Materi Narsum III

1
Evolution of Inspection
management
Fixed Condition Risk
Interval Based Based
Everything Trend Analysis Risk Analysis

inspected at Consequences (Probability and
the same not Considered Consequences)
interval Reactive Proactive
(Backward Looking) (Forward Looking)
Introduction 3
Illustration
Water Disposal Condensate HP Gas

Operation 8 hour / day Operation 8 hour / day Operation 24 hour / day
Inside plant Inside plant Inside plant
Low Risk Medium Risk High Risk
Inspection based on Time Based, same interval every 1 year

Not consider with fluid contains and location
With RBI will be change for inspection interval
Introduction 4
Why need RBI
Causes of Major Property Losses in the Oil Refining and
Petrochemical Industries During Period 1960 to 1990
Mechanical Failure
Operational Error
Process Upset
Natural Hazard
Design Error
Sabotage/Arson
Others/Unknown
0 10 20 30 40 50
Introduction Percent of Losses 5
Why need RBI

Equipment Involved in Major Property Losses in the Oil
Refining and Petrochemical Industries During 1960 to 1990
Piping Systems
Tanks
Reactors
Drums
Pumps/Compressors
Heat Exchangers
Towers
Heaters/Boilers
Others/Unknown
0 5 10 15 20 25 30 35
Introduction Percent of Losses 6

Why need RBI
Frequency and Cost of Major Property Losses in the Oil
Refining and Petrochemical Industries 1960 to 1990
100 5
Number
BILLIONS OF DOLLARS
Cost
80 4
Number of Losses
60 3
40 2
20 1
0 0
1962-71 1972-81 1982-91
Introduction 7
Major property loss
Introduction 8
How Risk is Used for Planning
Tolerable line risk level
Mitigation
Probability of failure
Activity
Based line risk level

Time in service
Introduction 9

Maintain too late - Excessive risk
Mitigation
Tolerable line risk level Activity

Time in service
Introduction 10
Maintain too early Excessive cost
Tolerable line risk level
Mitigation Mitigation
Activity Activity

Time in service
Introduction 11
Potential Benefits of RBI

Increased plant availability due to
better inspection and maintenance
fewer Critical failures
the use of on-line methods
Reduced risk of failure due to
use of methods that match failure modes
Reduced direct costs for low risk items
Introduction 12
Recommended Practice for
Risk Based Inspection
History
OSHA in 1992, issued standard Process safety
management of highly Hazardous Chemical, with one
of statement is
Inspection and test shall be performed on process
equipment and inspection and testing procedures and
the frequency of inspection shall follow generally
accepted good engineering practices
History
API RBI was initiated as joint industry project in
August 1993, with 16 sponsors
Publication produced
API 581 Based Resource Document Risk based Inspection
(1st edt. May, 2000),
Provides quantitative RBI methods for inspection planning
Grew to 25 sponsor companies as January 2001
History
Publication produced
API RP 580 Risk based Inspection (1st edt. May, 2002),
Introduces the principles and presents minimum
general guidelines for RBI
API RP 581 Risk based Inspection Technology (2nd edt.

September 2008), significantly revised to a new three
part document
- Part 1: Inspection Planning Using API RBI Technology
- Part 2: Determination of Probability of Failure in an API RBI Assessment
- Part 3: Consequence Analysis in an API RBI Assessment
API RP 580 Risk based Inspection (2nd edt. November

2009)
API RP 580 Sponsors
TEXACO MOBIL ARCO
BP DOW DSM
SHELL ARAMCO CANADA
UNOCAL
CITGO SUN
PETRO-
KOCH CONOCO
CANADA
EXXON MARATHON SYNCRUDE
CHEVRON FINA
DNO HEATHER EQUISTAR
AMOCO ASHLAND
PENNZOIL SYNCRUDE
Overview of API 580 Contents

Purpose, Scope, Normative reference
Basic Risk Assessment Concept
Introduction to Risk-Based Inspection
Planning the RBI Assessment
Data and Information Collection for RBI Assessment
Damage Mechanisms and Failure Modes
Assessing Probability of Failure
Assessing Consequence of Failure
Overview of API 580 Contents
Risk Determination, Assessment and Management
Risk Management with Inspection Activities
Other Risk Mitigation Activities
Reassessment and Updating RBI Assessments
Roles, Responsibilities, Training and Qualifications
RBI Documentation and Record Keeping
Summary of Pit RBI Pitfalls
Purpose
Intended to provide guidance on :
Developing
implementing
maintaining
a risk based inspection program on fixed equipment and
piping in the hydrocarbon and chemical process industries.
Or
What RBI is
What are the key elements of RBI
How to implement an RBI Program
20
Purpose
The expected outcome from the use of the RBI process
should be the linkage of risk with appropriate inspection,
process control, or other risk mitigation activities to
manage risk.
The RBI process is capable of generating:

A ranking by relative risk of all equipment evaluated;
Description of the inspection plan for each equipment item,
including:
- inspection method(s)
- extent of application of the inspection method(s) (e.g. percent of
total area examined or specific locations)
- risk management achieved through implementation of the
inspection plan;
21
Purpose
Description of any other risk mitigation activities such
as repairs, replacements or safety equipment upgrades,
Expected risk levels of all equipment after the inspection
plan and other risk mitigation activities have been
implemented
identification of risk drivers.
22
RBI Benefits and Limitations
The primary work products of the RBI assessment
and management approach are plans that address
ways to manage risks on an equipment level.
These equipment plans highlight risks from a:

