TECHNICAL WORKSHOP
An Introduction to RBI
Methodology and
Guidance on How to
Choose The Right RBI
Software for Your
Facility
Ashraf Elwerfali
The Workshop Agenda:
The Definition of Inspection
Why Do We Need to Inspect the Pressurized Equipment
The definition of the Risk
The Evolution of Inspection Intervals
Risk-Based Inspection (RBI)
The Benefits of RBI Program
RBI Assessment Limitations
RBI Standards and Recommended Practices References Ashraf Elwerfali
Types of RBI Assessment
Implementation of a Risk-Based Inspection Program Technical Coordinator
(Inspection & Asset Integrity )
Guidelines for Selecting the Right RBI Software
Bsc ME/ API 510,570,653,580,571,577,580,SIFE
CMRP, CAWI, NDE LEVEL II
The Inspection
• Activities performed to verify that materials,
fabrication, erection, examinations, testing, repairs,
and any other data relevant to the equipment
conform to applicable codes, engineering, and the
owner-user’s written procedure requirements.
• Inspection includes the planning, implementation,
and evaluation of the results of inspection activities.
• It covers an external, internal, or on-stream
assessment (or any combination of the three)of the
condition of pressure equipment.
• Inspection provides information about the current
condition of the equipment in question and may
provide information to validate the reliability
prediction for the equipment (i.e. validate the
accuracy of the equipment remaining life
estimation).
Ashraf Elwerfali / Email:
[email protected] Why Do We Need to Inspect the Pressurized Equipment ?
Determine the physical condition of Identify damage that could result in
the fixed assets and to determine a process safety incident, such as
the type, rate, and causes of loss of containment, which could
damage mechanisms and lead to fire, toxic exposure,
associated deterioration. or other environmental hazard.
Contribute to overall plant reliability
Compliance with the regulatory and
by reducing the number or duration of
jurisdictional authorities.
unplanned shutdowns.
The Risk
• Combination of the probability of
an event and its consequence. In
some situations, risk is a deviation
from the expected.
• When probability and
consequence are expressed
numerically, risk is the product
The Evolution of Inspection Intervals
1950s 1970s 1990s 2000s Todays
Reactive Time-Based ½ Remaining Digitalization Era
RBI
Maintenance Inspection Life (CBI, NII) ( AI, ML, IIOT,DT)
Risk-Based Inspection (RBI)
RBI is an analysis methodology and process that, as
opposed to condition-based inspection, requires
qualitative or quantitative assessment of the probability
of failure (PoF) and the consequence of failure (CoF)
associated with each equipment item, piping circuits
included, in a particular process unit.
A properly-implemented RBI program categorizes
individual pieces of equipment by their risks and
prioritizes inspection efforts based on this
categorization.
RBI estimates that around 80% of a plant’s risk is
isolated in about 20% of its assets. (The Pareto
principle)
The Pareto principle states that for many outcomes, roughly 80% of consequences come from
20% of causes
Ashraf Elwerfali / Email: [email protected]
Ashraf Elwerfali / Email: [email protected]
General Approach of RBI
Management of Risk Using RBI
Increased facility availability, and preserve reliability.
The Benefits of RBI Focused inspection on high risk equipment
Program Increased intervals between inspections
Shorter and fewer facility shutdowns
Clearer understanding of high-risk equipment and ability to
implement mitigation measures
Identified deterioration modes and mechanisms
Significant reduction in total cost of inspection
Regulatory compliance/acceptance.
Improved Turnaround planning.
