corrosion Principles
Corrosion rate is measured as weight loss per unit area
and is expressed in mils per year (mpy) or mm/y.
Corrosion Rates can be affected by:
Passivity forming protective surface films (including
corrosion inhibitors, paints and coatings)
Oxygen content
Flow velocity/rates
Temperature
pH effects (Low and High)
Contaminants/intermediates

16. Some Corrosives Found In The Process Industry
Water
Oxygen
Naphthenic Acid
Polythionic Acid
Chlorides
Carbon Dioxide
Ammonia
Cyanides
Deposits
Hydrogen Chloride
Sulfuric Acid
Hydrogen
Phenols
Dimer and Trimer
acids
Other

17. Low Temperature Corrosion
Below 500°F (260°C)
Occurrences
Inorganic compounds such as water, hydrogen sulphide,
hydrogen chloride, sulphuric acid, salts, etc.
Presence of water (even in very small amounts)
Electrolyte in hydrocarbon stream
Hydrocarbons in water streams creating acidic conditions
Solids .. Under deposit
Organic acids
Vapour Streams at water condensation points
Obeys electrochemical laws
Stable films can reduce or prevent corrosion

18. Low Temperature Corrosion
From Process chemicals
From Process contaminants
Not caused by clean hydrocarbons
Caused by inorganic compounds such as water, hydrogen
sulphide, hydrogen chloride, sulphuric acid, salts, etc.

19. High Temperature Corrosion
Above 500°F (260°C)
No water present
Result of a reaction between metal and
process ions (such as oxygen O-, sulphur S,
etc.)

20. High Temperature Corrosion
Important due to serious consequences
High temperatures usually involve high pressures.
Dependent on the nature of the scale formed
General thinning
Localized thinning (pitting)
Inter-granular attack
Mixed phase flow
Metallurgical changes

21. Situations Leading To Deterioration
Normal operation, upset, startup /shutdown
conditions
Material/Environment condition interactions
Many combinations of corrosive process streams
and temperature/pressure conditions.
In the absence of corrosion, mechanical and
metallurgical deterioration can occur.
Weather effects ….

22. Forms Of The Damage
General loss due to general or localized corrosion
Pitting attack
Stress Corrosion Cracking (SCC)
Metallurgical Changes
Mechanical damage
High Temperature Hydrogen Attack (HTHA)
Damage types occur with specific combinations of
materials and environmental/ operating conditions

23. SOHIC in soft base metal.
Stress-Oriented Hydrogen
Induced Cracking
In contrast to general
corrosion, SCC is very hard to
detect visually even when it
has progressed to an extreme
condition.
Stress Corrosion Cracking Detection

24. Types of Stress Corrosion Cracking
Chloride stress corrosion cracking (Cl-)
Nitrates
Caustic stress cracking (NaOH)
Polythionic acid stress corrosion cracking
Ammonia stress corrosion cracking (NH4)
Hydrogen effects (in steel)
Sulfide stress corrosion cracking SSC, hydrogen induced
cracking HIC, stress oriented hydrogen induced cracking
SOHIC
Hydrogen cyanide HCN
Others

25. High Temperature Hydrogen Attack (HTHA)
Carbon and low alloys steels exposed to hydrogen above
430°F (221°C)
Hydrogen Partial pressure above 200 psi (14 bar)
Dissociation of molecular hydrogen to atomic hydrogen
H2 - 2 H+
Atomic hydrogen permeation into the steel
Reaction of atomic hydrogen with carbon in steel
Formation of methane at discontinuities
API 941 recommended for new installation

26. Longitudinal Weld
Magnification: 500x Etch: 2% Nital
High Temperature Hydrogen Attack

27. Metallurgical And Environmental Failures
Temper embrittlement
Liquid metal embrittlement
Carburization
Metal dusting
Decarburization
Selective leaching
Grain growth
Graphitization
Hardening
Sensitization
Sigma phase
885 F embrittlement

28. Mechanical Failures
Over pressurization
Brittle fracture
Creep
Stress rupture
Thermal shock
Thermal fatigue
Incorrect or defective
materials
Mechanical fatigue
Corrosion fatigue
Cavitation damage
Mechanical damage
Overloading

29. Conclusions
There are many causes of equipment failures in the
process industry.
Many are common and well documented.
Other, less common deterioration mechanisms are not
well documented.
Deterioration is the result of metal and environment/
operating conditions combinations.
These combinations vary somewhat in different process
units.
Detection and characterization of the different forms is a
challenging and critical activity.

