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Table of Contents
Appendices
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Table of Contents
Revision History
Version
Date
Author
Description
30-Ago-2007
V. Nihalani
Initial draft
15-Sep-2007
M. Gurley
16-Feb-2008
M. Gurley
16-Mar-2008
M. Gurley
10-Ago-2008
D. Rodas, M.
Gurley
13-Sep-2011
D. Rodas, F.
Perillo
Chapter 1
Introduction to RBI
Page 1
It is often said that, 80% of the risk is associated with less than 20%
of the Equipment. Thus, in order to optimize the utilization of finite
Inspection resources, companies deploy their Inspection resources on
their most critical equipment.
Page 2
Page 3
1.1.7 Evergreening
It is important that the RBI Process be an evergreen process. Most
often, companies invest a lot of time and resources performing an RBI
study for an upcoming Turnaround, but then fail to update the study
on a regular basis. Since RBI is essentially a condition-based
inspection program and equipment conditions change over the life of
the equipment, RBI studies should be updated as the equipment or
process conditions change. As equipment conditions change, an RBI
assessment should be re-evaluated. Companies often define Trigger
Points that necessitate an RBI re-analysis. These trigger points may be
either new Inspection data or changes in the process or process
excursions. The RBI process should be integrated with other processes
such as the MOC, PHA and CPP (Critical Process Parameter)
processes. This methodology can be particularly useful when
optimizing the scope of work for a turnaround/Shutdown.
Page 4
Page 5
1.1.13 Conclusion
The RBI method of comparative risk ranking provides a useful tool to
deploy resources more efficiently and make better manpower staffing
decisions.
Page 6
Page 7
Page 8
Page 9
1.3.1 Summary
API 580 lays the groundwork for a well rounded successful RBI
program. Using this document as a base resource will help to
understand the fundamental parts that make up the overall RBI
program. Once these principles are applied, API 581 can be used as a
tool to help determine which specific methods to use. At the end of the
RBI assessment, the company has a better understanding of the
process, the associated damage mechanisms, and the risk associated
with it. Good documentation not only helps companies during audits
but also helps keep the analysis alive.
Page 10
Probability Categories
11
High
Medium-High
16
13
Risk Ranking
Medium
Low
20
17
14
23
21
18
15
10
25
24
22
19
12
E
D
C
B
A
Consequence Categories
Page 11
Page 12
Phase Three: Identify Risk Mitigation Alternatives - Highrisk equipment is examined and different risk mitigation
alternatives are investigated. These alternatives might include a
more sensitive Inspection Plan, Equipment Re-design,
Equipment replacement, Equipment repair, or in some extreme
cases a Change in Process.
Page 13
Page 14
Page 15
Page 16
Chapter 2
Degradation Mechanism
Evaluations
Page 17
2.1 Introduction
During the Risk Assessment of an RBI Component, one of the main
tasks is to perform Degradation Mechanism Evaluations. These
evaluations take into account a host of different information depending
on the specific mechanism being evaluated and run that data through
stored calculations within the Meridium software. The objective of
these evaluations is a Probability Category for each Potential
Degradation Mechanism (PDM). These Probability Categories are then
used in conjunction with the Consequence Categories to determine the
overall Inspection Priority. Consequence Evaluations are covered in
Chapter 3. This section will discuss the methods that are used to
evaluate each damage mechanism. The calculations and decision
sequences that are shown in this chapter are automatically computed
by the Meridium software. They are displayed here to explain how the
data input is being used in these evaluations.
Page 18
CRLT
CRST
o
o
o
o
Vbase - Vlast
=
Where
Dbase - Dlast
Vnear Vlast
Dnear - Dlast
Where
Page 19
Fundamentally, the Design Code choice determines what Allowable Stress tables are
applicable. The Material Specification is a pick list of the materials listed in the Allowable
Stress table for the chosen Design Code. The Material Grade is a pick list that is based on the
choice of Material Specification.
First, the user selects what Design Code applies:
o ASME VIII Div 1
o ASME B31.3
o API 650
o Null
If Null is chosen for Design Code, then the user can enter the Allowable Stress, Material
Specification, and Material Grade manually. If the Design Code is not Null, then the
Material Specification and Material Grade must be selected from the pick-lists.
The Allowable Stress is a look-up based on the choices of Design Code, Material
Specification, Material Grade and Design Temperature. The determination of Allowable
Stress for Storage Tank Bottoms, however, is based on Material Specification and Material
Grade selections, but not Design Temperature. In addition, there is an Override option that
will permit manual entry of Allowable Stress.
