RBI
Risk Directed Mechanical
Integrity Program
(RDMIPtm)
APTECH Engineering Services
Houston, TX
www.aptechtexas.com
“There are risks and costs to a program of
action, but, they are far less than the long
range risks and costs
of comfortable inaction!
John F. Kennedy
1) Introduction
2) Standards, Codes and PSM
3) Risk Assessments and RBI
4) Organisation and Implementation
5) Software and Methodologies
7) Benefits and Compliance
8) Conclusions
Risk Directed Mechanical Integrity
• Analyzed over 20,000 Pieces of Fixed Equipment, Piping
and Pumps
• Extensive Database of units, processes
and equipment items
• Approx. 25 plants World-Wide
– United States, South Africa,
– South Korea, Australia
• Refineries, Gas Plants, Chemical Plants
• Interaction with Regulatory
Authorities (TED, SA, Australia)
• Training, Technology Transfer,
Full Implementation
OSHA 1910.119
•Central to both OSHA and EPA regulations is
“ The avoidance of catastrophic failure”.
•Contains requirements for the management of
hazards associated with processes using
highly hazardous chemicals (HHC’s).
•Paragraph (j) concerned with Mechanical Integrity
•Inspection and Testing - Use Industry codes and Standards
OSHA 1910.119 (j) -
Mechanical Integrity
• Documentation of Covered Equipment
• Written Procedures and Training
• Process Maintenance
• Inspection and Testing
• Equipment Deficiencies
• Quality Assurance
Use industry codes, standards
and guidelines
Risk Management Programs
n Process Safety Management Regulations
n EPA Risk Management Planning Rule
n API 750 - Management of Process Hazards
n CMA Responsible Care Program
n ASME Section XI
n ASME Risk Based Inspection Programs
n Reliability Centered Maintenance Programs
n API 580 and 581
API 579
n
Related Programs
PHA - Different methods for determining and
identifying Process Hazards. One of these is:
HAZOP - Hazard and Operability analysis, emphasizes
identification of scenarios and their consequences but usually does
not look at likelihood.
RCM - a method by which operators can use its failure
data, system design redundancies, and operating experiences
to develop a flexible and cohesive maintenance system.
Does not
necessarily include consequence evaluation.
Ultra-Pipe - Inspection Planning Tools
Causes of Large Property
Losses
Mechanical
Operations
Upsets
Natural Hazards
Design
Arson
Others
0 25 50
Percent of Losses
Why was RBI developed?
n All pressure equipment contain flaws
n Most flaws are innocuous - Don’t cause problems
n Few flaws cause catastrophic failure
n Must find (inspect) those critical flaws in
high risk service - Cost effectively
nTypically 80% of the risk is associated with
< 20% of the pressure equipment
Comparison With Traditional Methods
• API 570 & 510 Now Recognize
RDMIP/RBI Approach
the use of Risk Based
Inspection Technologies
•Extend internals beyond 10 years.
•Minimal or existing inspection data
can help focus initial effort
Traditional Approach
Definition of Risk
RBI defines risk as:
The product of the likelihood that a failure will occur
and the consequence of that failure
Risk = Probability X Consequence
Conducting a Risk Assessment
Stepwise Process
•Hazard Identification [PHA (Hazop)]
•Likelihood Assessment
•Consequence Assessment
•Evaluation and Reporting
Risk hazard = Consequence X Likelihood
Types of RBI Analysis
• Level I - Qualitative risk analysis, simple ,
brief prioritization of equipment.
• Level II - Semi-quantitative risk analysis,
more detailed prioritization and
planning.
• Level III - Quantitative risk analysis, in
depth analysis
Risk Assessments
Perform minimum level of analysis necessary
to provide information adequate for decision
making.
•Detailed analysis, when not necessary, does not only not
benefit the decision maker, but also inappropriately use
resources which could have been spent reducing the risk
By inappropriately using resources (time and money)
one increases the risk
API 580 and 581
API Risk Based Inspection Project was initiated in 1993
and due for completion later this year.
API 580 Recommended Practice that
describes all vital issues to be considered
when implementing a RBI program . Not
prescribing - Recognizes different risk
approaches.
API 581 Base Resource Document that
describes specific RBI methodology for oil
and gas plants.
Risk Measurement
No risk standards in petrochemical industry -
many variables and uncertainties
- therefore no absolute risk (cannot fully quantify the risk)
For risk calculations associated with RBI
- usually use relative risk (rank equipment relative to each
other)
Accuracy is not as important as consistency in
assigning likelihood and consequence values
Output and Reporting
1) Reporting relative risk as numbers or simply high, medium or low
2) Quantify risk as a value - Area or dollars / frequency (sq ft/year)
3) Risk matrix
Prioritize equipment
Inspection Scope and Frequency
Develop Specific Inspection Plans
Turnaround planning
STUMBLING BLOCKS
Misconception that project may threaten jobs
Change may make personnel feel uncomfortable or
incompetent
People perceive risk differently
If you can remove the misconceptions that
1) Risk is a theoretical tool without practical application and
2) Meaningful risk calculations cannot be performed in
situations with sparse data,
the hardest part of the project is over.