Safety
Health
environment
Economic

Implementation of these plans provides :
an overall reduction in risk for the facilities and
equipment assessed,
an acceptance/understanding of the current risk.
identify equipment that does not require inspection or
some other form of mitigation because of the
acceptable level of risk
RBI will not compensate for:
inaccurate or missing information,
inadequate designs or faulty equipment installation,
operating outside the acceptable IOW (integrity
operating windows),
not effectively executing the plans,
lack of qualified personnel or teamwork,
lack of sound engineering or operational judgment.
RBI, PHA, HAZOP, RCM

RBI is a risk assessment and management tool that
addresses an area of risk management not
completely addressed in other organizational risk
management efforts such as process hazards analyses
(PHA), IOWs or reliability centered maintenance
(RCM).
The RBI process is focused on maintaining the
mechanical integrity of pressure equipment items and
minimizing the risk of loss of containment due to
deterioration.
Typically, PHA risk assessments focus on the process

unit design and operating practices and their
adequacy given the units current or anticipated
operating conditions.

RBI complements the PHA by focusing on the
mechanical integrity related damage mechanisms
and risk management through inspection.
RBI also is complementary to RCM programs in that

both programs are focused on understanding failure
modes, addressing the modes and therefore
improving the reliability of equipment and process
facilities
Correlation With Other Standard
API STANDARD :
API 510, Pressure Vessel Inspection Code: Maintenance

Inspection, Rating, Repair, and Alteration
API 570, Piping Inspection Code: In-service Inspection,

Rating, Repair, and Alteration of Piping Systems
API 653, Tank Inspection, Repair, Alteration, and

Reconstruction
Correlation With Other Standard .

API 510, 570 & 653 are standards
API 580 is a Recommendation Practice
RBI is not a replacement for API-510, 570 or 653!

We may do RBI, but all inspection must still meet the
requirements of API 510, 570 & 653
API 510 (9th edition)
Sect 5 Inspection, examination and pressure testing
practice
5.2 RBI can be used to determine inspection intervals
and the type and extent of future inspection /
examination
5.2.1 Probability Assessment
5.2.2 Consequence Assessment
5.2.3 Documentation
5.2.4 Frequency of RBI Assessments

Sect 6 Risk-based Inspection
6.3.1 A RBI assessment may be used to establish
the appropriate inspection intervals for internal, on-
stream, and external inspections. The RBI assessment
may allow previously established inspection intervals to
be exceeded from limits specified in 6.4 and 6.5
including the 10-year inspection and one-half remaining
life limits for internal and on-stream inspections, and
the five-year inspection limit for the external
inspections.
6.3.2 When a RBI interval for the internal or on-
stream inspection exceeds the 10-year limit, the RBI
assessment shall be reviewed and approved by the
engineer and inspector at intervals not to exceed 10 years
or more often if warranted by process, equipment, or
consequence changes.
6.3.3 When a RBI assessment is used to extend the
internal or on-stream inspection interval, the
assessment should include a review of the inspection
history and potential fouling of the vessels pressure-
relieving device(s).

API 570 (3rd edition)
This inspection code recognizes RBI concepts for
determining inspection intervals. API 580 provides
guidelines for conducting a risk-based assessment.
RBI can be used to determine inspection intervals and the
type and extent of future inspection/examinations (Par
5.2)
5.2.1 Probability Assessment
5.2.2 Consequence Assessment
5.2.3 Documentation
5.2.4 Frequency of RBI Assessments
An RBI assessment may be used to increase or decrease the
inspection limits described in Table 2 (par 6.3.2)
API 653 (3rd edition)
RBI assessment used to establish appropriate tank
bottom inspection interval (Table 6.1)
When using an RBI interval for the internal or on-
stream, the RBI assessment shall be reviewed and
approved by the engineer and inspector at least every
10 years
Approval by an authorized inspector and an
engineer(s), knowledgeable and experienced in tank
design (including tank foundations) and corrosion
Goal
The goal of inspection is
The safety and reliability of operating facilities
The goal of RBI is

To develop plans that address way to manage
risk on an equipment level
Goal
The output of the inspection planning process
conducted according to these guidelines should be an
inspection plan for each equipment item analyzed that
includes:
a) inspection methods that should be used,
b) extent of inspection (percent of total area to be
examined or specific locations),
c) inspection interval or next inspection date (timing),
d) other risk mitigation activities,
e) the residual level of risk after inspection and other
mitigation actions have been implemented.
Scope
Industrial Scope
Specially targeted at the application in the
hydrocarbon and chemical process industry.
Flexibility in Application
Other RBI methods exist and are currently being
applied throughout industry. API RP 580 is not
intended to single out one specific approach as the
recommended method for conducting an RBI effort.
The document instead is intended to identify and
clarify the essential elements of an RBI analysis and
program
Equipment covered
a) Pressure VesselsAll pressure containing
components.
b) Process PipingPipe and piping components.
c) Storage TanksAtmospheric and pressurized.
d) Rotating EquipmentPressure containing
components.
e) Boilers and HeatersPressurized components.
f) Heat exchangers (shells, floating heads, channels,
and bundles).
g) Pressure-relief devices.
Equipment not covered

