Risk Based Inspection - RBI

Md Aminul Islam, CMRP, aminulju@gmail.
com 1
Risk Based
Inspection (RBI)
Md.Aminul Islam , CMRP, Reliability Engineer

Prepared by: Email: aminulju@gmail.com, Mob: +966-592475978
What is Risk-Based Inspection (RBI)?
2
A risk assessment and management process that is focused on loss of

containment of pressurized equipment in processing facilities due to
material deterioration. These risks are managed primarily through
equipment inspection.
The risk-based inspection is a systematic and integrated use of expertise
from the different disciplines that impact plant integrity. These include
design, materials selection, operating parameters and scenarios, and
understanding of the current and future degradation mechanisms and risks
involved.
Risk-based methodologies enable the assessment of the likelihood and
potential consequences of equipment failures. Risk-Based Inspection (RBI)
provides companies the opportunity to prioritize their equipment for
inspection; optimize inspection methods, frequencies, and resources; and
develop specific equipment inspection plans the extent of inspection, and
the most suitable type of Non-Destructive Examination (NDE).
Md Aminul Islam, CMRP, aminulju@gmail.com
3
RBI is most often used in engineering industries and is predominant in the oi

l and gas, petrochemical industries. Assessed risk level are used to
develop a prioritised inspection plan. It is related to
(or sometimes a part of) Risk Based Asset Management (RBAM),
Risk Based Integrity Management (RBIM) and Risk Based
Management(RBM).Generally, RBI is part
of Risk and Reliability Management (RRM). Inspections typically employ non-
destructive testing (NDT).
Risk-Based Inspection (RBI) is a methodology that, as opposed to condition-
based inspection involves 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.

4
RBI is a risk assessment and management tool that addresses an area not
completely addressed in other organizational risk management efforts such
as Process Hazards Analyses (PHA) or reliability centered maintenance
(RCM).
RBI produces Inspection and Maintenance Plans for equipment that
identifies the actions that should be implemented to provide reliable and
safe operation.
The RBI effort can provide input into an organizations annual planning and
budgeting that dene the stafng and funds required to maintain equipment
operation at acceptable levels of performance and risk.
Risk-Based Inspection is Proactive It Utilizes the Information Available to
Manage Risk

Purpose of Risk-Based Inspection
5
Screen operating units within a plant to identify

areas of high risk.
Estimate a risk value associated with the operation
of each piece of equipment
Prioritize the equipment based on the measured risk
Design an appropriate inspection program
Systematically manage the risk of equipment
failures. *

Purpose of Risk-Based Inspection
6
*Systematically manage the risk of equipment failures.

1) To improve risk management results
2) To provide a holistic, interdependent approach for managing risks
3) To apply a strategy of doing what is needed for safeguarding integrity and improvin
g reliability & availability of the asset by planning and executing those inspections
that are needed
4) To reduce inspections and shutdowns and provide longer run length without compr
omising safety or reliability
5) To safeguard integrity
6) To reduce the risk of failures
7) To increase plant availability and reduce unplanned outages
8) To provide a flexible technique able to continuously improve and adopt to changin
g risks
9) To ensure inspection techniques and methods consider potential failure modes
Key Elements of a RBI Program
7
Key elements that should exist in any RBI

program are:
Management systems for maintaining documentation,
personnel qualications, data requirements and analysis
updates.
Documented method for probability of failure determination.
Documented method for consequence of failure
determination.
Documented methodology for managing risk through
inspection and other mitigation activities.

Equipment Covered in RBI
8
The following types of pressurized equipment and associated

components/internals are covered by this document:
Pressure vesselsall pressure containing components.
Process pipingpipe and piping components.
Storage tanksatmospheric and pressurized.
Rotating equipmentpressure containing components.

Boilers and heaterspressurized components.
Heat exchangers (shells, heads, channels and bundles).

Pressure relief devices.

Equipment Not Covered in RBI
9
The following non-pressurized equipment is not covered by this

document:
Instrument and control systems.
Electrical systems.
Structural systems.
Machinery components (except pump and compressor
casings).

