25 Years of Risk-Based Inspection

Valerie Magyari
Principal Engineer Consultant
E2G | The Equity Engineering Group, Inc.

Presentation Overview
2

The Start of RBI Within API

The API RBI JIP is Born
The DNV ERA
The E2G ERA
Summary of API RBI Documents
Summary of ASME RBI Documents
Whats next
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The Start of RBI Within API

3

ASME Research

in Washington DC notifies API that a development effort

for RBI is being formalized to cover multiple industries including
Commercial Nuclear and Fossil Utility (1991-1992)

ASME Research

also wants to include Refining and Petrochemical Industries

API appoints representatives from the CRE Subcommittee on Pressure

Vessels & Tanks to attend meetings and evaluate RBI technology and
potential usefulness in the refining petrochemical industries

After attending meetings, the recommendation is technology is useful and

valuable, and recommend proceeding with ASME effort

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The Start of RBI Within API

4

CRE accepts recommendation but re-assigns responsibility for

development to the CRE Inspection Subcommittee (SCI)

Due to the complexities of the ASME RBI Technology (highly

quantitative), the CRE Inspection Subcommittee decides to issue

an RFQ for the develop of RBI technology suitable for
implementation by inspectors in the refining and petrochemical
industry
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The API RBI JIP is born

5

May 1993
DNV wins the bid to develop
the API RBI technology
API forms a JIP to pay for
technology development
16 original Sponsor Group
Companies

Amoco
Amoco

Conoco
Conoco

Phillips
Phillips

Arco
Arco

Exxon
Exxon

Shell
Shell

Ashland
Ashland

Koch
Koch

Sunoco
Sunoco

BP
BP

Marathon
Marathon

Texaco
Texaco

Chevron
Chevron

Mobil
Mobil

Unocal
Unocal

Citgo
Citgo

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Brief History of API RBI

6

The API RBI JIP is formed - Objective (Original)

o Develop a Base Resource Document (BRD) outlining a Risk-Based Inspection
Methodology aimed at inspectors and plant engineers experienced in the inspection
and design of pressure-containing equipment
o Technology development proves difficult because industry inspection and materials
specialists were not familiar with Probability, Consequence, and Risk concepts
o Initial rules were developed; demonstration of the technology and the benefits for
optimization of inspection plans becomes difficult
o Software is needed to sharpen methods and make comparisons to actual equipment
using interval-based inspection methods

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The DNV ERA

7

Revised Project Objective - 1997

o Create an RBI Methodology for the Petroleum and Petrochemical
Industry along with a User-Friendly Software package that includes
RBI Analysis.

Implementation of the method in software is required to perform

these evaluations the API RBI software tool is born!
V3 Access 97 based tool initially developed in 1998, starts to be used
commercially
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The E2G ERA

8

Management of the API RBI JIP is re-bid in 2001

E2G (M&M) wins the bid to further develop the API RBI technology and manage
software development; First UG meeting with E 2G as contractor October 2001.
October 2001 UG Meeting - The product will be a web-based program with its
computational code residing on a central server that would be accessible by users via the
internet. Users would also have the option of storing the software on a central corporate
server as well.
Transition from DNV to E2G includes final 3.3.3 delivery in July 2002 and updated draft
of BRD and delivery of technical modules.
Oct 2002, UG unanimously voted to eliminate the 3 levels of RBI (qualitative, semiquantitative, quantitative).
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The E2G ERA

9

Implementation of the technology within the software proves to be difficult

The documentation of technology in the API RBI Base Resource Document does not
include many of the features and changes developed and implemented in the
Version 3.3.3 software.
o Some had to be reverse engineered
o Pf and corrosion rate calculation are in the best shape
o Consequence modeling requires investigation and total documentation (fluids,
blending)
o The inspection planning methodology is poorly documented and is deemed
inadequate; basic issue is it does not provide a time to perform an inspection!