a) instrument and control systems,
b) electrical systems,
c) structural systems,
d) machinery components (except pump and
compressor casings).
Target Audience
The primary audience is inspection and engineering personnel
who are responsible for the mechanical integrity and operability
of equipment .
RBI is not exclusively an inspection activity.
RBI requires the involvement of various segments of the

organization such as engineering, maintenance and operations.
RBI requires the commitment and cooperation of the total

operating organization.
should be familiar with the concepts and principles embodied in

the RBI methodology
What is Risk
RISK is the change of something bad happening
from aspect of :
Safety
Health
Environment perspective
Economic stand point
Change Probability
Something Consequence
What is Risk
Risk is the combination of the probability of some event
occurring during a time period of interest and the
consequences, (generally negative) associated with the event.
In mathematical terms :
Risk = Probability Consequence
Effective risk assessment, contains at least two key steps.

First to determine how big the risk is
second, to determine whether the risk is acceptable.
What is Risk
Probability (likelihood)
Extent to which an event is likely to occur within the
time frame under consideration.
Consequence
An outcome from an event, always negative for safety
aspects.
Event
Occurrence of a particular set of circumstances.
What is Risk
Risk Management and Risk Reduction
Risk management - a process to assess risks, to determine

if risk reduction is required and to develop a plan to
maintain risks at an acceptable level.
By using risk management, some risks may be identified as

acceptable so that no risk reduction (mitigation) is required
What is Risk
Risk reduction - the act of mitigating a known risk to a
lower level of risk.
Risk reduction is only a part of risk management.

It is a process to :
Assess risks
Determine if risk reduction is required
Develop a plan to maintain risks at an acceptable level
What is risk
Correlation inspection with risk
Risk with typical inspection program

Risk
Risk using RBI

and an optimized Residual risk not
inspection program effected by RBI
Level of inspection activity
What is risk
Risk cannot be reduced to zero, still have residual risk.
The residual risk, are :

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 methods,
design errors,
unknown or unanticipated mechanisms of damage.
What is risk
Developing an inspection program to manage with risk
with RBI involve systematically identifying :
What type of damage to inspect for
Where to find the identified damage
What inspection technique to use
How often to inspect
What is risk (result)

Calculation of Risk in API RBI
Involves determination of Probability Of Failure (POF) and
consequence of failure (COF) for pressurized equipment
Failure in API RBI is defined as loss of containment resulting
in leakage to atmosphere or rupture of vessel
Accumulation of damage over time results in increased risk
At some point in time, the calculated risk exceeds a user
specified risk target and an inspection is required
Role of Inspection in API RBI

Inspection is used to better quantify damage
Reduces uncertainty, reducing probability of unexpected
failures
Key element
Key elements that should exist in any RBI program
include:
management systems for maintaining documentation,
personnel qualifications, data requirements, consistency
of the program and analysis updates;
documented method for POF determination;
documented method for COF determination;
documented methodology for managing risk through
inspection, process control and other mitigation
activities.
Consequence and Probability

The objective of RBI is to determine what incident
could occur (consequence) in the event of an
equipment failure, and how likely (probability) it is
that the incident could happen
For example, if a pressure vessel subject to damage

from corrosion under insulation develops a leak
Consequence could occur :
Minor seep have minimal impact on safety and production
Small hole cause minor environmental / safety incident
Large hole result in major spill creating a significant
environmental incident
Catastrophic failure release that has major impact on the
facilities
Probability (likelihood) how many leak from CUI

happened on one year

Combining the probability of one or more of these
events with its consequences will determine the risk to
the operation.
Some failures have potentially serious consequences, but if

the probability of the incident is low, the risk may not
warrant immediate or extensive action
if the probability and consequence combination (risk) is

high enough to be unacceptable, then a mitigation action to
reduce the probability and/or the consequence of the event is
appropriate
Iso risk line
POF RISK RANKING An iso risk line

Represent a constant
Significant Risk level.
3 2 1 To separate acceptable
Risk item from unacceptable
Moderate
4 3 2
Minor
5 4 3
Low Medium High Iso Risk line
COF
Type of Risk assessment

Various types of RBI assessment, but they all have the
same result end.
The choice of approach is dependent on :

objective of the study,
number of facilities and equipment items to study,
available resources,
assessment time frame,
complexity of facilities and processes,
nature and quality of available data,
the amount of risk discrimination needed.
Continuum of RBI approaches
High
Detail of
RBI analysis
Low
Qualitative Semi quantitative RBI Quantitative
RBI RBI

Qualitative Approach
Requires data inputs based on descriptive information
using engineering judgment and experience
Given in data ranges instead of discrete values
Given in qualitative terms (high, medium, low)
Enables risk analysis in the absence of detailed
quantitative data
Simple brief prioritization of equipment
Quantitative Approach
Fully QRA integrates lots of relevant information :
facility design,
Operating practices,
Operating history,
Component reliability,
Human actions,
Physical progression of accidents,
Potential environmental and health effects.