Risk Analysis
10
A risk assessment involves first establishing the current and

anticipated condition of the equipment, by asking the following
questions:
What material degradations have been experienced or could be
experienced?
What are the likelihood (probabilities) of these degradations occurring?
What are the consequences of these degradations?
The next step is to determine the risk of operating equipment as the
combination of two separate terms:
Risk = Likelihood or Probability of Failure x Consequence of Failure

Risk Analysis
11
Likelihood - failure per year - needs to understand failure cause (at what point it fails).
The likelihood analysis assesses the probability and effects of specific failure mechanisms based on:
The history of the equipment
The history of similar or identical equipment in identical service conditions
Consequence - need to understand failure mode (how it fails, what will result from failure).
Possible consequences:
1. Injury/fatality (safety) due to a toxic or flammable event
2. Environmental damage
3. Production Loss
4. Minimal impact (this is considered)
In general, risk is calculated as a function of time as follows. R(t) =POF(t)*C(t)

The probability of failure is a function of time, since damage due to cracking, thinning or other
damage mechanisms increases with time

Risk Analysis
12
In API RBI, the consequence of failure is assumed to be independent of time, therefore
R(t)= POF(t)*CA for Area Based Risk

R(t) = POF(t)*FC for Financial Based Risk
The Probability of Failure used in API RBI is:
POF(t) = Gff* Df(t)* Fms
POF(t)- the probability of failure as a function of time

Gff- Generic failure frequency
Df(t)- Damage factor as a function of time
Fms - Management systems factor

Risk Analysis
13
The time dependency of probability of failure is the basis of using RBI for inspection
planning
Risk cannot be reduced to zero solely by inspection efforts. The residual risk factors for
loss of containment include, but are not limited to, the following:
Human error.
Natural disasters.
External events (e.g., collisions or falling objects).
Secondary effects from nearby units.
Consequential effects from associated equipment in the same unit.
Deliberate acts (e.g., sabotage)
Fundamental limitations of inspection method.
Design errors.
Unknown mechanisms of deterioration.
Many of these factors are strongly inuenced by the process safety management system
in place at the facility.
Inspection Planning
14

Inspection Planning
15
Inspection plan is developed on a component basis

Equipment is modelled as a group of individual components in API
RBI
The final inspection plan for the equipment is based on the results
derived for the components
The inspection plan includes: The date and timing of the required
inspection, The type of Inspection method(s) / NDE (e.g. Visual,
UT, DPT, MPT, RT, ECT, WFMT) based on the active damage
mechanisms Extent of application of the inspection method(s)
(e.g., % of total area examined or specic locations). Location of
inspection (external or internal) - Risk management achieved
through implementation of the inspection plan.
The expected risk levels of all equipment after the inspection plan
and other risk mitigation activities have been implemented.
Types of RBI Assessment
16
Various types of RBI assessment may be conducted at several levels. The

choice of approach is dependent on multiple variables such as:
Objective of the study.
Number of facilities and equipment items to study.
Available resources.
Study time frame.
Complexity of facilities and processes.
Nature and quality of available data.
RBI is both a qualitative and quantitative process for systematically
combining both the likelihood of failure and the consequence of failure to
establish a prioritized list of pressure equipment basis total risk. Three levels
of risk based inspection have been developed by API for prioritizing risk
levels associated with individual pieces of pressure equipment.

17
Qualitative Risk Analysis (Assessment): Methods that use engineering

judgment and experience as the bases for the analysis of probabilities and
consequences of failure. The results of qualitative risk analyses are
dependent on the background and expertise of the analysts and the
objectives of the analysis. Failure Modes, Effects, and Criticality Analysis
(FMECA) and HAZOPs are examples of qualitative risk analysis techniques
that become quantitative risk analysis methods when consequence and
failure probability values are estimated along with the respective
descriptive input.
Semi-quantitative Risk Analysis (Assessment): This is an intermediate
method of quantitative RBI, for risk ranking individual pieces of equipment
in a process unit. Its also uses a risk matrix for displaying risk analysis
results. Semi-quantitative RBI analysis asks more questions, and therefore
takes more time to accomplish, but results in more accuracy and avoids
overly conservative risk ranking that may result from simpler methods.
18
Quantitative Risk Analysis (Assessment): An analysis that:

Identies 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.
Estimates the frequency of occurrence for each combination.
Estimates the consequences.
Quantitative risk analysis integrates into a uniform methodology the relevant information
about facility design, operating practices, operating history, component reliability, human
actions, the physical progression of accidents, and potential environmental and health
effects, usually in as realistic a manner as possible. Quantitative risk analysis uses logic
models depicting combinations of events that could result in severe accidents and physical
models depicting the progression of accidents and the transport of a hazardous material to
the environment. The models are evaluated probabilistically to provide both qualitative and
quantitative insights about the level of risk and to identify the design, site, or operational
characteristics that are the most important to risk. Quantitative risk analysis logic models
generally consist of event trees and fault trees. Event trees delineate initiating events and
combinations of system successes and failures, while fault trees depict ways in which the
system failures represented in the event trees can occur. These models are analysed to
estimate the frequency of each accident sequence
Planning the RBI Assessment
19
A RBI assessment is a team-based process. At the beginning of the exercise, it is

important to dene:
Why the assessment is being done
How the RBI assessment will be carried out.
What knowledge and skills are required for the assessment.
Who is on the RBI team.
What are their roles in the RBI process.
Who is responsible and accountable for what actions.
Which facilities, assets, and components will be included.
What data is to be used in the assessment.
What codes and standards are applicable.
When the assessment will be completed.
How long the assessment will remain in effect and when it will be updated.
How the results will be used.
Steps in applying RBI principles within
the framework:
20
1. Planning the RBI Assessment.

2. Define the Scope
3. Establish the Team
4. Roles, Responsibilities, Training and Qualications.
5. Create an Equipment List
6. General Equipment Data and Information Collection.
7. Identifying Deterioration Mechanisms and Failure Modes.
8. Assessing Probability of Failure.
9. Assessing Consequence of Failure.
10. Risk Determination, Assessment and Management.
11. Risk Management with Inspection Activities and Risk Benefit.
12. Other Risk Mitigation Activities.
13. Reassessment and Updating.
14. Documentation and record-keeping.
Benefits of RBI
21
A ranking by risk of all equipment evaluated.

A description of any other risk mitigation activities (such as repairs,
replacements or safety equipment upgrades).
An overall reduction in risk for the facilities and equipment assessed.
An acceptance/understanding of the current risk.
Improved health, safety and environment management
Avoiding unnecessary inspection Inspection intervals are based on the risks
associated with the equipment and therefore inspection personnel can
spend most of their time on the high risk areas and less time in the low risk
areas.
Cost saving Equipment with no history of problems and no anticipated
problems is inspected on longer intervals rather than just inspecting every
few years as is the case with a time-based inspection program.

Benefits of RBI
22
Information from inspections on one piece of equipment can be utilized in

determining the inspection intervals and scopes for similar equipment.
The RBI program is totally dynamic: risks are updated after inspections or
even the inspection of similar equipment, changes to process conditions
or even if new information becomes available. Any of the above may
result in a change in inspection frequencies or changes to the inspection
scopes.
The methods used to determine the inspection intervals and inspection
scopes are documented and repeatable.
Reliability and compliance with applicable Codes/Standards
Increasing plant availability and optimum repair and replacement
scheduling
Extended plant and equipment life.

ESTIMATING RESOURCES AND TIME
REQUIRED
23
The resources and time required to implement a RBI assessment

will vary widely between organizations depending on a number
of factors including:
Implementation strategy/plans.
Knowledge and training of implementers.
Availability and quality of necessary data and information.
Availability and cost of resources needed for implementation.
Amount of equipment included in each level of RBI analysis.
Degree of complexity of RBI analysis selected.
Degree of accuracy required.

ESTIMATING RESOURCES AND TIME
REQUIRED
24
The estimate of scope and cost involved in completing a RBI

assessment might include the following:
Number of facilities, units, equipment items, and components to be
evaluated.
Time and resources required to gather data for the items to be
evaluated.
Training time for implementers.
Time and resources required for RBI assessment of data and information.
Time and resources to evaluate RBI assessment results and develop
inspection, maintenance, and mitigation plans.

