API RBI SOFTWARE

Originally developed as an API-sponsored joint industry project to implement the

recommended procedures and quantitative calculations for Risk-Based Inspection (RBI) as
defined in API RP 581, API RBI is now developed and maintained by the experts at E²G.
API RBI remains the only true quantitative tool available that is fully compliant with
API RP 581, including the most recent updates.

A P I R B I K E Y D I F F E R E N T I AT O R S

DA M AG E FAC TO R C A LC U L AT I O N S PRESSURE RELIEF DEVICE SUPPORT

» All API RP 581 damage mechanisms are supported » Manage multiple protected components

» User-defined extensions such as direct damage » All overpressure scenarios considered, including
factor entry to support additional cracking user- specified cases
damage mechanisms are supported

LEVEL 1 AND LEVEL 2 CONSEQUENCE INVENTORY GROUPS

MODELS

» Standard representative fluids for simple modeling » Manage components at the unit level to
accurately define fluid inventory and additional
» State-of-the-art proprietary fluid modeler release mass
available to calculate multi-component fluid
streams and two-phase fluid mixture properties » Accurately characterize risk; this is not considered
over a significant range of operating conditions by many solutions

Q UA N T I TAT I V E O U T P U T A DVA N C E D I N S P E C T I O N P L A N N I N G

» Risk reduction can be compared to reliability » Standard risk and damage factor plans based on
program expenses superposition approach to multiple damage factors

» Risk values expressed in safety area or financial » Advanced options, including secondary damage
terms mechanism consideration and minimum thickness
targets, refined through extensive real world
» Qualitative risk interpretation using tools such application
as configurable risk matrices, including the new
ISO-risk format » Inspection plan reports available for each piece of
equipment
» Numerous risk, POF, and COF reports are available

HEAT EXCHANGER TUBE BUNDLE SUPPORT AT M O S P H E R I C S T O R A G E TA N K S U P P O R T

» Cost/benefit analysis incorporating Bayesian » Standard tank consequence financial model

updating provided

» Extensive failure database provided to supplement » Additional Level 2 consequence model available,
customer historical data superposition approach leveraging fluid modeler for safety area results
to multiple damage factors
» Tanks designed to API 650 as well as low-pressure
» Advanced options, including secondary damage API 620 tanks supported
mechanism consideration and minimum thickness
targets, refined through extensive real world
application
API RBI
A P I R B I S O F T WA R E D E TA I L S
D A T A + R E S U LT S The API RBI application provides equipment and
component-level extensions to PlantManager™ for
the additional data considered in the RBI process.
A P I R B I R E S U LT S
A series of input categories in a convenient tab
The API RBI application delivers a calculated inspection plan layout organizes all required and supplemental data
for each component based on risk, defined in API RP 581 as the in an instantly accessible structure:
product of POF and COF.

» When the calculated risk for a component exceeds a

user-specified risk target before the specified plan date,
an inspection will be recommended with the category or
inspection level required and a target date for inspection.

» Each plan includes inspection recommendations for

thinning, cracking, external damage, and HTHA.

» A detailed risk results summary is provided for risk and

damage factors at the RBI date, the target date of SUBTITLE
MONTH, YEAR

inspection, the specified plan date without inspection, and

the specified plan date with inspection.

» Detailed damage factor and consequence results are easily

accessible for insight into the risk drivers for each component.

API RBI REPORTS

PlantManager™ provides a custom reporting plugin allowing GENERAL
for analysis and visualization using third-party software such
Design, geometry, material of construction, and inventory group.
as Excel, Crystal Reports, SQL Server Reporting Services,
and others. Using this feature, specified users may archive
COMPONENT SETTINGS
time-stamped snapshots of the complete API RBI database,
allowing powerful analysis of data, such as total risk over Level 1 or Level 2 consequence model, RBI date, RBI target,
time, and comparing time-based and risk-based approaches plan date, and other component settings used to calculate risk.
to inspection.
O P E R AT I N G C O N D I T I O N S
API RBI includes more than 30 standard RBI summary sheets Operating pressure, temperature, and process fluid.
categories such as the following:
INSPECTION HISTORY
» Inspection planning – Available summary collates all
equipment and components, design and operating Inspection activity can be entered directly or imported from
conditions, recommended inspection levels, and dates external sources.

