5/30/2015

RBI
RISK BASED INSPECTION
Presented by:
Mohammad Javad Ranjbar
5 May 2014

Outline
Introduction to RBI
what is RBI
what are the key elements of RBI
how to implement an RBI program
how to sustain an RBI program

RBI Softwares
TWI - RISKWISE
ReliaSoft RBI

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What is RBI?
Risk-based Inspection (RBI) is a methodology for
identification of high-risk equipment by review of
active/potential damage mechanisms and the suitability of
mitigation methods
RBI allows inspection/maintenance RBI systematical
evaluated both the probability of failure and the
associated consequence of failure.
Risk is the combination of the probability of some event
occurring during a time period of interest and the
consequences,(generally negative) associated with the
event. In mathematical terms, risk can be calculated by
the equation:
Risk = Probability Consequence

RBI vs. Other Inspection Methods

Fixed Interval
STANDARD
Inspection
Service Interval

Condition
Based

Risk Based

TREND Analysis

RISK Analysis

Consequences
not considered
Backward Looking

Probability &
Consequences
Proactive
Forward Looking

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Objectives of RBI
Increase Availability

1
CATASROPHIC
FAILURE OF
STEAMLINE
(JAPAN 2004)

(reducing unplanned outages )

2
3

Improve Safety
)Ensure Safe Operation)

Optimise Inspection
Costs

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RBI Benefits and Limitations

a) an overall reduction in risk for the facilities and

equipment assessed,
b) an acceptance/understanding of the current risk.
RBI will not compensate:
c) inaccurate or missing information,
d) Design errors or faulty equipment installation,
e) External events (e.g. Collisions or falling object)
f) not effectively executing the plans,
g) Secondary effects from nearby units
h) lack of qualified personnel or teamwork,

Outcome of an RBI?
Appropriate
Inspection
Technique

Types of
damage
expected

Inspection
Frequency

What?

How?

When?

Where?
Hotspot
locations

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International Standards

ASME PCC-3

API 580 / API 581

CWA 15740

DNV-RP-G101
(Offshore topsides)

Type of RBI Assessment

Qualitative: Provides a broad-based risk assessment of

an operating unit or a part of an operating unit, required

less detail information about the facility. In this
assessment using engineering judgement and experience
for the analysis of probability and consequences of failure.
Quantitative: Provides risk values for each equipment
item and pipe segment in a operating unit, required
comprehensive detail information about the facility and
equipment. In this assessment using logic models,
likelihood and probability data to calculate the risk of
failure.
Semi-quantitative: Some were between either approach.

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RBI planning process overview

1. Data Collection
design and construction records/drawings:
P&IDs, process flow diagrams, material selection diagrams (MSDs), etc.,
piping isometric drawings,
engineering specification sheets,
materials of construction records,
construction QA/QC records,
codes and standards used,
protective instrument systems,
leak detection and monitoring systems,
isolation systems,
inventory records
emergency depressurizing and relief systems,
safety systems,
fire-proofing and fire-fighting systems,
layout;

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1. Data Collection
inspection records
schedules and frequency,
amount and types of inspection,
repairs and alterations
inspection results

process data
fluid composition analysis including contaminants or trace
components,
distributed control system data,
operating procedures,
start-up and shutdown procedures,
emergency procedures,
operating logs and process records,

1. Data Collection
Off-site data and information
if consequence may affect off-site areas;

Failure data
generic failure frequency data
industry specific failure data,
plant and equipment specific failure data,
reliability and condition monitoring records,
leak data;

Site conditions
climate/weather records,
seismic activity records;

Equipment replacement costs

project cost reports,
industry databases;

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1. Identification of Damage Mechanisms

2. Probability of Failure
Probability Information
1. Number of units and type of plant:
pressure vessel, tank, column,
pipework, heat exchanger etc.
2. Plant function: distillation unit, cat
cracker, storage etc
3. Plant processes: gas, hydrocarbon,
steam etc, number of planned and
unplanned interruptions per year
4. Process stability: rate stability from
a) very stable no known upset
conditions known to exist to b) loss of
control is inherent in process
5. Plant maintenance history: repairs,
modifications, quality of maintenance,
painting & insulation maintenance

6. Material of construction: steel,

stainless steel, cast steel, aluminium
etc, any coatings
7. Damage mechanisms: what damage
mechanisms are known to occur or
have the potential to occur in the
plant. eg stress corrosion, brittle
failure, temper embrittlement, fatigue,
localised or general corrosion, creep,
others,
8. Inspection: dates, type (visual,
thickness, MPI, UT etc) and extent of
inspection, inspectability, inspection
results, corrosion allowance.
Effectiveness and management of the
inspection programme.