Options for Implementation
• Team Process
– Project Manager/Champion
– Data Clerks, Inspectors, Maintenance,
– Reliability, Operations
– Process Engineer
– Metallurgical/Corrosion Engineer
• Cost
– Priced per equipment item
– Software
• Time
– Depends on team size (approx. 50 items per week)
• Company Options
– Do it yourself
– Part time assistance or Technology Transfer
– Hand over to consultants
Risk Directed Management Process
• Determine Goals/Objectives
• Assemble Resources
• Determine Technical Approach
• Conduct Initial Screen (Scope)
• Identify Hazards
• Develop Initial Risk Ranks
• Establish Inspection Plan
• Deal with High Risk Items
• Evergreen Implementation/MOC
Goal/Ojectives
Assemble Determine Technical
Resources Approach/Software
Initial Screen (Scope)
RISK MANAGEMENT Identify
Hazards
Data
Collection
COF LOF
Quality Initial Risk
Assurance Ranks
(QA)
Risk Management Others
MOC/
Risk Reduction
Operational (Mitigation)
Changes No
Deficiencies Inspection Deficiencies
Others
Plans
Evergreen Fitness For
Implementation Services
Remedial
Actions
RDMIPTM System
Volume I —RDMIP Management Overview
Volume II— RDMIP Implementation
Volume III—RDMIP Work Management Program
Volume IV—Software Manual
Volume V—Training Manual
RDMIPTM Software Features
• Over 5 years in Development
• Modules for
– Fixed Equipment (to Subcomponent Level)
– Piping (to Circuit & Element Level)
• Useful for Any Process Facility
• Levels A & B, Simple to Advanced
• Reports for Operations, Maintenance, and Inspection
• Can interface with Existing Inspection Planning SW
• 1600 Chemicals and Toxics, Mixing Rules
• 70 Damage Mechanisms
Rank Equipment
Process Documentation
Risk Ranking Units Review
Development of Equipment
Worksheet
Scope:
Pressure Vessels Consequence
Likelihood of
of Failure
Piping (COF)
Failure (LOF)
Dynamic Equipment (Pumps) Identify Industry Specific
Review of
Tanks Process and
Unit Exp.(Interviews -
Process, Maint.
Relief Devices Operational Data
Engrs./Insp.)
I&C Gather Data for Identify Potential
Consequence Damage
Software tools for all equipment Estimate Mechanisms
Calculate Identify
Preliminary Failure
Consequence Index Modes
Identify
Calculate Initial
Consequence
Damage Rank
Modifiers
Review and Review and
Adjust COF Adjust LOF
Rating Rating
Risk
Directed
Risk Rank = COF Inspection
x LOF Plan -
Scope &
Risk Management
Risk Management
Reduce risk of equipment by reducing the consequence of failure,
likelihood of failure or both.
Consequence Mitigation:
•Reduce Inventory
•Alarms
•Sprinklers, Dikes
•Isolation valves
Use Process Flow Diagrams and
P&ID’s to Highlight areas of
High COF and plan mitigation steps
Risk Reduction
LOF Reduction is not only restricted to inspections.
Likelihood Mitigation:
• Inspection and Maintenance
•Understanding damage
•Correct NDE techniques
•MOC/Record Keeping/Report
•Repair, Replace, FFS
•Operational Controls
•Online Monitoring
•Materials
Inspection Planning
After Development of the Risk Matrix and
Prioritization of Equipment
• Inspection Schedules
– Based on Risk ranking
– Damage mechanisms
– Internal / External / Both
– Online / By Pass / Shutdown
– Operational considerations
• Specific Equipment Inspection Plans
How, what, where and how often
(Damage mechanisms, NDE techniques, scope and
frequency)
Successful Implementation
•Management Approval/RBI Champion
•Determine Goals and Plan
•Determine Approach/Software
•Assemble Team
•Collect data
•Input
•Analyze
•Develop Inspection Plans Based
on Risk Ranking
•Begin with Critical Equipment List
•Document Findings
•Update, Improve and Maintain
•Present Results
Overall Benefits
4Regulatory Compliance/Acceptance
4 Improved Safety and Reduced Risk
4 Long Term Cost Benefits
4 TML Reduction
4 Focus Inspection Resources
4Turnaround Planning
4 Use of New Inspection Technology
4 Informed, Documented, Defensible Decisions
Conclusions
1) RBI is becoming recognized by industry as a cost
effective methodology for the planning of inspection
and maintenance activities
2) Case studies demonstrate cost savings and
justification for program
3) Can be relatively simple to implement using
existing inspection data
4) Vision is to standardize and integrate all
inspection planning tools
5) APTECH has the experience, personnel and tools
to achieve this goal
