RBI in Major Plants

Presented by Eur.Ing. R.T.Canaway, B.Sc., F.I.Chem.E., Managing Director of Suregrove Limited +44-1737-813605 [email protected]

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Risk Based Inspection An Overview

Introduction:Risk Based Inspection, or RBI, is increasingly being promoted in the process industries as a means of optimising the costs of complying with statutory and other HSE obligations.

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What is the Purpose of Inspection?

Check the plant is fit for purpose Monitor the deterioration of vessel or piping

thickness Assess the REMAINING SAFE OPERATING LIFE say 5 years left Retire plant which is deemed not usable Examine failure mode

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The Inspector Must Be/Have

Able to undertake

his/her work without interference Competent Tools Records Able to trend thinning Or tolerances

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Why use RBI ?

Focus on Critical Plant to ensure the business is in a safe and profitable state

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Inspection Methods
Visual Penetrant Dye Testing finds surface flaws Radiography volumetric Magnetic Particle Flux Field Distorted Ultrasonic Testing planar and volumetric

Eddy Current AC near surface flaws

ACFM/ACPD Ultrasonic TOFD Time of size of flaw Testing - size of Flight Alternating Current Field flaw Diffraction all Measurement or Potential Drop details from 2 probes
ultrasound from upper and lower extremes of flaw

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Failure Modes
Corrosion/Erosion, Water, Chloride, High Temperature Sulphidation, V/L Impingement

Creep > 350oC High Temp Damage > 450oC - Cracks grow Embrittlement Stress Corrosion Caustic with T>70oC, Cracking
Ammonia, Chlorides H2 Partial P>5 bar, H2S Partial P>0.05 psia HCN/HF promotes

Fatigue Cracking Cyclic stressing - e.g. Toe of welds Brittle Fracture

OK if T > 0oC But not if T < 0oC

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Can use RBI to focus on:

Corrosion/Erosion If conditions are severe e.g. high PP of contaminant Thereby eliminating lower risk areas? Ignore systems where conditions are outside concern range? E.g. low T and no or low Contaminant PP Condition Monitoring Machine reliability not adequate Critical to production/safety Mechanical failure could lead to VCE? Ignore safe systems such as potable water pumping?

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Objective
The main aim of RBI, if properly carried out, is to manage the Risk of plant failure at an acceptable level. Risk = Likelihood x Consequence

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If the risk of failure of a component has an effect:

Assess the Risk in terms of: - Safety (Personnel? Fire?Toxicity?..) - Loss of Production? - Failure to meet Legislation? Then cost the risk of failure and its probability Or likelihood - Set Inspection Requirement and Frequency
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Then we can :
Eliminate unnecessary work? Reduce inspection work load Increase/Decrease Frequency of Inspection Save Time and Money

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The HSE will accept:

Goal setting safety legislation (UK in 1989

& 2000) has enabled a move towards inspection strategies based on the risk of failure. This legislation allowed a user/owner together with a nominated Competent Person the flexibility to decide a suitable written inspection regime based on system information and good engineering practice.
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Application:
The evolution to a risk-based approach has

been supported by specific process plant operating experience together with better knowledge of material degradation mechanisms and availability of fitness-forservice assessment procedures. Also, developments in NDT technology have improved inspection ability, performance and consistency.
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Major Plants
Industry considers there are benefits from

more informed inspection, particularly in refining & petrochemicals where they are now setting inspection priorities on the specific risk of failure. Benefits include: Improved inspection screening for high risk areas; Prioritising inspection based on measured risk;
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 Cost savings by stopping ineffective

inspection, extending inspection intervals and greater plant availability; Systematic management of risks associated with equipment failures.

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But!
Inspection is usually only one part of a

sites integrated integrity management strategy which also normally includes routine and preventative maintenance and they are usually linked within a common framework.

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What is Risk Based Inspection?

Risk Based Inspection is a systematic process that involves planning an inspection on the basis of the information obtained from a Risk Analysis of the equipment concerned. The purpose of the Risk Analysis is to identify the potential deterioration mechanisms and threats to the integrity of the equipment and to assess the consequences and risks of failure.

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Risk Analysis
Risk Analysis usually contains the following 6 stages: Identification of equipment failure scenarios Identification of potential deterioration mechanisms and modes of failure Assessment of the probability of failure from each mode/mechanism

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Risk Analysis
Assessment of consequences resulting from

failure Determination of the risks from failure Risk ranking and categorisation.

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Types of Risk Analysis

Qualitative; Semi-Quantitative; Fully Quantitative.

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Measuring Risk
Qualitative risk analysis is based primarily

on objective engineering judgements made by an RBI team. The Likelihood and Consequences of Failure (LoF & CoF) are expressed in relative terms, as below: Risks are usually expressed within a Risk Matrix.

