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