Joint Efficiency is also selected from a pick-list. The default value is 1.00.
Page 20
1 <= CF < 10
CF >=1000
In order to account for over design, the final Internal Corrosion Probability Category
(ICPC) is lowered by one category (the numeric ICPC goes down one Rank) if:
- The Corrosion Rate is less than 0.127mm/year
and
- The wall ratio is greater than 1.5
Page 21
Coating Factor
Age Adjustment
Best
-10
Average
-5
None
.2
-1
Insulation is visually inspected and graded with an Insulation Condition. The resulting
Insulation Condition is used to apply a Corrosion Rate Adjustment, as follows:
Insulation Condition
Good (G)
x 0.5
Fair (F)
No adjustment
Poor (P)
x 1.5
Page 22
Asbestos
x 1.5
No adjustment
x 0.75
x 0.75
x 0.50
A Corrosion Rate Adjustment is applied to account for Local Humidity. Local Humidity
may be either atmospheric or resulting from the proximity of equipment to a cooling tower.
If atmospheric humidity is High, then the corrosion rate is adjusted higher by a
factor of 50%.
If the equipment is located within 50 yards of a cooling tower, then the user-selected
humidity factor should be raised by one category.
The External Age and Corrosion Rate are used to calculate Wall Loss.
Wall Loss divided by the Initial Wall Thickness results in Fractional Wall Loss.
Wall Remaining is obtained by Estimated Wall Loss from Initial Wall Thickness.
Number of inspections
Inspection Confidence (Very High, High, Medium, Low) Based on inspection history
Page 23
1 <= CF < 10
CF >= 1000
In order to account for over design, the final External Corrosion Probability Category
(ECPC) is lowered by one category (the numeric ECPC goes up one Rank) if:
- The Corrosion Rate is less than 0.127mm/year
and
- The wall ratio is greater than 1.5
Page 24
Page 25
Caustic
Cracking
Amine
Cracking
(ASCC)
Polythionic
Acid SCC
(PTA)
Chloride (Cl-) concentration 5 - 25 ppm, dissolved O2 < 0.1 ppm, pH >= 9.0,
temperature > 120F
Carbon steel at temperatures > 200F and < 30% caustic concentration,
PWHT of CS welds and bends.
Carbon steel not PWHT and MEA all concentrations and temperatures or
DEA/MDEA > 140F
Carbon steel not PWHT and MEA and operating temperatures of 125 - 150F
for all types of amines
Sensitized austentic SS are likely when: surface has iron sulfide scale,
operating temperature > 800F process upsets with air and water ingress,
poor caustic wash procedures
A chance for sensitized austentic SS and thermally stabilized 321 and 347
when: surface has iron sulfide scale, stable operation (no process upsets),
good caustic wash procedures
Page 26
0
>0
N/A
Low
N/A
No
Initial Potential
Initial Potential
>0
Low
Yes
Very High
Yes
>1
Very High
Yes
High
Yes
>1
High
Yes
Two Categories
Higher than Initial
Potential, up to High
Medium
Yes
>1
Medium
Yes
Two Categories
Higher than Initial
Potential, up to High
Very High
No
Page 27
# Prior
Environmental
Cracking
Inspections
Damage
Current Potential for
Inspection Found
Environmental
Confidence (Last
Cracking
Inspection)
>1
Very High
No
High
No
>1
High
No
Medium
No
>1
Medium
No
Low
The corrosion factor for environmental cracking is then calculated by using the current
potential for environmental cracking and the adjusted years since the last inspection. Based
on these values, Pressure Minimum Thickness can be calculated:
ECCF = f (POTcurrent, , Yadjusted))
where:
1-9
10 - 99
100 - 999
1000+
Page 28
Mechanical Fatigue
Temper Embrittlement
Liquid Metal Embrittlement
Graphitization
Brittle Fracture
Carburization
Creep
Erosion
Hot Hydrogen Attack
Hydrogen Embrittlement
Phase Change Embrittlement
Stress Corrosion Cracking
Thermal Fatigue
Clients have the ability to add additional degradation mechanisms that can be evaluated in a
similar qualitative manner.
Page 29
Page 30
Having such guidelines available provides the RBI Analyst with the necessary information
that facilitates ranking POF categories in a consistent manner.
Page 31
Chapter 3
Consequence Evaluation
Page 32
3.1 Introduction
As discussed in Chapter 2, the two main parts of an RBI Risk
Assessment are Degradation Mechanism Evaluations (covered in Chapter
2) and Consequence Evaluations. When evaluating Consequences of
failure for an RBI component we are not concerned with the mechanism
(i.e. internal corrosion, CUI, crackingetc) but the overall consequence of
the failure. Because of this, once all of the consequences have been
evaluated the worst case consequence scenario (in conjunction with the
Probability Category) is used as a basis for determining the Inspection
Priority/Risk Ranking. The following sections explain in more detail the
different Consequence Evaluations performed within Meridium.
