Reliability Based Mechanical Integrity (RBMI)

An integrated software system to implement risk based inspection Traditional inspection management methods are often over conservative and do not allow for changes in operating conditions, such as output or feedstocks. The frequency of inspection is often inconsistent with the actual risk of failure. In the current landscape, chemical producers are regularly changing feedstock suppliers, and varying production levels to meet market demand. Under these conditions, you need an asset integrity programme that integrates production and maintenance to ensure the safety and reliability of your equipment without unnecessarily halting production. In response, we offer Reliability Based Mechanical Integrity (RBMI), a risk based inspection management software system designed to identify and address the risk of loss of performance caused by poorly-understood or improperly-managed deterioration mechanisms. Over a five year period, the benefit of RBMI is generally 5 to 20 times the cost of implementation and management. Contact us to find out how you can start managing your asset integrity programmes more intelligently.

More benefits of RBMI

Extends plant shutdown intervals and reduces the number of equipment items being opened by 30 to 60% Generally requires 50 to 90% fewer inspection points than a traditional API inspection program while reducing the risk of failures by 80 to 95% Identifies when to perform Fitness for Service (FFS) assessments Focuses inspection resources on critical equipment in ways which will prevent failures, particularly catastrophic ones Meets and exceeds API 580 specifications An essential local or global multilingual tool in an integrated reliability and Risk Based Inspection (RBI) programme Provides information to help make informed decisions about how, when and where to inspect Provides product road map identifying time frame for delivering additional asset families including rotating equipment, instrumentation and control systems as well as electrical systems

Technical specifications
Data structure The database is designed with an easy to use data structure. It has a familiar browser that allows the user to navigate to any part of the program with only one or two mouse clicks. The browser also allows the user to always know exactly where he is in the program. Pre-

designed data sheets are included for each type of equipment and major components, such as the shell, channel, and bundle of a shell and tube heat exchanger. Data from the datasheet is automatically used by the Criticality Calculator in the risk analysis. Summary data from the risk analysis is also displayed on the data sheets. Links to external files The software supports links to external files, permitting easy access to documents, photographs (including scanned documents), videos, and drawings. The linked files can include written procedures, corrosion control documents, inspection sketches, isometric drawings, scanned U-1 forms, or inspection photographs. The files can be linked at the equipment item level or with an inspection report. Criticality Calculator The software includes a calculator that performs the risk analysis for each type of equipment or component being evaluated. Forms capture the information required to perform the technical studies for the RBI analysis. The corrosion study identifies the materials of construction and the process conditions that can cause deterioration of the equipment. The damage mechanisms are identified along with the critical process variables. The form to review the prior inspection history provides a single location to summarize the previous inspections performed on the equipment. This allows inspection confidence to be assigned based on the expected damage mechanisms and the actual inspections performed. The calculator evaluates both the likelihood and consequence of failure. Based on identified failure modes, the calculator also assigns inspection priority categories, which are used by the Inspection Planning Module to recommend inspection methods, intervals and extent of inspection.

Meets the technical requirements and is certified by a third party to API 580 complete RBI assessments in qualitative, semi-quantitative and quantitative methods calculates absolute consequence results based on various failure scenarios, production loss and environmental impact calculates deterioration rates for various deterioration mechanisms based upon industry experience in lieu of measured data or incorporates actual measured rates ability to perform what-if analysis to predict future risk: life extension analyses, surgical turnaround planning, risk profile updates due to proposed inspections/maintenance, etc. technical reviews to support risk study

Inspection planning The Inspection Planner looks at the type of equipment and the failure mechanisms and applies the inspection strategies to generate a recommended inspection plan. The inspector can review and accept or modify the recommended plan to create an approved inspection plan. Once due dates are automatically assigned for the inspections based on the date of last inspection, the software will track due dates and provide notification.

Includes integrated inspection strategies that can be modified by the end user to represent client as well as regulatory requirements

provides required inspection protocols based on assessed risk levels and identified damage / deterioration mechanisms inspection documentation forms are provided to document all types of condition monitoring inspections, including internal and external visuals, thickness measurements, and specialized inspections such as AE, Eddy Current, PT, WFMPT, In-Line, ROV and others. The results of the inspections are used to update the risk analysis, which in turn is used to create an updated inspection plan receive, stores and computes corrosion monitoring data for minimum thickness, short and long term corrosion rates and remaining life in accordance with original code of design and API 579 level 1 assessment receive, store and compute visual and non destructive inspection results modules are included for reporting the results of all types of inspections

ERP Integration A CMMS interface is available to ensure the asset registry is synchronized and notifications can be provided to CMMS. Automatically updates CMMS with new inspection interval as well as non conformance reports based on computed risk results. Peripheral Devices Users can import data directly from thickness data loggers or use PDAs to collect visual inspection information, reducing operating costs while improving data integrity Localization Settings Strategy Rules, Lookups, Application Settings, etc can be localized providing the capability to allow an entire organization to reside in one database but offer the flexibility to customize each location to fit their own business practices. Reporting and KPIs Provides effective communication with owner, operators and management through advanced reporting capabilities and services such as strong ad hoc reporting as well as role based subscription and scheduling. 70+ reports are available including Key Performance Indicators such as Score Cards; Cumulative Risk and Inspections due. Data Historian interface The Data Historian interface allows users to define integrity operating widows for a given process, trigger alerts and email notifications as appropriate and documents supporting data feeds when the values exceed the windows and an excursion occurs. Additionally, users can feed the data historian information directly into the criticality assessment to execute a nearreal time or what-if risk analysis. The interface is used to tie production with asset integrity, reliability, maintenance, inspection and corrosion monitoring activities to effectively bridge operations with maintenance/inspection. Security

The robust security provides the capability to manage role based users at the unit, plant and organizational levels. The role based security settings can be customized for individual users enabling cross-unit/plant/organizational access to pertinent data for a given process system(s), providing full access to some units/plants and read only access for others. In addition, all user actions within the software are auditable.