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Measuring Risk
L.o.F: Very unlikely Possible Reasonably probable and Probable C.o.F: High Moderate or Low

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Typical Risk Matrix

5 Medium-High Risk LIKELIHOOD CATEGORY 4 3 2 1 Low Risk A B C D E CONSEQUENCE CATEGORY Medium Risk Medium Risk High Risk High Risk Med High Risk .

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Measuring Risk
Semi-Quantitative risk analysis determines

single numerical values for the probability of failure and the consequences from every cause and effect. Analysis of failure is more numerically based and detailed than the Qualitative approach, but may still include a large element of engineering judgement.

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Likelihood and Consequence X-Y Plot

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Measuring Risk
For a fully Quantitative risk analysis, the

likelihood and consequences of failure are determined for each scenario using standard reliability analysis methods with the total probability of failure evaluated using methods such as survival statistics. Results are normally presented on logarithmic probability-consequence plots.

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Iso Risk Lines

10-1

Likelihood

10-3 10-5 10-7 10 104 102 103 Consequence 105

Risk = 10 Risk = 1

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Measuring Risk
Whilst all these approaches to Risk

Analysis may be valid, the process and the data needs to be transparent and the use of non-validated software may be restricted. The risk analysis & measuring process must be consistent and able to be independently assessed.

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Definitions
Risk The risk of failure of an item combines the probability or likelihood of failure with a measure of the consequences of that failure:Risk = Probability x Consequence The Consequence of failure through the unintentional release of stored energy and/or hazardous material is the potential for injury, damage, lost production, pollution, reputation etc. These can be measured in a variety of ways fatalities, fines and compensation payments, bankruptcy, higher insurance premiums..
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Definitions cont.
Inspection in RBI is the planning, implementation and evaluation of examinations to determine the physical and metallurgical condition of equipment or a structure in terms of fitness-for-service. It is usually part of a company, site or facility Integrated Integrity Management Strategy for managing risk of failure which should still include conventional routine and preventive maintenance.
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Process of Risk Inspection

Risk Based Inspection is defined as a

logical and structured process of planning and evaluation as shown in the following flow chart for plant integrity management by RBI:-

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Definitions etc
In-service inspection is most valuable where there is uncertainty about the process operating conditions, their effect on materials, particularly where the conditions are such as to promote deterioration. Deterioration is defined as damage, defects or degradation from the design intent or the as-manufactured condition.
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Guidelines on Inspection Frequency

Guidelines have been published by various organisations giving guidance on good practice for setting intervals between statutory inspection of pressure equipment, 3 of these are: SAFeD (Safety Assessment Federation) - In 1997 SAFeD produced guidelines on extension of existing intervals.
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Guidelines on Inspection Frequency

CEOC (European Confederation of

Organisations for Testing, Inspecting, Certification and Prevention - recognised inspection intervals varied significantly within the EEC and basis is not one of risk and that it would be desirable to inspect on a variable throughout cycle life.

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Guidelines on Inspection Frequency

Institute of Petroleum In the IP Code of

Safe Practice proposed two interrelated concepts Grade Allocation and Sampling examination procedures. - allocation of grading depends upon assessment following 1st examination if rapid deterioration item is allocated a low grade (i.e. high failure risk). If reasonable deterioration and predictable then given less severe grade.
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Guidelines on Inspection Frequency

This is a semi-quantitative method for assessment of risk and recognises the importance of good information. The periodicity (in months) between inspections is set according to type of vessel and allocated grading as follows:-

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IoP Guidelines on Inspection

Equipment Pressure Vessels & Heat Exchangers Pressure Storage Vessels Protective Devices Grade Grade 0 1 36 48 Grade 2 84 Grade 3 144

60

72

108

144

24

36

72

~
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Guidelines on Risk Assessments

1. 2. 3. 4. 5.

The UK HSE published a Guide to Risk Assessment Requirements in 1996 intended for employers which set down 5 steps:Look for Hazards; Decide who might be harmed and how; Evaluate risks and review precautions; Record findings; Review assessment & revise if necessary.

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Guidelines on Risk Assessments

In 1999 the UK HSE published a discussion

document which described the assessment of risk process adopted by the HSE.
It also introduced the important concept of

tolerability i.e. the willingness of society to live with a risk etc

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Guidelines on Risk Assessments

CEOC produced guidelines* on a

Qualitative & Quantitative approach including historical and analytical approaches to estimating probability of failure they noted weaknesses of both methods and concluded improvement of both methods should continue and also building of data bases required.

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Guidelines on RBI
The UK HSE Hazardous Installations

Directorate issued an internal circular in 1999 as guidance for HSE inspectors for auditing plant inspection systems which adopt RBI.