The traditional QRA is generally comprised of five
tasks:
systems identification,
hazards identification,
probability assessment,
consequence analysis,
risk results.
The QRA typically involves a much more detailed
evaluation than an RBI analysis.
The following data are typically analyzed:
existing HAZOP or PHA results,
dike and drainage design,
hazard detection systems,
fire protection systems,
release statistics, injury statistics,
population distributions,
Topography,
Weather conditions,
Land use

Use logic models of event trees and fault trees.
Event trees delineate initiating events and
combinations of system successes and failures,
Fault trees depict ways in which the system failures
represented in the event trees can occur.
These models are analyzed to estimate the
probability of each accident sequence.
Results using this approach are typically presented as
risk numbers (e.g. cost per year).
A QRA is generally performed by experienced risk
analysts
A QRA deals with total risk, not just risk associated
with equipment damage

Semi-quantitative Approach
Semi-quantitative is a term that describes any
approach that has aspects derived from both the
qualitative and quantitative approaches
Most of the data used in a quantitative approach, but
in less detail
The results are given in consequence and probability
categories than as risk numbers
Geared to obtain the major benefits of qualitative and
quantitative approaches. Has the speed of one, and
the detail of the other
Tree types of RBI assessment approaches
Level Input Result Value
Qualitative Provide in data ranges Given in qualitative Enables risk analysis in
rather than discrete terms the absence of detailed
value. Required data (low, medium, high) quantitative data,
input based on simple, brief
engineering judgments prioritization of
and experience equipment
Semi Quantitative Most of the data used in Result are usually given Geared to obtain the
quantitative approach, in consequence and major benefits of
but less detail probability categories quantitative
rather than as risk approaches. Has the
number speed of one, and the
detail of the other
Quantitative Typically uses logic Higher accuracy. Result More accurate. More
model. Contains more from this approach as detailed prioritization
detailed information risk number (cost per and planning
year)
RBI planning process

RBI typically uses aspects of qualitative, quantitative
and semi-quantitative approaches. These RBI
approaches are not considered as competing but
rather as complementary
Consequence of
Data & failure
Information Risk Inspection Mitigation
Collection ranking plan (if any)
Probability of
failure
Reassessment
Getting Started
it is important to answer the following questions
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?
What is the plan period?

After planning, the following should have been
completed:
establish the objectives of the risk analysis,
identify the physical boundaries,
identify the operating boundaries,
develop screening questions and criteria consistent with
the objectives of the analysis and identified physical and
operating boundaries.
Establishing Objectives and Goals of an RBI
Assessment
All team members need to understand goals and
objectives of the assessment
Understand Risks - understand the risks involved in the
operation of a plant or process unit and to understand
the effects that inspection, maintenance and mitigation
actions have on the risks
Define Risk Criteria - establish criteria to judge
acceptability of risk

Management of risks identification of risk reducing
actions (not always related to inspect on activities)
Reduce Costs reducing inspections costs is a side
effect of optimization.
This is because :
ineffective, unnecessary or inappropriate inspection activities
may be eliminated;
inspection of low-risk items may be eliminated or reduced;
on-line or noninvasive inspection methods may be
substituted for invasive methods that require equipment
shutdown;
more effective infrequent inspections may be substituted for
less effective frequent inspections
Meet Safety and Environmental Management Requirements - RBI focuses
efforts on areas where the greatest risks exist
Identify Mitigation Alternatives - Data in the RBI assessment can be useful in
determining the optimum economic strategy to reduce risk.
This could include: but not limited to
modification of the process to eliminate conditions driving the risk;
modification of operating procedures to avoid situations driving the risk;
chemical treatment of the process to reduce deterioration rates/susceptibilities;
change metallurgy of components to reduce POF;
removal of unnecessary insulation to reduce probability of corrosion under
insulation;
reduce or limit available inventories to reduce COF;
upgrade safety, detection or loss limiting systems;
change process fluids to less flammable or toxic fluids;
change component design to reduce POF;
process control and adherence to IOWs.

New Project Risk Assessment - An RBI on a proposed
new project can provide another eye to identify
potential risks. This may allow potential risks to be
designed out or have a RBI plan in place prior to
actual installation
Facilities End of Life Strategies - As equipment nears
end of life, its risk can increase. RBI will identify this
as a high risk with appropriate mitigation steps
identified.
FFS assessment of damage component may be used
It is important to revisit the RBI assessment if the
remaining life is extended
Initial screening
focuses the analysis on the most important group of
equipment items so that time and resources are more
effectively utilized
Establish Physical Boundaries - The scope may vary between
an entire refinery or plant and a single component, so that
make saving time
Facilities Screening
- RBI may be applied to all types of plants, like : oil and gas production
- processing facilities, refineries, petrochemical and chemical plants,
pipelines and pipeline stations, liquefied natural gas plants.
- Screening at the facility level could also be done by: asset or product
value, history of problems/failures at each facility, age of facilities,
proximity to the public or to environmentally sensitive areas.

Process Units Screening - If the scope of the RBI
assessment is a multi-unit facility, the first screening the
units to points out areas that are higher priority
which process units to begin with.
System with process unit screens
- Equipment is a process unit may be grouped into systems,
loops, or circuits . This equipment has common operating
condition (process chemistry, pressure and temperature,
metallurgy, equipment design and operating history )
- Selection of system may be based on relative risk of : the
process units, economic impact , COF, reliability, expected
benefit from applying RBI, sensitivities of risk to changes in
process conditions.
Equipment Item Screening - In most plants, a large
percentage of the total unit risk will be concentrated in a
relatively small percentage of the equipment items.
Higher risk items should receive greater attention
Utilities, Emergency and Off-plot Systems - emergency
and off-plot systems should be included depends on the
planned use of the RBI assessment and the current
inspection requirements of the facility.