30. Tools exist to assist to assess the severity
of corrosion or determine the appropriate
materials of construction
For Example:

31. NaOH Chart

32. These Tools Are Generally Used By
Experienced Corrosion Engineers.
They can also be implemented in
software as corrosion evaluation
supplements

33. Determining Equipment Integrity
Requires information about the level of degradation:
Monitoring (Fluid corrosivity) and
Inspection (Wall condition)

34. “MONITORING” POSSIBILITIES
Monitoring
Fluid Composition/Quality
Pressure, Temperature, pH
Contaminants when relevant
Fluid corrosivity
Corrosion probes (e.g. Weight loss, electrical
resistance, linear polarization)
Function of protective systems e.g. inhibitor injection
Inspection: Pressure boundary condition checks, e.g.
Visual examination
Thickness measurements
Other checks

35. Non Destructive Examination
- Inspection

36. Selecting Inspection method. Factors to consider
Type of defect
General metal loss
Localized metal loss
Pitting
Cracks
Metallurgical changes
Location of defect
On the outside wall of an item
The inside wall
Within the body of the wall
Associated with a weld

37. Selecting Inspection method. Factors to consider:
Material of construction
Magnetic
Non magnetic
Operating at high temperatures
Insulated
Equipment geometry:
May be hard to access
May require extensive activity e.g. scaffolding,
entry preparations, to perform the inspection
Many considerations when determining how to
inspect.
Also, need to justify the need for inspection.

38. NDE Methods
American Society for Nondestructive Testing (ASNT)
Acoustic Emission Testing (AE) Volumetric
Eddy Current Testing (ET) Surface/ Volumetric
Infrared/Thermal Testing (IR) Surface
Leak Testing (LT)
Magnetic Particle Testing (MPT) Surface
Neutron Radiographic Testing (NR) Volumetric
Penetrant Testing (PT) Surface
Radiographic Testing (RT) Volumetric
Ultrasonic Testing (UT) Volumetric
Visual Testing (VT) Surface
Magnetic Flux Leakage (MFL)

39. Penetrant Testing
Penetrant solution is applied to
the surface of a pre-cleaned
component. The liquid is pulled
into surface-breaking defects by
capillary action.
Excess penetrant material is
carefully cleaned from the surface.
A developer is applied to pull the
trapped penetrant back to the
surface
The penetrant spreads out and
forms an indication. The indication
is much easier to see than the
actual defect.

40. Magnetic Particle Testing
A magnetic field is established in a
component made from ferromagnetic
material.
The magnetic lines of force or flux
travel through the material, and exit
and reenter the material at the poles.
Defects such as cracks or voids are
filled with air that cannot support as
much flux, and force some of the flux
outside of the part.
Magnetic particles distributed over
the component will be attracted to
areas of flux leakage and produce a
visible indication.

41. Radiography Testing
X-rays are used to produce images
of objects using film or other detector
that is sensitive to radiation.
The test object is placed between the
radiation source and the detector.
The thickness and the density of the
material that X-rays must penetrate
affect the amount of radiation
reaching the detector.
This variation in radiation produces
an image on the detector that shows
the internal features of the test object.

42. Ultrasonic Testing
High frequency sound waves are sent into a material by use of a
transducer. The sound waves travel through the material and are
received by the same transducer or a second transducer. The
amount of energy transmitted or received, and the time the energy
is received are analyzed to determine the presence and locations of
flaws. Changes in material thickness, and changes in material
properties can also be measured.

43. Ultrasonic Principles
Straight Beam
(Longitudinal Wave)
Angle Beam
(Shear Wave)

44. Ultrasonic Presentations
TOP VIEW
(C-SCAN)
END VIEW
(B-SCAN)
SIDE VIEW
(D-SCAN)
A-SCAN

45. Risk Based Inspection

46. Presentation Topics
General Introduction
The benefits of RBI
What RBI is
How RBI fits within existing plant systems
Implementing RBI
Some case studies

47. The Value of RBI
What is the first duty of Business?
“The first duty of business is to survive, and the guiding
principle of business economics is not the
maximisation of profit - it is the avoidance of loss.”
Peter Drucker

48. The Key Benefits of an RBI Study
Identify the high risk items
Understand the risk drivers and develop mitigation plans
Focussed inspection plans which:
Increase safety and reduce risk
Help to improve reliability
Often results in cost benefits due to:
Reduced turnaround time and/or
A reduction in the number of items to be inspected
The associated “maintenance” costs e.g access
arrangements
Normally an overall reduction in risk and cost savings
from the inspection activity.

