INTRODUCTION TO RISK

BASED INSPECTION
Asset Integrity Management
 “A risk assessment and management
process that focused on loss of
containment of pressurized equipment in
What is Risk processing facilities, due to material
deterioration. These risks are managed
Based primarily through equipment
inspection.”
Inspection
(RBI)? -American Petroleum Institute (API)
Recommended Practice 580
Second edition, 2009-
What is risk?
Risk is a product of two parts:
• PROBABILITY of Failure (PoF)

X
• CONSEQUENCE of Failure (CoF)
 Risk Matrix
To define the level of risk by considering the PoF and CoF
Key Normative References

• API 510, Pressure Vessel Inspection Code: Inspection, Rating, Repair & Alteration
• API 570, Piping Inspection Code: Inspection Repair, Alteration & Rerating of In-
service Piping Systems
• API 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry
• API 579-1, Fitness For Service
• API 580, Risk-Based Inspection
• API 581, Risk-Based Inspection Technology
• API 653, Tank Inspection, Repair, Alteration & Reconstruction
 To Deliver Safety & Reliable Operation
RBI • The RBI analysis used to evaluate the
probability of failure (POF) and the
Objectives & consequence of failure (COF) for given
components in a pressurized
environment.

Goals • RBI evaluation enables to cost-

effective inspection plan and reduce
the risk of failure. “We are safe and we know
it”
• RBI minimizes or avoid unscheduled
and short term shutdowns &
downtimes.

• RBI minimizes the risk to Health, Safety

and Environment (HSE).

• RBI Increases reliability, availability

and maintainability (RAM) &
maximizes the resource utilization and
increase the effectiveness of Asset
Integrity.
RBI Coverage
Assets that can be modelled by
RBI:
• Static equipment (PV, Heat
Exchangers, Tower, etc.)
• Metallic piping system
• Tube (Heat Exchangers, Air
Coolers, etc.)
• Tank
• PRD
Assets that RBI can’t model:
• Rotating equipment (Pump,
Compressor, etc.)
• Valves
• Special items (Strainers,
Silencers, etc.)
 RBI
Flowchart
(API RP 580)
RBI Phase and Involvement
Risk Analysis Methods

• Qualitative Risk Analysis

Simple risk analysis method, brief prioritization of equipment, utilizes experience and
judgement.
• Semi-Quantitative Risk Analysis
More accurate, more detailed prioritization and planning
• Quantitative Risk Analysis
An analysis that:
a. Identifies and delineates the combinations of events that, if they occur, will lead to a severe
accident (e.g., major explosion) or any other undesired event.
b. Estimates the frequency of occurrence for each combination.
c. Estimates the consequences.
Qualitative vs Quantitative Quantitative
It's not quite that simple...
Qualitative Area COF Financial
1.0E+00 1.0E+00

Probability of Failure (/yr)

5
1.0E-01 1.0E-01
4 4D
Likelihood

1.0E-02 1.0E-02
3
1.0E-03 1.0E-03
2 1.0E-04
1.0E-04
1 Areas for 1.0E-05
1.0E-05
$10 $10,000
A B C D E 1● Toxic injury(event/yr)
●1000
Equpment ● Personnel2 injury
x scenarios = m2/ yr(Financial)
(m /event)Consequence
Consequence for ... 4 hole sizes and all release
Consequence (damage area m2)

More ‘accurate’
+ Simple
Less data hungry
Quantitative
Decision making tool
Cost of Inspection vs
Risk reduction (CBV)
Too ‘generic’ ‘simplistic’ COFs Most data needed
- Less discriminating Less common

7/9/2019 SPE Workshop Process Safety & Integrity 11

Risk Assessment Approach
RBI is focused on systematic determination of relative risk. The risk of one item against another and against industry generic failure
frequencies. Risk levels are compared to risk criteria to determine when it is most appropriate to take action.

GFF – Generic Failure Frequencies

API RBI uses four hole sizes to model the release scenarios
POF
covering a full range of eventsCOF RISK
/y $ $/y

• Damage Area
GFF x Item DF x MF
• Item Repair Where:
• Other Repairs DF = Damage Factor
• Age
• Injury GFF = Generic Failure Frequency
• Damage Type/Rate
• Business Int. MF = Management Factor (opt)
• Insp. Effectiveness
• Env Clean Up

Generic Failure Frequency (GFF) is the probability of failure based on a large population of
component data that doesn’t include the effects of specific damage mechanisms.