Establish Operating Boundaries
The RBI assessment normally for normal operating conditions,
but Start-up, shutdown conditions as well as emergency and
non-routine conditions should also be reviewed.
The purpose of establishing operational boundaries is to
identify key process parameters that may impact deterioration
Start-up and Shutdown process conditions during start-up and
shutdown can have a significant effect on the risk of deterioration.
A good example is potential for cracking when steaming out an
amine vessel to gas free it
Normal, Upset, and Cyclic Operation - normal operating
conditions should be verified against design condition
Operating Time Period - The unit run lengths should be defined,
may include entire operating life, or just selected time period.
Selecting a Type of RBI Assessment
The type of RBI assessment will be dependent on a variety
of factors, such as:
is the assessment at a facility, process unit, system, equipment
item, or component level;
objective of the assessment;
availability and quality of data;
resource availability;
perceived or previously evaluated risks;
time constraints.
A strategy should be developed, matching the type of

assessment to the expected or evaluated risk

Estimating Resources and Time Required
To implement an RBI assessment, time required depend on a number of
factors :
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 precision required.
The estimate of cost 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 information
The data collected will provide the information needed to assess
potential damage mechanisms, potential failure modes and scenarios of
failure, assess probabilities, assess consequences and assist in inspection
planning.
Typical data needed for an RBI analysis may include but is not limited to:
type of equipment
materials of construction;
inspection, repair and replacement records;
process fluid compositions;
inventory of fluids;
operating conditions;
safety systems;
detection systems;
damage mechanisms, rates, and severity;
personnel densities;
coating, cladding, and insulation data;
business interruption cost;
equipment replacement costs;
environmental remediation costs.
Data information
Data quality
The data quality has a direct relation to the relative
accuracy of the RBI analysis.
In any inspection program, data validation is
essential, because of :
outdated drawings and documentation,
inspection error,
clerical and data transcription errors,
measurement equipment accuracy.
Data information
Data Validation
Validation of data becomes important during the team
meeting. That is no time to be sitting around wondering
if the data is accurate.
When validation step has not been done, the RBI time
requirement can increase. This can leave the wrong
impression with some managers believing that RBI is
more time consuming and expensive than it should be.
Data information
Codes and StandardsNational and International
The data collection stage will include :
What codes and standards are currently inuse
What codes and standards were in use during
equipment design
Data information
Sources of Site-specific Data and Information
Information for RBI can be found in many places within a facility. It is important to stress that the
precision of the data should match the complexity of the RBI method used
Potential sources of specific information include but are not limited to:
a) design and construction records/drawings:
- P&IDs, process flow diagrams, material selection diagrams (MSDs), etc.,
- piping isometric drawings,
- engineering specification 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-proofing and fire-fighting systems,
- layout;
Data information
b) inspection records:
- schedules and frequency,
- amount and types of inspection,
- repairs and alterations,
- positive material identification (PMI) records,
- inspection results;
c) process data,
- fluid composition analysis including contaminants or trace components,
- distributed control system data,
- operating procedures,
- start-up and shutdown procedures,
- emergency procedures,
- operating logs and process records,
- PSM, PHA, RCM, and QRA data or reports;
d) MOC records;
e) off-site data and informationif consequence may affect off-site areas;

Data information
f) failure data:
- generic failure frequency data-industry or in-house,
- industry specific failure data,
- plant and equipment specific failure data,
- reliability and condition monitoring records,
- leak data;
g) site conditions:
- climate/weather records,
- seismic activity records;
h) equipment replacement costs:

- project cost reports,
- industry databases;
i) hazards data:
- PSM studies,
- PHA studies,
- QRA studies,
- other site specific risk or hazard studies;
j) incident investigations.

Damage mechanisms include:
Corrosion
Cracking
Mechanical
Metallurgical damage
Understanding damage mechanisms is important for:

the analysis of the POF;
the selection of appropriate inspection intervals/due dates, locations and
techniques;
the ability to make decisions (e.g. modifications to process, materials selection,
monitoring, etc.) that can eliminate or reduce the probability of a specific
damage mechanism.
Understanding failure modes is important for three reasons:

the analysis of the COF,
the ability to make run-or-repair decisions,
the selection of repair techniques.
Damage mechanisms include:
Corrosion
Cracking
Mechanical
Metallurgical damage
Understanding damage mechanisms is important for:

the analysis of the POF;
the selection of appropriate inspection intervals/due dates, locations and
techniques;
the ability to make decisions (e.g. modifications to process, materials selection,
monitoring, etc.) that can eliminate or reduce the probability of a specific
damage mechanism.
Understanding failure modes is important for three reasons:

the analysis of the COF,
the ability to make run-or-repair decisions,
the selection of repair techniques.
Data information
Damage Mechanisms
Understanding equipment operation and the interaction with the process
environment (both internal and external) and mechanical environment is
key to identifying damage mechanisms
Failure Modes
Examples of failure modes include:
pinhole leak,
small to moderate leak,
large leak,
ductile rupture,
brittle fracture
For example, cracking could lead to a through-wall crack with a leak before break
scenario or could lead to a catastrophic rupture. The failure mode will depend on
the type of cracking, the geometric orientation, the material properties, the
component thickness, the temperature, and the stress level.
Data information
Accumulated Damage
Damage rates may vary as damage mechanisms progress (i.e.
various mechanisms may accelerate or slow or stop completely).
Damage by one mechanism may progress to a point at which a
different mechanism takes over
Tabulating Results
The results of a damage mechanisms and failure modes analysis
for RBI should indicate:
A list of credible damage mechanism
- example: external corrosion
a list of credible damage mode(s) resulting from the damage
mechanisms(s)
- example 1: localized thinning,
- example 2: general thinning