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2. Consequence of Failure
Consequence Information
1. Fire: are external fire fighting
resources required for the most
serious event
2. Incident mitigation: which one:
i) gas detection systems,
ii) plant operated under inert atmosphere,
iii) secure fire fighting system,
iv) automatic or manual isolation systems
v) blast walls around high pressure
equipment,
vi) drain, dump or blowdown systems that
will deinventory plant
vii) fire proofing of plant strct. and cables
viii) available supply of fire water, hour?
ix) foam system or water curtain

3. Chemical data: relates to the

chemicals tendency to ignite. What is
the flash point of the material, rate its
stability when unconfined.
4. Quantity: how much material could
be released in a single event
5. Chemical state: what is the process
temperature,what is the boiling point?
6. Commercial damage potential: what
is the value of plant within a 30m
radius, within 150m?
7. Toxicity: rate the toxicity from: a) no
hazard to b) death or major injury on
very short exposure
8. Population: number of people, on site
and off site, within 500m of release
point

3. Risk Analysis

RISK MATRIX: The LoF value is plotted on the

vertical axis, and the CoF value is plotted on
the horizontal axis, of the dimensionless 55

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4. Inspection Planning
When or before the risk target is reached, an inspection of the
equipment is recommended based on a ranking of the
component damage mechanisms that have the highest
calculated damage factors.

An inspection program is the combination of NDE methods

(i.e. visual, ultrasonic, radiographic etc.), frequency of
inspection, and the location and coverage of an inspection.
Inspection programs vary in their effectiveness for locating
and sizing damage, and thus for determining damage rates.

4. Inspection Effectiveness
Lack of coverage of an area subject to deterioration,
Inherent limitations of some inspection methods to detect and
quantify certain types of deterioration,
Selection of inappropriate inspection methods and tools,
Application of methods and tools by inadequately trained
inspection personnel,
Inadequate inspection procedures,
The damage rate under some conditions (e.g. start-up, shutdown, or process upsets) may increase the likelihood or
probability that failure may occur within a very short time.
Inaccurate analysis of results leading to inaccurate trending of
individual components, and Probability of detection of the applied
NDE technique for a given component type, metallurgy,
temperature and geometry .

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5. Mitigation
Reducing the POF, Primary source of consequence,
magnitude of consequence:
Equipment Replacement and Repair
Evaluating Flaws for Fitness-For-Service

Equipment Modification, Redesign, and Rerating

Emergency Isolation
Emergency Depressurizing/Deinventorying
Modify Process
Water Spray/Deluge
Blast-resistant Construction
spill detector
Fireproofing
.;

6. Reassessment and
Updating RBI Assessments
Why Conduct an RBI Reassessment?
Damage Mechanisms and Inspection Activities
Process and Hardware Changes
RBI Assessment Premise Change
The Effect of Mitigation Strategies

When to Conduct an RBI Reassessment?

After Significant Changes
After a Set Time Period
After Implementation of Risk Mitigation Strategies
Before and After Maintenance Turnarounds

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RBI Softwares
RBI

ORBIT S.RBI

RiskWISE

RBI

RB.Eye
RB.QEye
FAME+
Credo

RDMIP

RISKWISE
Risk Based Inspection / Risk Based
Maintenance software

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TWI Ltd is the sole owner of this software

demonstration show and may change this
demonstration without issuing notice. No
person or entity may reproduce or transmit
any part of the demonstration without written
permission from TWI Ltd.

Demonstrator Contents

System Overview
Introduction
Ease of Use
Access Controls
Knowledge-base
Options and Settings
Fluid Properties
Nameplate Information
Inspection History
Damage Mechanisms
Risk Factors
Risk Summary
Risk Profile
Record Data Tables
Record Properties
Risk Mitigation
Risk Comparison
Inspection Plans
Management Reporting
Contact TWI

RISKWISE has a friendly Microsoft style graphical user interface )GUI),

developed in Visual Basic using object-oriented design tools.
Microsoft
Toolbar

Folder
Tree
Drag n Drop
Table Sorting

Intuitive
Interface
Graphical
Navigation

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RISKWISE is an API RP580 compliant riskbased inspection (RBI) planning tool for use with
pressure equipment, pipelines, power boilers
and storage tanks. The risk model is semiquantitative, so it can be easily learned and is
convenient to use.
RBI management systems are applied to:

Features
Integration
RISKWISE is a second
generation client-server
product, using the ODBC
(Open DataBase
Connectivity) protocol for
SQL databases (eg
FoxPro, SQL Server,
Oracle and Access).