2)
3)
Page 33
5)
These basic concepts will be covered in subsequent sections. Some additional factors will
also be considered for heat exchanger bundles and storage tank bottoms.
Page 34
Page 35
Ql = f ( , A, P )
where:
Ql = Liquid mass flow
= Liquid density
The Gas Release Rate with Sonic Flows is a function of the following variables:
Qv = f (T, A, Cp/Cv)
where:
Qv = Gas Mass Flow
T = Upstream Temperature
A = Cross-sectional Area of hole
Cp/Cv = Ratio of Heat Capacities
where:
Qv = Gas Mass Flow
P = Upstream Pressure
T = Upstream Temperature
A = Cross-sectional Area of hole
Cp/Cv = Ratio of Heat Capacities
Page 36
Liquid
Liquid
Model as liquid
Gas
Gas
Model as gas
Gas
Liquid
Model as liquid
Gas
Liquid
Page 37
Page 38
Page 39
where:
Page 40
Consequence Category
> 464,515.2
46,451.5 464,515.2
4,645.2 46,451.5
464.5 4,645.2
< 464.5
Page 41
Page 42
Qr = f ( , LFA, Qt )
where:
= Liquid Density
Qr = f ( , LFB, Qt )
where:
= Liquid Density
Page 43
Consequence Category
> 464,515.2
46,451.5 464,515.2
4,645.2 46,451.5
464.5 4,645.2
< 464.5
Page 44
For example, if a product has a product unit price of 5000SAR and the downtime caused by
a failure is 24 hours and the Product Throughput Rate Impacted is 5 metric tons per day and
the overall estimated then the calculated result would be (5000 X 24 X 5 = 600,000SAR)
The following ranking guidelines are recommended while Performing Economic Impact
Consequence Evaluation:
Consequence Category
Description
Economic Impact
Catastrophic
Very Serious
Serious
Significant
Minor
Page 45
Environment
Release/Spillage
Environment
Release/Spillage
Environment
Release/Spillage
Environment
Release/Spillage
Environment
Off Spec
Discharge
Environment
Off Spec
Discharge
Environment
Off Spec
Discharge
Page 46
Environment
Other
Environment
Other
Environment
Other
Environment
Other
Environment
Other
Page 47
Flammable
Toxic
Major
Minor
Page 48
Then Flammable
Consequence
Category is:
Major or Minor
Liquid or Gas
Major
Gas
Minor
Gas
Major
Liquid
Minor
Liquid
Major
Liquid or Gas
Minor
Liquid or Gas
Page 49
Then Toxic
Consequence
Category is:
Major or Minor
Liquid or Gas
Major
Liquid or Gas
Minor
Liquid or Gas
Major
Liquid or Gas
Minor
Liquid or Gas
Major or Minor
Liquid or Gas
Description
Catastrophic
Very Serious
Serious
Significant
Minor
Page 50
*Note Inspection Interval refers to an estimated time that the equipment would be normally
opened such as a re-occurring turnaround or cleaning cycle. This is an estimate, so there is
no need to change this value based on precise inspection intervals that are calculated.
**Product refers to whatever process fluid is currently contained within the piece of
equipment.
Page 51
Page 52
Page 53
No safety/health impact
Page 54
Chapter 4
Risk Ranking
Page 55
Page 56
Probability Categories
11
16
13
20
17
14
23
21
18
15
10
25
24
22
19
12
E
D
C
B
A
Consequence Categories
Risk Ranking
Inspection Priority
High
1-5
Medium High
6 - 12
Medium
13 - 19
Low
20 - 25
Page 57
Page 58
Page 59
Chapter 5
Inspection Strategy
Management
Page 60
Environmental Cracking
Environmental Cracking
Inspection Priority
1-5
LC19
1st
Inspection?
6-12
LC191
LC20
1st
Inspection?
13-19
LC201
LC21
1st
Inspection?
20-22
LC211
LC22
1st
Inspection?
23-25
LC221
LC23
1st
Inspection?
LC231
These logic trees have been entered as strategies within the Meridium software. After
performing a risk assessment for an RBI Component the strategies are executed and the
appropriate inspection scope is recommended based on the logic case that the decision
making process ended on (i.e. for the tree above if the inspection priority is a 3 and the
half life is less than 2 years then logic case (LC) 10 would be used to generate a
recommended inspection scope). For a detailed explanation of these strategies refer to the
SABIC_STRP4 RBI Strategy Management document.