Data needed for a RBI analysis
25
Typical data needed for a RBI analysis may include but

is not limited to:
Type of equipment.
Materials of construction.
Inspection, repair and replacement records.
Process uid compositions.
Inventory of uids.
Operating conditions.
Safety systems.
Detection systems.
Deterioration mechanisms, rates and severity.
Personnel densities. k. Coating, cladding and insulation data.
Business interruption cost.
Equipment replacement costs.
Environmental remediation costs.
Potential sources of information
26
1. Design and Construction Records/Drawings.

P&IDs, PFDs, MFDs, etc.
Piping isometric drawings.
Engineering specication sheets.
Materials of construction records.
Construction QA/QC records.
Codes and standards used.
Protective instrument systems.
Leak detection and monitoring systems
Isolation systems.
Inventory records.
Emergency depressurizing and relief systems.
Safety systems.
Fire-proong and re ghting systems.
Layout.
27
2. Inspection Records.
Schedules and frequency.
Amount and types of inspection.
Repairs and alterations.
PMI records.
Inspection results.
3. Process Data.
Fluid composition analysis including contaminants or trace
components
Distributed control system data.
Operating procedures.
Start-up and shut-down procedures.
Emergency procedures.
Operating logs and process records.
PSM, PHA, RCM and QRA data or reports.
28
4. Management of change (MOC) records.

5. Off-Site data and informationif consequence may affect off-
site areas.
6. Failure data.
Generic failure frequency dataindustry or in-house.
Industry specic failure data.
Plant and equipment specic failure data.
Reliability and condition monitoring records.
Leak data.
7.Site conditions.
Climate/weather records.
Seismic activity records.
29
8. Equipment replacement costs.

Project cost reports
Industry databases.
9. Hazards data.
PSM studies.
PHA studies.
QRA studies.
Other site specic risk or hazard studies.
10. Incident investigations

Risk Based Inspection - In the context
of RCM
30
Functional Failure Mode-1

RCM
Functional Failure Mode-2
Functional Failure Mode-3 :Loss of containment**
**
1. Special knowledge & expertise required
2. Team structure is different to RCM (Mech, materials/corrosion,
ops, process, inspection)
3. Some failure modes happen over long period RBI start
Reassessment and Updating RBI
31
RBI is a dynamic tool that can provide current and projected future risk
evaluations. However, these evaluations are based on data and knowledge at
the time of the assessment. As time goes by, changes are inevitable and the
results from the RBI assessment should be updated. It is important to maintain
and update a RBI program to assure the most recent inspection, process, and
maintenance information is included. The results of inspections, changes in
process conditions and implementation of maintenance practices can all have
signicant effects on risk and can trigger the need to perform a reassessment.
Reasons to Conduct an RBI Reassessment: There are several events that will
change risks and make it prudent to conduct a RBI reassessment. It is
important that the facility have an effective management of change process
that identies when a reassessment is necessary.
Deterioration Mechanisms and Inspection Activities Process &
Hardware changes RBI Assessment Premise Change Effect of
Mitigation Strategies
Reassessment and Updating RBI
32
When to Conduct an RBI Reassessment:

After significant changes After a set Time Period After
Implementation of Risk Mitigation Strategies Before and After
Maintenance Turnarounds
Additional Reasons for Re-evaluation

Changes in RBI technology or improvements that affect the risk calculation
Changes in code that affect the recommendations Changes in law or
regulatory policies Change in company risk policy Process changes, includes
debottlenecking, changes in feed, changes in catalyst, changes in alloying, etc.
Considerations as learned from a failure in that plant or another plant with a
similar process Extension of run length between turnarounds

Five Critical Success Factors for Best
Practice RBI Program
33
1. Successful RBI Tool Implementation

2. Develop Operational Documents
3. Execute a Transition Phase
4. Establish a Training Program
5. Sustain and Review RBI Program
Other Key Information to Achieve Best Practice

Each RBI Program should have Four Phases
1. Implement
2. Transition
3. Sustain
4. Review/Measure