Multi-lingual

Improve the safety of critical plant

Reduce the duration of inspection outages
Extend the interval between major
inspections
Reduce direct inspection and maintenance
costs

RISKWISE enables the system administrator

to control user access, tailoring it to the specific
needs of the inspection and maintenance
organisation. This allows simple control and
auditability of previous assessment records.

RISKWISE is designed
to provide complete
multi-lingual capability
for rapid native language
implementation.

Features
Access Control
Three main levels:
Read-Only
Proposal Write
Item Write Access

Auditability
The name of the
assessor undertaking the
RBI evaluations for each
item of equipment is
recorded, in compliance
with best practice
auditing principles.

Record Hierarchy
Proposed inspection
plans
RBI assessment results
which cannot be
changed or deleted

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RISKWISE stores equipment nameplate

information in the Item Properties and Materials
screens. This information can be easily
integrated with asset information in other
applications, via the in-built RISKWISE Import
Wizard.

Features
Item Properties
Captures general
information about the
equipment including
drawings, design and
operating parameters.

Materials
Captures information
about the materials of
construction
components within
equipment or pressure
system.

RISKWISE contains an inspection knowledgebase covering non-destructive testing (NDT)

methods and comprehensive descriptions of
over 30 damage mechanisms (DM), including 20
corrosive species leading to general and
localised corrosion and 10 species leading to
stress corrosion cracking.

Features
NDT
The knowledge-base
covers visual, magnetic,
ultrasonic, eddy current,
metallurgical,
radiographic,
thermographic, acoustic
emission and other nonintrusive methods.

Damage Mechanisms
The common
mechanisms are
categorised in terms of
leading to Metal loss,
Environmental or
Metallurgical and
mechanical damage.

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RISKWISE allows users complete freedom to

undertake assessments in European, US
Customary units or User-defined units. System
administrators have the ability to define safety
factors based on assessment consequence
categories, for direct use in the derivation of
equipment inspection intervals.

RISKWISE assesses consequence of failure

generally in accordance with guidance provided
in API BRD581 based on the fluid property
classifications presented by National Fire
Protection Association (NFPA).

Features
Units
Define system wide
defaults for assessment,
such as engineering
units of measure.

Factors of Safety
Modify configuration of
safety factors, that are
linked to the
consequence categories,
in the calculation of
remaining life indicators
for all damage
mechanisms.

Features
Chemical Factor
A Flammability Factor is
used by RISKWISE, in
combination with a
Reactivity Factor, to derive
a Chemical Factor,
representing a fluids
inherent tendency to ignite.

Explosion and Fire

RISKWISE assesses a
State Factor and the
Chemical Factor, in
accordance with the
procedure in publication
API BRD581.

Toxicity
RISKWISE employs the
NFPA ranking of the
probable severity of the
effects of a fluid on
exposure to personnel, in
the event of a release and a
fire.

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RISKWISE captures all relevant historical

inspection and maintenance history in the
Inspection Methods screen for subsequent use
in the identification of equipment damage
mechanism prior to the risk assessment.

Features
Inspection Methods
Captures relevant
historical information
including coverage and
findings, that will be
regularly updated
following future
inspections.

Inspection Plans
RISKWISE transfers
historical findings as well
as the proposed
inspection activities, to
the Written Scheme of
Examination.

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RISKWISE captures the location of all active

and potentially active damage mechanisms
within each item of pressure equipment.

Features
Checklist
RISKWISE deals with
damage mechanisms
relevant to oil, gas and
petrochemical process
equipment, storage
tanks, pipelines, and
fossil fuel power boilers.

Remaining Life
Indicators
The estimated remaining
life of each damage
mechanism is assessed
within RISKWISE, to
establish equipment
inspection intervals.

RISKWISE assesses seven likelihood

(probability) of failure factors and nine
consequence of failure factors, for each item of
equipment.

Features
Time-based Risk
Analysis
RISKWISE assesses
failure probability over
three forward periods of
time, for each active or
potentially active damage
mechanism.

Inspection
Effectiveness
RISKWISE assesses
the effectiveness of the
current inspection
program for each
damage mechanism
separately.

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RISKWISE presents the results of the risk

analysis for each of the damage mechanisms,
over the three forward time intervals, as well as
the resulting remaining life indicator (RLI) which
defines a safe inspection interval.

Features
Risk Matrix
RISKWISE plots each
assessment point on an
API RP580 five-by-five
risk matrix for risk
regions ranging from
Favourable to Critical.

Limiting Damage
Mechanisms
The lowest RLI out of all
damage mechanisms
equates to the maximum
allowable inspection
interval for the
equipment.