The probability that a specific consequence will occur is the product of the
POF and the scenario under consideration
The POF analysis should address :

all damage mechanisms the equipment is susceptible.
The situation where equipment is be susceptible to multiple damage
mechanisms (e.g. thinning and creep).
Other causes of loss of containment could include but are not limited to:
seismic activity,
weather extremes,
overpressure due to pressure-relief device failure,
operator error,
inadvertent substitution of materials of construction,
design error,
sabotage.
Units of Measure in the POF Analysis
POF is typically expressed in terms of frequency. Frequency is

expressed as a number of events occurring during a specific time
frame.
Example :
the time frame is typically expressed as a fixed interval (e.g. one
year)
is expressed as events per interval (e.g. 0.0002 failures per year).
may also be expressed as an occasion (e.g. one run length)
would be events per occasion (e.g. 0.03 failures per run).
For a qualitative analysis, the POF may be categorized (e.g. high,

medium and low, or one through five).

Types of Probability Analysis
Qualitative POF Analysis
Engineering judgment is the basis for this assessment. A POF
category can then be assigned for each unit, system, grouping or
equipment item. The categories may be described with words
(such as high, medium, or low) or may have numerical
descriptors (such as 0.1 to 0.01 times per year).
Quantitative POF Analysis

There are several approaches to a quantitative probability analysis.
- a probabilistic approach , where specific failure data or expert
solicitations are used to calculate a POF. This probability may be
expressed as a distribution
- Another approach is general data industry, when inaccurate or
insufficient failure data exists on the specific item of interest. In this
case, general industry, company or manufacturer failure data are used.

Determination POF
Two main considerations:
damage mechanisms and rates of the equipment
items material of construction, resulting from its
operating
effectiveness of the inspection program to identify and
monitor the damage mechanisms so that the equipment
can be repaired or replaced prior to failure.
Analyzing the effect of in-service deterioration and inspection
on the POF involves the following steps.
Identify active and credible damage mechanisms that are
reasonably expected to occur during the time period being
considered (considering normal and upset conditions).
Determine the deterioration susceptibility and rate. For
example, a fatigue crack is driven by cyclic stress; corrosion
damage is driven by the temperature, concentration of
corrosive, corrosion current, etc.
quantify the effectiveness of the past inspection, maintenance
and process monitoring program and a proposed future inspection,
maintenance and process monitoring program.
Determine the probability that with the current condition,
continued deterioration at the predicted/expected rate will exceed
the damage tolerance of the equipment and result in a failure. The
failure mode (e.g. small leak, large leak, equipment rupture) should
also be determined based on the damage mechanism.

Determine the Deterioration Susceptibility and Rate
The deterioration rate in specific process equipment is
often not known in certainly.
The ability to establish the rate is affected by
equipment complexity,
type of damage mechanism,
process and metallurgical variations,
inaccessibility for inspection,
limitations of inspection and test methods and
the inspectors expertise
Sources of deterioration rate information include :
published data and unpublished company data
laboratory testing,
in-situ testing and in-service monitoring,
experience with similar equipment,
previous inspection data.

The best information will come from operating experiences
where the conditions that led to the observed deterioration rate
could realistically be expected to occur in the equipment. This
due to:
fluid stream composition, including electrolytes and ions in
solution;
the process condition, temperature, pressure, phase etc.;
the mechanical properties of the metal (hardness, cold work, grain
size, etc.);
the metallurgical properties and corrosion resistance of the alloy;
the weld properties: heat treatment, hardness, residual stresses,
sensitization, inclusions, etc.
the component geometry (crevices, local turbulence, etc.);
the coating and lining condition (no holiday);
the relative size of anodic and cathodic regions;
etc.
Determine Failure Mode
POF analysis is used to evaluate the failure mode (e.g. small hole, crack,
catastrophic rupture). It is important to link the damage mechanism to the
most likely resulting failure mode.
For example:
pitting generally leads to small-hole-sized leaks;
stress corrosion cracking can develop into small, through wall cracks or, in some
cases, catastrophic rupture;
metallurgical deterioration and mechanical damage can lead to failure
modes that vary from small holes to ruptures;
general thinning from corrosion often leads to larger leaks or rupture;
localized corrosion can lead to small to medium-sized leaks.
Failure mode primarily affects the magnitude of the consequences.
For this and other reasons, the probability and consequence analyses should
be worked interactively.

Limitations in the effectiveness of an inspection program
could be due to the following items.
Lack of coverage of an area subject to deterioration.