Damage Factor (DF) is an adjustment factor applied to the generic failure

frequency to account for damage mechanisms that are active in a component.
12
Risk is Time
Dependent
Inspection Effectiveness D
Inadequate
inspection

C Min
Inspection effectiveness is an INPUT (past insp.) Required

… and also an OUTPUT (inspection plan)

Higher inspection effectiveness = higher confidence,
Risk Exceeded. Desired
lower POF (2xB’s = 1xA, …) Do Inspection Date

Cost / Benefit Assessment

More $$
More $$
Execution: Inventory Grouping
Inventory groups determine the consequence of release (mass available and duration of event)

Inventory grouping is significant:

─ Determines fluid release type & damage area
─ Isolations determine release duration through
‘duration modifiers’ – e.g. Manual valve – full
inventory release
Execution: Corrosion and Material Diagram
Corrosion loop shows common metallurgy and environment (same damage modes and rates)
Execution: Data Input
• General
• Design data, Geometry, MoC, Inventory Group, etc.
• Component Settings
• Consequence Model, RBI Date, RBI target, Plan date, etc.
• Operating Condition
• Operating Pressure, Temperature, and Process Fluid, etc.
• Inspection History
• Inspection activity reports for each components (incl. Corr.
Rate).
• Damage Mechanism
• Active damage mechanism based on MoC, fluid (including
Chemical Injection for MIC), and component location.
Example of Risk Criteria
A critical first step is to establish quantitative risk criteria relevant to the Risk Based Inspection process

API RBI Risk Criteria

Mandatory Action Required

Safety Risk 1 x 10-4 (all facilities)
Threshold

Cost Benefit Analysis and

Management Approval Required
for Strategies in this Region

$300,000/yr (Financial Risk Target)

Broadly Considered Acceptable
Inspection effectiveness
determined to ensure ALARP
Broadly 1 x 10-6 (all facilities)
Acceptable
Risk Level $30,000/yr (financial risk)
No Inspection Required
Maintain Integrity Management
Plan (IMP) Activities
Examples of RBI
Software Available
• RiskWISE (by TWI)

• Plant Manager (by The E2G)

• Risk-IT (by Honeywell)

• Synergi Plant-RBI (by DNV-GL)

Experienced
Personnel
DELLA SEVILLA
Piping Material Engineer
10 years of Oil and Gas experience with 7 years of experience in
RBI
MSc in Materials Science TUM, Munich (2009)
BSc in Materials Engineering ITB, Bandung (2002)
Project:
• SANTOS East Australia
• HESS Ujung Pangkah
• HESS Gulf of Mexico
RBI Software Experience
• Plant Manager (by E2G)
• NEXUS (by WoodPLC)
 Experienced Personnel
ANDRIAN HADIANA
RUBI HERWIN
Piping Material Engineer
Piping Material Engineer
7 years of Oil and Gas
experience with 2 years of 4 years of Oil and Gas experience
experience in RBI with 1 year of experience in RBI
BSc in Materials Engineering BSc in Materials Engineering ITB,
ITB, Bandung (2007)
Bandung (2006)
Project:
Project:
• Pertamina EP
• SANTOS East Australia
• PHE ONWJ
RBI Software Experience
RBI Software Experience
• Plant Manager (by E2G)
• RiskWISE (by TWI)
Services Offered to Client

• Training for Corrosion and RBI

• Consultant & Facilitator for RBI Implementation
• Third party RBI Implementor for Client
 Other
Component
information
Name & Type
Plant/Unit tabs
Hierarchy

Example of
API-RBI (by
E2G) Software
Inputs
Material
Properties

Geometry
Data
Example of API-RBI (by E2G) Software Outputs

Contribution each
scenario has on risk
Risk Driver

Due Date
Impact distances for
each scenario

Remaining Life Internal thinning

mechanism
dominates risk
RBI Output Deliverables
• Software with completed Database
• Inspection plan recommendation report
• Corrosion Loop Diagram, Inventory Group, & Piping Group
• Consequence of Failure
• Probability of Failure
• Risk Ranking
• Risk Matrix Reports
• All Inspection related documents
Example of Risk Matrix Report Output
Visualising the risk of equipment components across a unit or plant (or between plants) helps prioritise and
focus limited resources on what is important
1.0E+00

1.0E-01

Probability of Failure (/yr)

1.0E-02

Crude and Naphtha Storages

1.0E-03 Debutaniser
Depropaniser
Feed Preheat and Deethaniser
Hot Oil System

1.0E-04 LPG Product Treating

1.0E-05
$10 $100 $1,000 $10,000 $100,000 $1,000,000
Thousands
Consequence (Financial)
“We are safe and
we know it”