Codes and Standards
34
International engineering standards and recommended practices out

line requirements, methodologies and the implementation of RBI.
1. API 580 Risk Based Inspection Recommended Practice.
2. ASME PCC3 Inspection Planning Using Risk Based Methods.
3. API 581 Risk Based Inspection Resource.
4. DNV-
RP G101Risk Based Inspection Of Offshore Topsides Static Mecha
nical Equipment.
5. API 571 Damage Mechanisms Affecting Fixed Equipment in the R
efining Industry

CONCLUSION
35
RBI provides a logical, documented, repeatable methodology for

determining the optimum combination of inspection frequencies
and inspection scopes. RBI objective is to ensure focus of inspection
to areas with high risk, while inspection in areas with low risk will be
reduced or excluded from the normal inspection program and
therefore result in significant inspection and maintenance cost
reduction.

36

Risk Based Inspection - RBI

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Md Aminul Islam, CMRP, aminulju@gmail.

Md.Aminul Islam , CMRP, Reliability Engineer

A risk assessment and management process that is focused on loss of

RBI is most often used in engineering industries and is predominant in the oi

Md Aminul Islam, CMRP, aminulju@gmail.com

Md Aminul Islam, CMRP, aminulju@gmail.com

Screen operating units within a plant to identify

Md Aminul Islam, CMRP, aminulju@gmail.com

*Systematically manage the risk of equipment failures.

Key elements that should exist in any RBI

Md Aminul Islam, CMRP, aminulju@gmail.com

The following types of pressurized equipment and associated

Rotating equipmentpressure containing components.

Heat exchangers (shells, heads, channels and bundles).

Md Aminul Islam, CMRP, aminulju@gmail.com

The following non-pressurized equipment is not covered by this

Machinery components (except pump and compressor

Md Aminul Islam, CMRP, aminulju@gmail.com

A risk assessment involves first establishing the current and

Md Aminul Islam, CMRP, aminulju@gmail.com

In general, risk is calculated as a function of time as follows. R(t) =POF(t)*C(t)

Md Aminul Islam, CMRP, aminulju@gmail.com

In API RBI, the consequence of failure is assumed to be independent of time, therefore

R(t)= POF(t)*CA for Area Based Risk

The Probability of Failure used in API RBI is:

POF(t) = Gff* Df(t)* Fms

POF(t)- the probability of failure as a function of time

Md Aminul Islam, CMRP, aminulju@gmail.com

Md Aminul Islam, CMRP, aminulju@gmail.com

Inspection plan is developed on a component basis

Various types of RBI assessment may be conducted at several levels. The

Md Aminul Islam, CMRP, aminulju@gmail.com

Qualitative Risk Analysis (Assessment): Methods that use engineering

Quantitative Risk Analysis (Assessment): An analysis that:

A RBI assessment is a team-based process. At the beginning of the exercise, it is

1. Planning the RBI Assessment.

A ranking by risk of all equipment evaluated.

Md Aminul Islam, CMRP, aminulju@gmail.com

Information from inspections on one piece of equipment can be utilized in

Md Aminul Islam, CMRP, aminulju@gmail.com

The resources and time required to implement a RBI assessment

Md Aminul Islam, CMRP, aminulju@gmail.com

The estimate of scope and cost involved in completing a RBI

Md Aminul Islam, CMRP, aminulju@gmail.com

Typical data needed for a RBI analysis may include but

1. Design and Construction Records/Drawings.

4. Management of change (MOC) records.

8. Equipment replacement costs.

Md Aminul Islam, CMRP, aminulju@gmail.com

Functional Failure Mode-1

Functional Failure Mode-3 :Loss of containment**

When to Conduct an RBI Reassessment:

Additional Reasons for Re-evaluation

Md Aminul Islam, CMRP, aminulju@gmail.com

1. Successful RBI Tool Implementation

Other Key Information to Achieve Best Practice

Md Aminul Islam, CMRP, aminulju@gmail.com

International engineering standards and recommended practices out

Md Aminul Islam, CMRP, aminulju@gmail.com

RBI provides a logical, documented, repeatable methodology for

Md Aminul Islam, CMRP, aminulju@gmail.com

Md Aminul Islam, CMRP, aminulju@gmail.com

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