Copyright Meridium, Inc. 2002-2011. All rights reserved.
Confidential and proprietary information of Meridium. Published Sep. 2011.
Page 61
Chapter 6
RBI Workflow
Page 62
Page 63
Page 64
Block
ID
Block
Description
Purpose
RBI System
Identification &
Collecting and
Loading Design
and Process
Data
Risk
Assessment
Developing
Inspection
Strategies
Executing
Inspection
Strategies
Page 65
Page 66
Page 67
Block
ID
Block
Description
Purpose
Involves taking a Process Unit and breaking it into RBI Systems
based on grouping of Equipment or Equipment Components that
are exposed to similar Corrosion Mechanism Environments.
A1
Define RBI
System
A2
Assign CPPs
(Critical
Process
Parameters) for
the RBI System
defined in A1
A3
Assign Potential
Degradation
Mechanisms for
the RBI
Systems
Identifying CPPs for the RBI System forms the basis of defining
the Operating Window from a Reliability Standpoint. This also
involves identifying the Process Parameters that need to be
monitored and the associated thresholds.
Page 68
A4
Block
Description
Identify and
Assign RBI
Components for
Respective RBI
System
Purpose
Define RBI Components - Since different components of the
same Equipment may be subjected to different Degradation
Mechanism Environments, an RBI Analysis is performed at the
RBI Component level rather at an Equipment Level. This step
involves identifying the RBI Components for the various
Equipments. These RBI Components form the basis for
performing the RBI Analysis in Step B4. For example, typical
RBI Components for a Shell and Tube Exchanger could be
Exchanger Channel, Exchanger Shell and Tube Bundle.
Assign RBI Components to respective RBI System By assigning RBI Components to the RBI System, the Potential
Degradation Mechanisms and CPPs assigned to the RBI System
get passed down to the RBI Components that are a part of the
RBI System. The individual Potential Degradation Mechanisms
and CPPs can still be validated and modified at the RBI
Component level.
A4a
Capture Design
and Process
Data on RBI
Components
A4b
Review and
Validate
Potential
Degradation
Mechanisms
obtained from
RBI System
Page 69
A5
A6
Block
Description
Purpose
Create
Inspection
Profile Items
Create TMLs
Create TML Groups and Define Technical Characteristics Since technical design data for each TML Group will be
different, TML Groups need to be defined for each equipment
and technical data needs to be captured for these TML Groups.
Some typical TML Groups for a Shell and Tube Exchanger
would be Channel Inlet Nozzle (N1), Channel Outlet Nozzle
(N2), Shell Inlet Nozzle (N3) and Shell Outlet Nozzle (N4),
Channel Head, Shell Head, Tubes, Tubesheet etc. Please note
that these TML Groups are different from the RBI Components
defined in A4.
Create TMLs for TML Groups - After the TML Groups have
been defined and TML Group data captured; TMLs are defined
for these TML Groups. Users also have an option of mapping
TML Groups to the RBI Components created in Step A4.
Page 70
Page 71
Page 72
Block
ID
Block Description
Purpose
Review/Analyze
Inspection Data
B2
Evaluate Captured
Excursion data
B3
Review Corrosion
Analysis Data
B1
B4
Risk Assessment
Page 73
Page 74
Page 75
Block
ID
Block Description
Purpose
Generate RBI Inspection Recommendations
RBI Recommendations are generated based on:
RBI Risk Assessment Results (B4) and Strategy Logic
configured in System RBI Strategy Rule Sets.
The output from this step is RBI Recommendations which
include Inspection Task, Plan and Scope. These RBI
Recommendations need to be evaluated and consolidated by
the RBI Analyst as outlined in the next step.
C1
Generating and
Consolidating RBI
Recommendations
C2
Task Management
Task Management has been broken down into steps C2a C2c.
Creation/Update of
Task
C2a
Page 76
Block Description
Purpose
The Inspector reviews the list of upcoming tasks with
Recommended Inspection Dates as calculated by the
System. The Inspector then aligns the Inspection Dates with
Turnarounds or other Events to determine the Scheduled
Inspection Dates based on Company guidelines and Policies.
C2b
Inspector reviews
and schedules Task
C2c
Inspector tracks
Scheduled
Inspection Task
Page 77
Page 78
Block ID
Block Description
Purpose
D1
Perform Inspections
D2
Document
Qualitative
Inspections
D3
Capture New
Thickness Readings
D4
Update Inspection
Schedules
D5
Manage
Recommendations
This has been broken down in more detail in Block D5Manage Inspection Recommendations (See figure 5-11).