Better-informed, documented, defensible decisions
Case study: The Gas Treating Units (GTUs)
Time Based Inspection Risk Based Inspection
• Eight weeks • 15 days
• over 100 people • 30-35 people
• 67,000 h/P • 6,300 h/P
Reference: four realized benefits of a transition from a time-based to a risk-based inspection approach MARCH |
APRIL 2018 Inspectioneering Journal
Ashraf Elwerfali / Email: [email protected]
Inaccurate or missing information;
Inadequate design, faulty equipment installation, or inadequate testing or
commissioning of equipment;
Not effectively executing the plans;
RBI Assessment Operating outside the acceptable process limits (e.g. not to exceed
Limitations limitations, IOWs, etc.);
Lack of qualified personnel or teamwork;
Lack of sound engineering or operational judgment;
Lack of sound engineering or operational judgment;
RBI Standards and Recommended
Practices References
• API RP 580: Elements of a Risk-Based
Inspection Program
• API RP 581: Risk-Based Inspection
Methodology
• ASME PCC3: Inspection Planning Using Risk-
Based Methods
• DNV-RP-G101: Risk Based Inspection Of
Offshore Topsides Static Mechanical
Equipment
• RIMAP : Risk-Based Inspection and
Maintenance for European Industries
Equipment Covered in
RBI Program
a) Pressure Vessels—all pressure-
containing components;
b) Process Piping—pipe and piping
components;
c) Storage Tanks—atmospheric and
pressurized;
d) Rotating equipment—pressure-
containing components;
e) Boilers and Heaters—pressurized
components;
f) Heat Exchangers (shells, floating heads,
channels, and bundles);
g) Pressure-Relief Devices
Ashraf Elwerfali / Email:
[email protected] Types of RBI
Qualitative Approach:
• This approach requires data inputs based on descriptive
information using engineering judgment, subject matter
Assessment expertise, and experience as the basis for the analysis of
probability and COF.
• Inputs are often given in data ranges instead of discrete
values.
• Results are typically given in qualitative terms such as
high, medium, and low, although numerical values may
also be associated with these categories
Quantitative Approach
• Quantitative programs are model-based approaches in
which numerical values are calculated and more discrete
input data is used.
• It is more systematic, consistent, and documented, and
they are easier to update with inspection results than
qualitative approaches.
• Generally, uses a software program to calculate risk and
develop inspection program recommendations
•
Types of RBI Assessment
Semi-quantitative Approach
• Semi-quantitative is a term that describes
any approach that has aspects derived from
both the qualitative and quantitative
approaches.
• It is geared to obtain the major benefits of
the previous two approaches (e.g. speed of
the qualitative and rigor of the
quantitative).
Implementation
Process of the RBI
Program
RBI Project Time Frame
RBI Team
The RBI team composition is a major
contributing factor to the success of the
overall RBI program, and should include
representation from personnel with
expertise in the following roles:
• Project Manager/RBI Champion
• Area/Unit Inspector
• Process Engineer
• RBI or Reliability Engineer
• Operations Representative
• Materials and Corrosion Engineer
Data and information
collection
• The data collected will provide the information needed
to assess potential damage mechanisms, potential
failure modes, and scenarios of failure
• Examples of data sources include the following:
a) design and construction records;
b) inspection and maintenance records;
c) operating and process technology records;
d) hazards analysis and management of change (MOC)
records;
e) Materials selection records, corrosion engineering
records, and library/database;
f) Cost and project engineering records.
Data and information collection
• Typical data needed for an RBI analysis may include but
is not limited to the following:
a) type of equipment;
b) materials of construction;
c) inspection, repair, and replacement records;
d) process fluid compositions;
e) inventory of fluids;
f) operating conditions;
g) safety systems;
h) detection systems;
i) damage mechanisms, rates, and severity;
j) personnel densities;
k) coating, cladding, and insulation data;
l) business interruption cost;
m) equipment replacement costs;
n) environmental remediation costs
Probability (Likelihood) of Failure (PoF)
• Probability of Failure (POF) is likelihood that a piece of equipment will fail (a loss of
containment) that occurs due to damage mechanism(s) at a given time.
• POF is calculated for individual pieces of equipment by looking at the potential
damage mechanisms it could be susceptible to, a general frequency of failures, and
management system factors.
• Other causes of loss of containment could include but are not limited to the
following:
• a) seismic activity,
b) weather extremes,
c) overpressure due to pressure-relief device failure,
d) operator error,
e) inadvertent substitution of materials of construction,
f) design error,
g) sabotage
• the POF is determined by two main considerations, as follows.
a) Damage mechanisms and rates of the equipment item’s material of construction,
resulting from its operating environment (internal and external).
b) Effectiveness of the inspection program to identify and monitor the damage
mechanisms so that the equipment can be repaired or replaced prior to failure.
Units of
Measure in
the POF
Analysis
Consequence of Failure (CoF)
• COF is calculated by reviewing and ranking the potential
consequences for the equipment, personnel, environment, etc.
in the event of equipment failure.
• COF provides discrimination between equipment items on the
basis of the significance of a potential failure.
• The consequence analysis should be a repeatable, simplified,
credible estimate of what might be expected to happen if a
failure were to occur in the equipment item being assessed.