» Fixed equipment VOLUME AND MASS

» POF Detailed fluid state data calculated by E²G’s proprietary fluid

modeler, with user-optional overrides. Volume and mass are
» COF computed for entire inventory groups and considered for
release in the event of containment loss.
» Risk matrix reports – available for both area and financial
targets in the traditional 5x5 or ISO-risk format DAMAGE MECHANISMS

» Pressure relief devices Each damage mechanism defined in API RP 581 is available
based on the selected material of construction and easily
» Heat exchanger tube bundles activated via a simple control interface. Only the input data
for the activated damage mechanisms is displayed at any
» Tank summaries given time and supplemented by relevant information from
other input areas, as well as previously calculated output,
to assist in evaluating the appropriate settings.
RBI CASE STUDY

O P T I M I Z E I N S P E C T I O N S T R AT E G I E S TO F O C U S O N H I G H - R I S K A S S E T S

Planning for a turnaround is a major endeavor. All accessible vessels are typically candidates for an intrusive
inspection. The Turnaround Planner prioritizes inspection activities, allowing the inspectors to focus their
attention on high-risk assets during the turnaround.

PROBLEM API RBI 581 R E C O M M E N DAT I O N S

ASSESSMENTS

The initial plan was to inspect A rigorous API 581 assessment was Based on components requiring
equipment in the Catalytic Reforming performed. The assessment analyzed additional mitigation action besides
Unit based on the API 510 time-based many aspects of the piece of equipment inspection:
interval. In addition, many assets were including, but not limited to, operation
scheduled to be stripped of insulation temperature and pressure, process fluid, » Perform the recommended inspection
for a CUI inspection. The inspection material of construction, thickness activities noted in the inspection
activities were numerous. The facility surveys, and damage mechanisms. plan.
desired to optimize the inspection
activities before the scheduled shutdown. » Actions such as the removal of
insulation, the increasing of the
corrosion allowance, or changes
to the metallurgy are suggested to
reduce the unmitigated risk to an
acceptable level.

CURRENT RISK VS. INSPECTION-MITIGATION RISK

BENEFITS TO THE CLIENT
200
Risk with Inspection FLEXIBILITY
Risk without Inspection
150 The inspections can be satisfied with either an intrusive or
Risk Target
non-intrusive inspection method, allowing more flexibility in
Risk (ft²)

scheduling the inspection activities. This also alleviates the issue

100 of having all inspections completed during the shutdown.

C O ST SAV I N G S
50
The RBI assessment in this unit provided significant cost savings
0
to the facility. The facility can restructure inspection resources
to focus on high-risk assets in other units. While inspection
Components cost savings are not the primary goal of an RBI assessment, in
many instances, it is a byproduct of optimizing the inspection
A total of 100 components are in the Catalytic Reforming unit. activities.
Each column represents one component. Components are
arranged from highest risk (left) to lowest risk (right) in the CONTINUOUS IMPROVEMENT
chart. When the risk level reaches the risk target, an inspection
activity is required. There are 21 components that exceed the Utilization of RBI provides a vehicle for continuously improving
risk target in the plan period. Seven components require other the inspection of facilities and systematically reducing the risk
risk mitigation to manage the risk besides inspection activity. associated with pressure boundary failures.

CORPORATE HEADQUARTERS SATELLITE OFFICE CONTACT

20600 Chagrin Boulevard, Suite 1200 Houston, TX 216.283.9519

Shaker Heights, OH 44122 Software@E2G.com
www.E2G.com