49. Presentation Topics
General Introduction
The benefits of RBI
What RBI is
How RBI fits within existing plant systems
Implementing RBI
Some case studies

50. What Is RBI?
A method/process for prioritizing equipment for
inspection based on risk.
It determines the risk associated with the
operation of specific items of equipment and
identifies the key factors driving the risk.
A tool which demonstrates the value (or not) of
performing specific inspection activities.
It is a decision making management tool applied
to the issue of Inspection Planning.

51. Equipment Types
•Pressure Vessels—All pressure containing
components.
•Process Piping—Pipe and piping components.
•Storage Tanks—Atmospheric and pressurized.
•Rotating Equipment—Pressure containing
components.
•Boilers and Heaters—Pressurized components.
•Heat exchangers (shells, floating heads, channels,
and bundles).
•Pressure-relief devices.

52. Strategic Process
Increasing reliability (revenue)
Lowering cost
Lowering risk
Integrated Methodology
Risk factors
Likelihood
Consequence
Supports effective decision making
Risk Based Inspection

53. What Constitutes an Undesirable Event In RBI?
Failure is defined as a leak of the
equipment contents to the atmosphere;
“breach of containment” or LOPC
Heat exchanger failures are channel or
shell leaks.
Pump failures are due to seal leaks and
adjacent piping fatigue cracking.

54. RBI_Key_Concepts.vsd
Risk = Likelihood of Failure X
Consequence
of Failure
GFF DF
x
Age
Damage
Type/Rate
Inspection
Effectiveness
Damage Area.
Equip. Repair
Other repairs
Injury
Business Int.
x
Abbreviations:
:
DF: Damage
Factor
GFF: Generic Failure
Frequency
Fi : Process, Mechanical
Universal Factor
Fdomino:Domino Eff.Factor
MF: Management Factor
x
MF Fp x Fm x Fu
RBI - Detailed Analysis
Components in the calculation of the risk
Fdomino x CoF

55. Common Damage Mechanisms in RBI
Damage
Mechanisms
Internal
Thinning
Stress
Corrosion
Cracking
External
Damage
Brittle
Fracture
Piping
Fatigue
HTHA Lining PRVs
General
• HCl
• HT Sulfide.
Nap. Acid
• HT H2
S/H2
• H2
SO4
• HF
• Sour Water
• Amine
• HT
Oxidation
• Caustic
• Amine
• SSC
• HIC/SOHIC
• Carbonate
• PTA
• ClSCC
• HSC-HF
• HIC/SOHIC-HF
Cl SCC
CUI

56. Damage factor Calculation
MANUAL ACTIVITY
Estimate the likely
damage state /
severity
Consider data source
Assess the
inspection history
(Effectiveness)
Inspection Effectiveness
Determine the Likelihood of being in one
of the different possible damage states:
1 No worse than predicted X %
2 Up to 2x worse than predicted Y %
3 Up to 4x worse than predicted Z %
Damage states
Calculate the failure frequency for each
state using the relevant limit state
equation
Calculate the weighted failure frequency
for the item based on the Likelihood of
being in the different states.
Steps in Bayes_LoF
CALCULATING THE FAILURE FREQUENCY
Failures only occur when
the rate of degradation is
higher than expected.

57. Undesirable Consequences in RBI
HEAT from flames destroys equipment, injures people
PRESSURE WAVE from explosions knocks down
structures and people, causes flying objects
TOXIC cloud, for some duration, causes toxic
exposure injuries
ENVIRONMENTAL DAMAGE due to spill (currently
only included in AST RBI software)

58. Consequence Calculation
Physical
Properties
Process
Information
Equipment Damage
Costs
Business
Interruption Costs
Calculate Release Rate or Release
Mass
Equipment
Information
Safety
Costs
Assessment of Incident
Outcome
Damage Areas

59. Amount of Effort - RBI vs QRA
QRA*
RBI**
Likelihood Consequence
* Quantitative Risk Assessment ** Risk Based Inspection

60. Input Data For A Quantitative RBI Assessment
For some damage
mechanisms, e.g. SCC,
brittle fracture, fatigue,
other data may be
needed e.g. PWHT,
Charpy test temp.
What has been
looked for and
what has been
found
Is it
operating as
intended?
Identify
all items
The main input data collected
Item
OD Tnom Matl Ins Press Temp Fluid Temp. Press Fluid Mechanism Severity/rate Done? Result?
A Thinning,
SCC,
Furnace,
HTHA,..
B
C
Inspection data
Design Data Operating Data Damage mechanisms
What do we
expect to find
and what at
what severity?