Inherent limitations of some inspection methods to detect
and quantify certain types of deterioration.
Selection of inappropriate inspection methods, techniques
and tools.
Application of methods and tools by inadequately trained
inspection personnel.
Inadequate inspection and examination procedures.
Deterioration rate under some extremes of conditions is so
high that failure can occur within a very short time
Determination of inspection effectiveness should
consider the following:
equipment type
active and credible damage mechanism(s);
rate of deterioration or susceptibility;
NDE methods, coverage and frequency (i.e. ability to
detect the specific deterioration);
accessibility to expected deterioration areas.

Calculate the POF by Deterioration Type
POF can be determined for each deterioration type
and failure mode by combining the :
expected damage mechanism,
rate or susceptibility,
process monitoring,
inspection data and inspection effectiveness,
Finally
POF is determined by :
Deterioration mechanisms and rate
Effectiveness of the inspection program to identify and
monitor the deterioration mechanisms

The consequence of loss of containments Is generally evaluated as loss of fluid to the
external environment.
Qualitative Consequences Analysis

Based on expert knowledge and experience is issued to assess the consequence of failure
Consequence category such as high, medium or low is typically assigned
Cost $ can be associated with each consequence category
Quantitative Consequences Analysis

Based on logic model depicting combinations of events.
Model are based on:
type of process fluid in equipment;
state of the process fluid inside the equipment (solid, liquid, or gas);
key properties of process fluid (molecular weight, boiling point, auto ignition
temperature, ignition energy, density, flammability, toxicity, etc.);
process operating variables such as temperature and pressure;
mass of inventory available for release in the event of a leak;
failure mode and resulting leak size;
state of fluid after release in ambient conditions (solid, gas, or liquid).
Units of Measure in Consequence Analysis
The RBI analyst should consider the nature of the hazards present and select
appropriate units of measure.
Safety
Safety consequences can be based on the severity of the injury : fatality,
serious injury, medical treatment, first aid
Costs
Costs is commonly used as an indicator of potential consequences. Typical
consequences expressed in costs include :
production loss due to rate reduction or downtime,
deployment of emergency response equipment and personnel,
Degradation of product quality
replacement or repair of damaged equipment
goodwill.
Etc.

Affected Area
Affected area is also used to describe potential consequences in
the field of risk assessment.
the amount of surface area that experiences an effect (toxic dose,
thermal radiation, explosion overpressure, etc.) greater than a pre-
defined limiting value.
It is typically assumed that equipment or personnel at risk are evenly
distributed throughout the unit (not a population density).
The affected area units of measurements (sq. ft.) dont translate
into consequence readily, so it measurement is not always used.
The affected area is able to compare toxic and flammable
consequences by relating to the physical area impacted by a release.
A drawback for area consequences is that it does not include the
business impact of failure, which can often be the largest portion of
total consequence.
Environmental Damage
This is the least developed among those currently used for
RBI. A common unit of measure for environmental
damage is not available in the current technology.
Typical parameters are:
acres of land affected per year;
miles of shoreline affected per year;
number of biological or human-use resources consumed;
the portrayal of environmental damage almost invariably
leads to the use of cost, in terms of dollars per year, for the
loss and restoration of environmental resources.

Determination of Risk
Personnel inexperienced in risk assessment methods
often link the POF with the most severe consequences
that can be envisioned.
The probability of the specific consequence is the
product of the probability of each event leading up to
the specific consequence
Costs-benefit analysis is being used to determine risk
acceptance
Risk acceptance may vary for different risks.
Calculate Risk
It is now possible to calculate the risk for each specific consequence.
The risk equation can now be stated as:
Risk of a Specific Consequence =
(Probability of a Specific Consequence) (Specific Consequence )
Risk Acceptance
Each company may be different in terms of acceptable risk levels,
Cost-benefit analysis is a powerful tool that is being used by
many companies, governments and regulatory authorities as one
method in determining risk acceptance.
Risk acceptance may vary for different risks.
For example, risk tolerance for an environmental risk may be higher
than for a safety/health risk.
Risk Matrix
Risk ranking methodologies that use consequence
and probability categories, presenting the results
in a risk matrix is a very effective way of
communicating the distribution of risks throughout a
plant or process unit without numerical values
Risk Management with inspection activities
Risk mitigation achieved through inspection
presumes that the organization will act on the results
of the inspection in a timely manner.
Inspection is only effective if the inspection
technique chosen is sufficient for detecting the
deterioration mechanism and its severity
RBI can be used as a what if tool to determine
when, what and how inspections should be
conducted to yield acceptable future risk levels
inspection costs will be more effectively managed
through the use of RBI.
RBI should provide lowest life cycle costs.
Risk Management with inspection activities

Managing Risk with Inspection Activities
RBI can be used as a what if tool to determine when,
what and how inspections should be conducted to yield an
acceptable future risk level.
Key parameters and examples that can affect the future risk
are as follows.
Frequency of Inspection
Coverage(not all part of the piping / vessel have the same
corrosion)
Tools and Techniques (X-ray can be more effective than UT in
some cases)
Procedures and Practices (not all inspector and NDE are equally
qualified)
Internal, On-stream, or External Inspection (external may be
preferable due to internal problems)
Why Conduct an RBI Reassessment?
Damage mechanisms are live when the equipment is
operation
Damage Mechanisms and Inspection Activities
- RBI typically projects deterioration as a continuous rate
- However, deterioration may vary over time.
- Inspection activities, the average rate of deterioration may be better
defined.
Process and Hardware Change
- Process change are linked to equipment failure from rapid or
unexpected corrosion or cracking
- Hardware changes
Internal change or piping change
Relocation of new equipment