• The COF analysis shall be performed to estimate the
consequences that are likely to occur due to a failure mode
typically resulting from an identified damage mechanism(s)
• Consequence should typically be categorized as:
a) safety and health impacts,
b) environmental impacts,
c) economic impacts.
Consequence of Failure (CoF)
• the major factors to consider in
evaluating the consequences of failure shall
include the following:
a) flammable events (fire and explosion) toxic
releases,
b) release of other hazardous fluids.
Additionally, other impacts that may be
considered include the following:
c) environmental consequences,
d) production consequences (business
interruption),
f) maintenance and reconstruction impact.
Ashraf Elwerfali / Email:
[email protected] Units of
Measure in
Consequence
Analysis
Calculate Risk (Ranking)
RISK = PROBABILITY × CONSEQUENCE
Inspection Plan
• The output of an RBI assessment is an inspection plan for
each piece or group of equipment assessed, which should
include the following:
a) Identified risk drivers;
b) Inspection methods that should be used;
c) The extent of inspection (percent of total area to be
examined or specific locations);
d) Inspection interval or next inspection date (timing);
e) other risk mitigation activities;
f) Residual level of risk after inspection and other mitigation
actions have been implemented.
Reassessment & Evergreening
• Reassessment refers to the process by which the RBI model
is fully revalidated when certain criteria are met, such as
after a significant change in the process conditions,
after a set amount of time set by the governing inspection
codes and jurisdictional regulations,
after a major change in the understanding of the damage
mechanisms present in the process unit.
• A reassessment should involve a fully reassembled RBI team
to reevaluate the input data to ensure that the resulting
inspection recommendations are as accurate and
appropriate as possible.
Reassessment & Evergreening
• Evergreening refers to the process by which the
RBI model is continually updated with new
information that is largely in accordance with the
assumptions used in the original implementation.
• While an expansion to the process unit would likely
require a full RBI reassessment, a large-scale update of
the inspection records following a unit turnaround
would qualify as an evergreening procedure and not
necessarily require a revalidation.
• This process allows the RBI model to remain accurate
while operating under the same or similar assumptions
used in the original RBI implementation
Guidelines for Selecting the Right RBI Software
Selecting the best Risk-Based Inspection (RBI) software requires careful
consideration of various factors. Here’s a structured approach to guide
you through the selection process:
Guidelines for Selecting
the Right RBI Software
• Specific Needs: Identify the
specific functionalities you
require, such as risk assessment,
data analysis, reporting, and
compliance management.
Guidelines for Selecting the
Right RBI Software
• Risk Assessment Capabilities: Look for robust
risk assessment models and tools that can
handle qualitative and quantitative analysis.
• User-Friendly Interface: Ensure the software is
easy to navigate for users at all levels.
• Customization Options: Check if the software
can be tailored to meet your organization’s
specific processes and workflows.
• Growth Potential: Choose software that can
scale with your organization’s needs as it grows
or as regulations change.
Guidelines for Selecting the
Right RBI Software
• Adaptability: Ensure the software can
adapt to new risks or inspection
methodologies.
• Integration Needs: Determine if the
software needs to integrate with
existing systems (e.g., maintenance
management, asset databases).
• Regulatory Compliance: Verify that
the software meets industry standards
and regulatory requirements relevant
to your operations.
Guidelines for Selecting the
Right RBI Software
• Best Practices: Research if the software
follows industry best practices for risk
management and inspection.
• Experience and Expertise: Look for vendors
with a proven track record in RBI software
development and implementation.
• Customer Reviews: Read testimonials and
case studies to gauge customer satisfaction
and success stories.
• Hands-On Experience: Request
demonstrations of the software to see how
it functions in real scenarios.
Guidelines for Selecting the
Right RBI Software
• Customer Support: Assess the level of
customer support offered, including
response times and availability.
• Training Resources: Ensure the vendor
provides adequate training materials and
resources for your team.
• Pricing Structure: Understand the pricing
model (e.g., subscription vs. one-time fee)
and any additional costs (e.g., training,
support).
• Return on Investment: Consider how the
software can improve efficiency and reduce
risks, which may justify the investment.
WWW.INSPECTIONEERING.COM
References: API RP 580: Risk-Based Inspection
API RP 581: Risk-Based
Inspection Methodology
Ashraf Elwerfali / Email:
[email protected]