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Guidelines on RBI
ASME issued an overview of RBI

1. 2. 3. 4.

principles in 1991 recommending a fourpart process:Definition of the System; A Qualitative Risk assessment; A Quantitative Risk Analysis; Development of inspection programme

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Guidelines on RBI
This ASME document mainly considered the theoretical approach to the problem detailing actual analysis methods i.e. FMECA (Failure Modes Effects Criticality Analysis), Structural Reliability & Risk Assessment (SRRA) and Probabilistic Risk Analysis (PRA).

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Guidelines on RBI
API 581 designed for the petroleum and

chemical industries was published in draft form in May 2000. It followed the same overall approach as ASME, aiming to:1. Define & measure level of risk; 2. Evaluate safety, environmental and Business Interruption risks; 3. Reduce risk of failure by effective use of inspection resources.
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Guidelines on RBI
The level of risk is assessed following the same procedure as ASME quantitative analysis applied after initial qualitative analysis. The qualitative analysis assesses each plant item in a 5 x 5 risk matrix. The likelihood of failure is determined from the sum of 6 weighted factors viz:Suregrove Limited 46

Guidelines on RBI
Amount of equipment within item; Damage mechanism; Usefulness of inspection; Current equipment condition; Nature of process; Safety design and mechanisms.

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Guidelines on RBI
The consequence of failure is divided into only two factors:1. Fire/Explosion; 2. Toxicity

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Guidelines on RBI
Risk is then calculated as the product of each consequence and likelihood for each damage scenario, the total risk for an item equated as the sum of all the scenario risks:-

Risks = Cs x Fs
where:S = Scenario Cs = Consequence of Scenario Fs = Failure frequency of Scenario
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Guidelines on RBI
RiskItem = Risks The inspection programme is then developed to reduce that risk. To do that one needs to establish:1. What type of damage to look for; 2. Where to look for damage; 3. How to look for damage; 4. When to look for damage.
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Guidelines on RBI
What and Where is established from design & process data and equipment history. How to look for damage by reviewing the damage density and variability, sample validity, sample size, detection capability of method and validity of future based on past observations. When to look for damage is related to estimated remaining life of item.

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Software Packages for RBI

There are many commercial software packages which vary in complexity but generally follow the semi-quantitative risk assessment methodology. 5 of these packages are listed below but a report prepared for the UK HSE did not specifically endorse any one and noted none of the methods used have been validated.

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Software Packages for RBI

They also noted their practical application is limited and they should only be used as a guide and not to replace risk assessment and inspection planning.
Akzo Nobel; Det Norsk Veritas (DNV); The Welding Institute (TWI); Tischuk; LMP Technical Services.

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RBI Team
In all but the simplest situations situations, RBI is best undertaken as a team activity similar to Hazop. Technical knowledge and experience should encompass; Risk assessment; Process hazards and failure consequences; Plant safety and integrity management; Mechanical engineering/metallurgy/design; Plant operation, maintenance & inspection history; Inspection methods/NDT effectiveness etc.
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RBI Team
Where there are significant Health & Safety

implications arising from equipment failure, the qualifications and competence of team members needs to be to a recognised professional standing. Where not available in-house duty holders will need to take advice from appropriate external experts and consultants.

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RBI Team
Ideally, the Team Leader should be independent

from the direct pressures of the site production function and should have appropriate seniority and authority. Good records need to be kept on how qualitative judgements and decisions were kept. In many cases the information required for a quantitative risk assessment either does not exist, or is not sufficiently accurate.

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Assessing Requirements for RBI

What reference has been made to published

information? What are the reasons/drivers for the risk-based approach? Is the availability and accuracy of information sufficient? Does the approach reflect the plant complexity and potential catastrophes? How do Integrity Management & Inspection link to plant operations? How is the documentation managed & controlled?
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Auditing the RBI Process

How often is the Management Process

audited and reviewed? Who carries out the audit and review? What aspects of the Management Process are covered; Is documentary evidence available to support each aspect? How has the Integrity Management process changed?
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RBI should not be used to:

Reactively spot check a Try to satisfy the system which has just Authorities been involved in a major accident Purely extend the period Just produce computer between maintenance output which is not turnarounds without good relevant to the job reason

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RBI will not solve:

Inadequate Design/Operation beyond intention/incorrect manufacture these are under Quality Assurance Deliberate damage/External factors such as storm, hurricane which exceed the design case

Failures caused by Wrong selection of presence of unforeseen materials or PMI failure presence of contaminants or pollution (perhaps intermittent occurrence)
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No Plant May Implement RBI if:

They have no records They cannot display the trends of the last inspections They are looking to save money only They have a poor loss record

Their Maintenance is inadequate

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RBI is useful:
In work prioritisation to focus on areas where business outage could be significant As a tool to help the company focus its resources Feedback in industry to highlight failure modes and educate other plants before failure To assess the risk to the business (in terms of loss of production)

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