When to Conduct an RBI Reassessment ?
After significant changes
- Different process conditions
- Noticeable deterioration mechanisms rates
After a set period oftime
Before and after turn-around
Team member
Team Leader (full-time)
Formation of the team and assurance of quality
membership
Assurance of proper RBI methodology
- Data gathering
- Assumptions
- Validity checks
Preparing report out on
RBI study
Follow-up on implementation of risk mitigation items
Team member .
Inspector
Data gathering, both new/design and current
Assessing the effectiveness of past inspection
Implementing the recommendation inspection plan derived from the RBI
assessment
Validity check on the implementation of recommendations produced by the
RBI study
Material & Corrosion Specialist

assessing the types of damage mechanisms and their severity
Validating assessment to the actual condition
Provide guidance on damage mechanisms, rates or severity to be used in the
RBI assessment.
Provide evaluating the appropriateness of the inspections in relation to the
damage mechanism.
Provide recommendations on methods of mitigating the POF (such as
changes in metallurgy, addition of inhibition, addition of coatings/linings,
etc.)
Team member .
Process Specialist
Provide operating data, including routine, upset and Start
up and shut down
Process composition of all fluids/gasses as well as their
potential toxicity and flammability.
Evaluate methods for risk mitigation as proposed by the
team
Operations and Maintenance Personnel

Provide data when process deviated from the limits of the
operating envelope (IOW).
Verify equipment repairs/replacements/additions as
described by the Inspector are correct (been implemented).
Evaluate methods for risk mitigation as proposed by the
team
Team member .
Management
Provide personnel & funding
Establishing the risk matrix
Provide resources and follow-up system to implement risk
mitigation decisions.
Risk Analyst (Assessment Person)

defining data required from other team members,
defining accuracy levels for the data,
inputting/transferring data into the computer program and running
the program (if one is used),
quality control of data input/output,
manually calculating the measures of risk (if a computer program is
not used),
displaying the results in an understandable way and preparing
appropriate reports on the RBI analysis.
Team member .
Environmental and Safety Personnel
Provide data on environmental and safety systems and
regulations.
Provide for assessing/recommending ways to mitigate
the COFs.
Financial/Business Personnel
Provide data on the cost of the facility/equipment
Provide recommendation on mitigating the financial
COF.
Summary of Risk-Based Inspection Pitfalls

It can be used as checklist to review the RBI work process
or to audit the effectiveness of an RBI program.
Planning
Data and Information Collection
Assessing POF
Assessing COF
Risk Determination, Assessment, and Management
Risk Management with Inspection Activities
Other Risk Management Activities
Reassessment and Updating RBI Assessment
Roles, Responsibilities, Training, and Qualifications for RBI
Team Members
RBI Documentation and Recordkeeping

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1

Everything Trend Analysis Risk Analysis

Water Disposal Condensate HP Gas

Inspection based on Time Based, same interval every 1 year

Why need RBI

Introduction Percent of Losses 6

Major property loss

Tolerable line risk level

Based line risk level

How Risk is Used for Planning

Based line risk level

Based line risk level

Potential Benefits of RBI

Grew to 25 sponsor companies as January 2001

API RP 581 Risk based Inspection Technology (2nd edt.

API RP 580 Risk based Inspection (2nd edt. November

Overview of API 580 Contents

The RBI process is capable of generating:

These equipment plans highlight risks from a:

RBI Benefits and Limitations

RBI, PHA, HAZOP, RCM

Typically, PHA risk assessments focus on the process

RBI, PHA, HAZOP, RCM

RBI also is complementary to RCM programs in that

API 510, Pressure Vessel Inspection Code: Maintenance

API 570, Piping Inspection Code: In-service Inspection,

API 653, Tank Inspection, Repair, Alteration, and

Correlation With Other Standard .

API 580 is a Recommendation Practice

RBI is not a replacement for API-510, 570 or 653!

Correlation With Other Standard .

Correlation With Other Standard .

The goal of RBI is

Equipment not covered

RBI is not exclusively an inspection activity.

RBI requires the involvement of various segments of the

RBI requires the commitment and cooperation of the total

should be familiar with the concepts and principles embodied in

Effective risk assessment, contains at least two key steps.

Risk management - a process to assess risks, to determine

By using risk management, some risks may be identified as

Risk reduction is only a part of risk management.

Risk with typical inspection program

Risk using RBI

Level of inspection activity

The residual risk, are :

What is risk (result)

Role of Inspection in API RBI

Consequence and Probability

For example, if a pressure vessel subject to damage

Probability (likelihood) how many leak from CUI

Consequence and Probability

Some failures have potentially serious consequences, but if

if the probability and consequence combination (risk) is

POF RISK RANKING An iso risk line

Type of Risk assessment

The choice of approach is dependent on :

Type of Risk assessment

Type of Risk assessment

Type of Risk assessment

Type of Risk assessment

RBI planning process

Planning the RBI Assessment

Planning the RBI Assessment