61. RBI Results?
Why -
(Damage mech.
factor)
Where / How -
(Item - Effectiveness - Material - Mechanism)
When -
(Basis Inspection
planning targets.)
What -
(Risk priority)
Item
no.
Type From To Damage
Mechanism
GFF DF LoF CoF Risk Insp.
Type
Insp.
Date
New
DF
1 Pipe Thinning 3000
2 Vessel CUI 100
3 Fin Fan Erosion 0.5
Calculation of the risk with a lookahead: Inspection Plan

62. 5
4
3
2
1
High Risk
Medium-High Risk
Med. High Risk
Medium Risk
Low Risk
Likelihood
Category
Consequence Category
A B C D E
The Presentation Of Risk

63. A B C D E
Consequence of Failure
Likelihood
of
Failure
A
C
B
How Will This Picture Change With Time?

64. Risk Increase Over Time
Likelihood of failure
will increase over
time because of time-
dependent material
degradation
A B C D E
Consequence of Failure
Likelihood
of
Failure

65. What is the effect of Inspection ?
A B C D E
Consequence of Failure
Likelihood
of
Failure

66. Steps Leading To The Inspection Plan

67. Risk Criteria
High Risk
Negligible risk
Unacceptable region
The ALARP or Tolerability
region
(Risk is undertaken only if
a benefit is desired)
Broadly acceptable region
(No need for detailed working to
demonstrate ALARP)
Risk cannot be justified
save in extraordinary
circumstances
Tolerable only if risk reduction is
impracticable or if it cost is grossly
disproportionate to the improvement
gained
Tolerable if cost of reduction would
exceed the improvement
Necessary to maintain assurance
that risk remains at this level

68. Traditional Vs. Risk-Based Inspection Planning
Traditional
Inspection based on
experience (usually by
previous leaks and
breakdowns)
Inspection effort driven by
“Likelihood of failure”
Reactive “fire fighting”, running
behind the ball
Use of appropriate /
Inappropriate NDT techniques
RBI
Inspection based on
experience and systematic
(risk) review
Inspection effort driven by
“risk”, i.e. Likelihood of failure
and consequences of failure
Pro-active planning and
execution of inspections
Systematic identification of
appropriate NDT techniques

69. Change inspection frequencies (when)
Change inspection scope / thoroughness (what)
Change inspection tools / techniques (how)
Inspection Program Options for Influencing Risk

70. RBI - Applications
Risk-prioritized Turnaround planning
High safety/reliability impact = more attention (in order to
lower risk
Less impact safety/reliability = less attention (in order to
lower costs)
Result:
Lower equipment life cycle costs
Fewer incidents / outages
Fewer unnecessary inspections
Higher reliability
May also assess the impact of delaying a turnaround/
shut down

71. RBI - Applications
Special focus studies e.g.:
Corrosion under insulation.
Positive material identification.
Hydrogen sulfide etc.
What if studies e.g.
Assess the impact of process changes.
Assess the impact of a different feed.

72. Can RBI Help To Prevent All Releases?

73. Mechanical
Failure
43%
Process
Upset
11%
Sabotage/Arson
1%
Unknown
14%
Operational
Error
21%
Design Error
5%
Natural Hazard
5%
About half of the
containment
losses in a
typical
petrochemical
process plant
can be
influenced by
inspection
activities
Where Inspection Can Help
Source: Large Property Damage Losses in the HC-Chemical Industries - A thirty year review, 17th edition, JH Marsh McLennan.

74. THE SYSTEM FACTORS
HARDWARE SOFTWARE PEOPLE
Managing Risk - Considerations

75. Risk Exposures (Potential Losses)
ExperiencedLosses-CauseandCosts
0
50
100
%
and
MM$
Percentage
Avg.$loss
Percentage 43 21 14 11 5 5 1
Avg.$loss 72.1 87.4 68.9 81 55.7 82.5 37.1
M
ech.
Fail.
Operator
error
Unknown
Process
upsets
Natural
hazards
Design
errors
Sabotage
/arson
Source: Large Property Damage Losses in the HC-Chemical Industries - A thirty year review, 17th edition, JH Marsh McLennan.