RISKWISE provides a risk profile of all

equipment within the facility for the identification
of critical and non-critical equipment.

Features
Summary
The distribution of risk
can be presented using a
risk matrix, pie charts or
bar charts as well as
comparatively, ie for
subsequent postassessment cost-benefit
analysis.

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RISKWISE simply identifies critical equipment

as those items where the RLI is less than
current inspection period, and non-critical
equipment as those items where the RLI is
greater than the current inspection period!

Features

RISKWISE ensures that the individual authors

of each equipment RBI assessment are fully
traceable.

Features

Table Sorting
The results of the RBI
assessment are
presented in the
RISKWISE data tables,
which can be easily
sorted using the drag n
drop column titles.

Auditability
RISKWISE enables
comprehensive tracking
of assessment results
and input assumptions,
in accordance with the
requirements of API
RP580.

Record Notes
RISKWISE includes a
simple catch-all free
text field for any other
information relevant to
the likelihood of
consequence of failure of
the equipment under
consideration.

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Action Grouping
RISKWISE assigns the
most frequently used risk
mitigating actions to six
groups, for ease of
evaluation during the
final inspection planning
and optimisation phase
of the RBI assessment.

Features
Inspection Optimisation
The process of risk
comparison within
RISKWISE enables users to
systematically evaluate the
effect of actions on the risk of
failure, while considering the
constraints.
Total Savings = $1.1M
B/C Ratio = 11:1
$900k

$700k

$500k

$300k

Production
Cost Savings

$100k

Inspection
Savings

RISKWISE allows the RBI assessor to

evaluate the impact of the proposed actions or
inspection changes on risk and the remaining
life indicator (RLI).

Features

RBI

RISKWISE presents RBI assessors with a risk

action plan from which the most suitable risk
mitigation options, for critical equipment, can be
evaluated.

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The final output of a RISKWISE assessment is

an optimised inspection plan )Written Scheme
of Examination) which focuses on each damage
mechanism.

RISKWISE provides a post-assessment

analysis capability to evaluate the impact of
actions on the risk distribution for all equipment.

Features
Reporting
RISKWISE presents a
detailed report of the RBI
assessment for use by
field inspection
engineers, or in other
reports application as
necessary.

Features
Time Tracking
RISKWISE enables the
user to assess the value of
RBI following successive
major inspections and
subsequent RBI updating,
eg. between Revision 0 and
Revision 1.

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NEW
Released
Feature

RISKWISE 2014

RBI EXAMPLE
Quantitative Assessment of a Boiler

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Application
Selection
Chosse boilers as
Oil,Gas and
Process Plant
Suite

Current Table
A table of current
revision records or a
table of all proposal
records can be
displayed by
navigating to these
screens via the
shortcut bar.
These lengthy tables
can be organised
and sorted by
dragging the column
titles to the top of the
screen, into any
ordered display
hierarchy:

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Item Proposal
Once you have
specified the
equipment class,
(for example,
specify that a
particular pipe is a
Hot Reheat Pipe),
the list of expected
damage
mechanisms is
shortened
automatically to
display the types of
damage that might
be expected.

Item Properties
The entries on the
unit properties
screen determine
the risk associated
with various items
in boilers.

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Item Properties
Enlarge the picture
to see the detailes
you have to enter.

Risk Factors
All of the items on
the Risk Factors
screen will be readonly if the item
properties, damage
mechanisms and
inspection methods
screens are fully
completed. If you
need to change any
of these values you
will need to change
back to manual
mode

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RISK Analysis
The assessment
points for each of the
three risk analysis
periods can be
toggled on or hidden
via the buttons on the
toolbar. For example,
if you wish to display
the assessment
points for the first
analysis period (1AP)
only, select the
buttons to HIDE 2AP
and HIDE 3AP. The
risk plot will then only
display 1AP ( )
assessments points.

Level 1
Assessment
The level 1
assessment is a
unit level
assessment to
assess a boiler as a
whole. To switch to
the level 1 view,
click on the
assessment level
toggle at the top of
the main screen.
When switching to
the level 1
assessment, the list
of items now only
shows units.

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Home
You can right-click
on an existing unit
to create a
proposal, or create
a new unit or
proposal
from the links on
the home screen.

Unit
Proposal
Each unit has a set
of properties
associated with it
in a similar way
that other (level 2)
components have
an item properties
list. The proposal
record can be
viewed by double
clicking on it in the
items list.

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Unit
Analysis
The analysis
screen shows the
business
consequence of
the major
components of the
boiler failure.

THANK YOU FOR YOUR ATTENTION

Your Questions Are Wellcomed

mj.ranjbar@gmail.com

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