Page 79
Page 80
Page 81
Page 82
Glossary
Glossary
Page 83
Glossary
Term/Acronym
Meaning
Absolute Risk
APM
Asset
COF
Consequence of Failure.
RBI System
Corrosion
Mechanisms
CPP
ERPs
Inspection
Confidence
Rating
Inspection Profile
Items
Inspection
Strategies
NDE
NID
Operating
Window
Persistent Fluid
A fluid that will remain in a liquid form once it has been released
from a storage tank. This is used in Tank Bottom consequence
evaluations.
POF
Probability of Failure.
Potential
Degradation
These are the Potential Damage Types, they are indicative on how
Corrosion Mechanisms are evaluated as part of the RBI Analysis.
Page 84
Glossary
Term/Acronym
Meaning
Mechanisms
(PDM)
Recommended
Inspection Dates
Relative Risk
Risk Assessment
Risk Matrix
Risk Matrix used to depict Risk on a 5X5 Risk Matrix with POF
Rankings on one scale and COF on another scale.
RT TML
Scheduled
Inspection Dates
Shell Side
A term referring to the process outside of the tubes of a shell and tube
heat exchanger.
System RBI
Strategy Rule
Sets
Rule Sets that are used to recommend Plan, Scope and Task based on
the Degradation Mechanism evaluated and associated Risk.
TMLs
Tube Side
A term referring to the process inside the tubes and channel of a shell
and tube heat exchanger. Also sometimes referred to as Channel Side.
UT TML
Page 85
Appendices
Probability Categories
11
16
13
20
17
14
23
21
18
15
10
25
24
22
19
12
E
D
C
B
A
Consequence Categories
Page 86
Appendices
1.
2.
3.
4.
5.
6.
7.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Sustainable
RBI Process
Page 87
Appendices
Equipment Type
Leak Size(Cm2)
Hole Diameter
(mm)
1" Pipe
1.5" Pipe
10" Pipe
12" Pipe
14" Pipe
16" Pipe
18" Pipe
2" Pipe
2.5" Pipe
20" Pipe
24" Pipe
3" Pipe
3/4" Pipe
30" Pipe
36" Pipe
4" Pipe
48" Pipe
6" Pipe
60" Pipe
8" Pipe
Column Bottom
Column Top
Filter
Fin/Fan Cooler
Heat Exchanger
Chan
Heat Exchanger
Shell
Pressure Vessel
Reactor
Storage Tank
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Pressure Vessel
Pressure Vessel
Pressure Vessel
Pressure Vessel
0.710
0.968
9.548
11.419
12.387
13.355
13.355
1.245
1.652
14.452
15.548
2.052
0.316
20.258
25.613
2.852
31.677
6.413
45.613
7.935
53.548
53.548
20.258
0.645
3.007
3.511
11.029
12.061
12.562
13.043
13.043
3.983
4.587
13.568
14.074
5.112
2.007
16.064
18.063
6.027
20.088
9.038
24.105
10.054
26.118
26.118
16.064
2.867
Pressure Vessel
38.323
22.095
Pressure Vessel
Pressure Vessel
Pressure Vessel
Pressure Vessel
38.323
53.548
126.709
2027.093
22.095
26.118
40.176
160.695
Page 88
Appendices
Equipment Type
1" Pipe
1.5" Pipe
10" Pipe
12" Pipe
14" Pipe
16" Pipe
18" Pipe
2" Pipe
2.5" Pipe
20" Pipe
24" Pipe
3" Pipe
3/4" Pipe
30" Pipe
36" Pipe
4" Pipe
48" Pipe
6" Pipe
60" Pipe
8" Pipe
Column Bottom
Column Top
Filter
Fin/Fan Header
Heat Exchanger Tubes
Heat Exchanger Chan
Heat Exchanger Shell
Pressure Vessel
Reactor
Storage Tank
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Piping
Pressure Vessel
Pressure Vessel
Pressure Vessel
Pressure Vessel
Pressure Vessel
Pressure Vessel
Pressure Vessel
Pressure Vessel
Pressure Vessel
Pressure Vessel
Structural Tmin
(mm)
1.575
1.575
3.175
3.175
3.175
3.175
3.175
2.388
2.388
3.175
3.175
2.388
1.575
3.175
3.175
2.388
3.175
2.388
3.175
2.388
3.175
3.175
3.175
3.175
0.889
3.175
3.175
3.175
3.175
3.175
Page 89