76. The Equipment Involved
LossesvsEquipment Type
0
50
100
%
and
MM$
%oflosses
Avg.$loss
%oflosses 33 15 10 8 8 7 5 5 5 2 2
Avg.$loss 76.9 61.9 151.8 86.9 68.1 38.9 69.6 60.6 34.6 82.4 16.3
Piping Tanks
React
ors
Tower
s
Pump
s/Com
Drum
s
Heat
exch.
Unkno
wn
Misc.
Vesse
ls
Heater
s

77. Presentation Topics
General Introduction
The benefits of RBI
What RBI is
How RBI fits within existing plant systems
Implementing RBI
Some case studies

78. Managing Integrity
Trained and Competent Staff
Plant
Integrity
Plant Design
Operating
Maintenance
Procedures
Data
Data
analysis
Management System
Normally fixed.
RBI project
procedures.
Data Integrity is
essential!
Trained staff are
needed.
Cannot be
neglected!

79. Model For An MI System
System
Documentation
(Say what you do)
Documentation/
Records
(Document the actions)
Actions
(Do what you say)
FILING SYSTEM:
Asset Register
Design data
MI equipment
Inspection data
Operational data
Deficiency data
Inspection Plans
Repair information
Defect Assessments
Inspection due dates
TOP LEVEL
SYSTEM
DOCUMENTS
GENERAL
PROCEDURES:
WORK
INSTRUCTIONS
STANDARDS
ESTABLISH
SYSTEM
INSPECT
UPDATE/REVISE PLANS:
ASSESS THE
RESULTS
PLANNING
RBI

80. The Integrated Plan
INSPECTION PLANNING
06_Inspection Planning RBI role.vsd
The Inspection
Plan
Database
Corporate Philosophy
Local Legislation
Corporate Policy
Inspection Planning activity
i. Inspect
ii. Onsite assessment
iii. Detailed FfS if
needed
Update database
Codes and
Standards, RP's,
RAGAGEP
Monitoring
info.
General
Good
House
keeping
findings
RBI
analysis/
priotitization
Data analysis
Design
Inspection
Operation
Construction
DM's
Anomalies

81. Presentation Topics
General Introduction
The benefits of RBI
What RBI is
How RBI fits within existing plant systems
Implementing RBI
Some case studies

82. Typical RBI implementation
Define scope of RBI Study
Set up RBI team and train
Collect Data
Identify inventory groups (For consequences)
Identify Corrosion circuits
Perform Screening Analysis
Select high risk equipment items for Detailed Analysis
Perform detailed RBI analysis
Consequence data-Likelihood data
Run risk assessment Review the results
Develop action criteria
Discuss Orbit proposed inspection guidelines and run final
Translate into an actual inspection plan with schedule
Implement plan-perform inspections
Update the model with latest inspections

83. Risk Target and Inspection Planning
Inspection
Target
Risk
/
Damage
Factor
(DF)
Predicted Risk
Increase
Now
Time to next
inspection
Highly Effective
Risk / DF
1st
Turnaround
Fairly Effective
2nd
Turnaround
Time

84. Implementation Timeline (Tight Deadlines)
Equipment Data Collection
Risk Analysis and Prioritization
Inspection Program Improvements
Weeks 2 4 6 8
Effort
Evergreen
Level of Effort

85. Critical Success Factors
Defined objectives and planning
A robust working process to assure
efficiency and quality
A good knowledge of the RBI theory
Trained competent staff
A good understanding of the tools to be used.
“Evergreening” the process.

86. Types of Analysis
A qualitative unit analysis (API 581 for Plant Units)
Which unit or platform should be the first based on risk
A system screening analysis
Which piping systems need to be included
A qualitative circuit based analysis
A qualitative equipment analysis
A semi-quantitative circuit based analysis
A semi-quantitative equipment based analysis
A fully quantitative equipment based analysis.

87. THE STEPWISE APPROACH
Will be of most benefit to
a large facility just
starting on the journey.
This course introduces
the semi-quantitative
approach but focuses on
the quantitative.
These steps may be
formal or informal.
System Screening
- Determine which systems to be included
Semi-quantitative analysis of the
included equipment
Quantitative analysis of
high risk items
FfS/ CBA
of a few.
Facility Screening
- Determine where to start the study
Vision for the RBI Services.vsd

88. Qualitative vs Quantitative - COST COMPARISON
For repeat analyses the quantitative approach is far
more efficient.
The benefits multiply with time
Method
Est. total
hours
Hours on
Accum.
Hours
Value
Data Coll. Analysis Insp. plan insp plan
Qual. 310 10% 40% 50% 155 na 40
Quant 500 60% 10% 30% 150 na 100
Qual. 310 10% 40% 50% 155 620 40
Quant 200 15% 15% 70% 140 700 100
Second time around:
Initial Analysis
Activity
Proportion of the time spent on activity:

89. ADVANTAGES OF THE QUANTITATIVE APPROACH
Not simply opinion based-easily reproducible
Accuracy-Time model
The results of qualitative and semi quantitative studies are
frozen in time. In reality the risk will change as the
equipment ages and as new data is available from
inspection. The quantitative method incorporates this.
What if studies, e.g.:
New campaigns in swing plants
If the study had been done qualitatively or semi
quantitatively, the effort would be much higher
i.e. It is more efficient and powerful to use an analytical
approach

90. Presentation Topics
General Introduction
The benefits of RBI
What RBI is
How RBI fits within existing plant systems
Implementing RBI
Some case studies

91. Issue:
Should we change our feed to a cheaper
but more corrosive alternative?
What does this mean for our risks and
inspection requirements?
EXAMPLE STUDY 1

92. Risk
Inspection Interval
Corrosive Conditions
Tolerable Risk
Maximum Tolerable Risk
Changed Inspection
Frequency
Unacceptable Risk
Standard
Operating
Conditions
Example Study 1

93. Financial Risk Exposure
$34,793
$46,846
$26,421
$15,000
$25,000
$35,000
$45,000
$55,000
$65,000
0.1% 0.5% 0.8%
Corrosive in the feed
Financial
Risk
after
Inspection
($
per
year
per
equipment
item)
Example Study 1

94. Cost of Inspection
$0
$50,000
$100,000
$150,000
$200,000
$250,000
$300,000
$350,000
0.1% 0.5% 0.8%
% Corrosive in Process Feed
Cost
of
Inspection Example Study 1

95. The study gave the facility the information on:
The increased risk exposure
The increased cost of inspection
They compared this with the cost benefits of the cheaper
feed and made their decision.
Example Study 1

96. -$400,000
-$200,000
$0
$200,000
$400,000
$600,000
$800,000
$1,000,000
$1,200,000
$1,400,000
Unit 30 Unit 33 Unit 34 Unit 48 Unit 51
Current Inspection Costs
Current Maintenance Costs
Total Current Costs
RBI Inspection Costs
RBI Maintenance Costs
RBI Total
Total Savings
Example Study 2

97. Inspection
Maintenance
Total
Savings
RBI
Current
$0
$500,000
$1,000,000
$1,500,000
$2,000,000
$2,500,000
$3,000,000
COST BENEFIT ANALYSIS Results for all Units
Example Study 2

98. Cost effective decision making
for an older refinery with a
limited inspection history.
Example Study 3

99. Using The Financial Risk Values
Total Risk vs. Risk Rank
Refinery Process Unit, Top 10% Risk Items
$0
$200,000
$400,000
$600,000
$800,000
$1,000,000
$1,200,000
$1,400,000
0 10 20 30 40 50
Risk Rank
Risk,$/yr
Total Risk =
$11,500,000/year

100. Assess The Cost Benefits Of Inspection
Total Risk vs. Risk Rank
Refinery Process Unit, Top 10% Risk Items,
Same Items, Each with 1 M ore Inspection
$0
$200,000
$400,000
$600,000
$800,000
$1,000,000
$1,200,000
0 10 20 30 40 50
Risk Rank
Risk,
$/yr
Total Risk = $4,100,000/yr,
Savings = $7,400,000/yr
Cost = $250,000 (mostly piping,
approximately $5,000 avg. insp. cost)

101. The Risk of the Lowest 10% Items
Total Risk vs. Risk Rank
Refinery Process Unit, Bottom 10% Risk Items
$0
$200
$400
$600
$800
$1,000
$1,200
$1,400
$1,600
0 10 20 30 40 50
Risk Rank
Risk,
$/yr
Total Risk = $12,000/yr

102. The Inspection Benefits Here
Total R isk vs. R isk R ank
R efine ry Proce ss Unit, B ottom 10% R isk Items,
Same Items, Each with 1 M ore Inspection
$0
$ 200
$ 400
$ 600
$ 800
$1,000
$1,200
0 1 0 20 30 40 50
Ris k Rank
Risk,
$/yr
Total Risk = $4,300/yr,
Savings = $7,700/yr
Cost = $250,000 (mostly piping,
approximately $5,000 avg. insp. cost)

103. END