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The E2G ERA

10

Inspection planning algorithm needed proposed and accepted by UG in

March 2002
o Pf is determined as a function of time; all
damage factor calculations are recast with time
as an independent variable
o The consequence is assumed to be invariant
with time
o Risk becomes a function of time
o The concept of risk targets is introduced by E 2G
to determine both the time for an inspection as
well as inspection techniques based on the
damage mechanisms present

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The E2G ERA

11

Other enhancements of the API RBI technology led by E 2G

o A level 2 consequence modeler that handles a variety of fluids, toxic consequences are also
addressed, embedded cloud modeler (2004)
o An inspection planning module for PRD, unique in the industry as the risk and inspection
frequency of the PRD is a function of the equipment that it protects and the specific causes
of overpressure (2004-2005)
o Implementation of RBI for Atmospheric Storage tanks (2005)
o Implementation of API RBI for HE Bundles (2006)

(9/2005 UG) E2G to lead group on international acceptance (GCA). The objective of
the group is to provide an API RBI international focus with the goal of providing
existing User Group members with the means to promote and use the tool
internationally within their companies

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The E2G ERA

12

Software History
V4.0 was E2Gs first attempt, web-based, unsuccessful
V5 went into production early 2004, UG concern about performance and

usability
V6 went into production in 2005, complete rewrite of client side GUI to

address UG concerns
V7 went into production September 2005, widespread adoption begins
V8 went into production April 2006, some users continue to use this

version
V9 released in 2009, V10 now available as of October 2016

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The E2G ERA

13

Up until this point, UG continued to operate under direction of API, with E 2G as

contractor, work items being proposed, voted on and funded by UG sponsors and API
A Steering Committee, a SWG, and a TWG were directing efforts
Software Working Group (SWG)
Subgroup of the Users Group was formed in November 2001 to oversee / assist in the
development of the software
Used the BRD as the basis, found BRD was not up to date, and software was doing
undocumented calculations
Unapproved and un-balloted changes were in V.3
SWG oversaw development for 4 years
Conducted comparison studies to V3.3.3
Disbanded with the release of V7, objectives were achieved; from here, ballot changes to
be driven by API 581 task force

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The E2G ERA

14

(Technical Working Group) TWG

ASTs, Heat Exchanger Bundles, PRDs, Furnace, Boilers

External Corrosion/CUI Module
HTHA
Soil/Underground Corrosion Module
Cooling Water Corrosion
Creep
Thermal Fatigue
Linings
Acid Sour Water
CO2 Corrosion

10/2006 UG disbanded and transferred to API 581 task force

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The E2G ERA

15

Transition of Software Ownership

API transferred ownership of API RBI Software in early 2007

Software ownership transfer letter notification from API

Software ownership transfer letter notification from E 2G

Invoices went out for 2006 2007 license period

API 581 Task Force established process continues today

581 Task force to handle on-going technical development,

API UG concentrate on SW Managed by E 2G

first meeting held Fall 2007

Focused on ballot resolution for all three Parts of the 2nd edition

Received action item list from UG

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Summary of API RBI Documents

16

API Risk-Based Inspection Publications

Risk-based Inspection

Risk-based Inspection Base Resource Document

API Recommended Practice 580, First Edition, May 2002

API Recommended Practice 580, Second Edition, November 2009
API Recommended Practice 580, Third Edition, February 2016
Risk-based Inspection Base Resource Document, API Publication 581 First Edition, May 2000
Risk-based Inspection Base Resource Document, API Publication 581 Second Edition, October 2000
NEVER RELEASED

Risk-based Inspection Technology, API Recommended Practice 581 Second Edition,

September 2008
Risk-based Inspection, API Recommended Practice 581 Third Edition, April 2016

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Summary of ASME RBI Documents

17

Prepared by ASME under The Research Task Force on Risk-Based Inspection

Guidelines
ASME Risk-Based Inspection Three Volume Set

Volume 1 General Document (CRTD-Vol. 20-1)

Volume 2 Part 1 Light Water Reactor (LWR) Nuclear Power Plant Components (CRTD-Vol.
20-2)
Volume 2 Part 2 Light Water Reactor (LWR) Nuclear Power Plant Components (CRTD-Vol.
20-4)
Volume 3 Fossil Fuel-Fired Electric Power Generating Station Applications (CRTD-Vol. 20-3)
Risk-based Methods for Equipment Life Management: An Application Handbook (CRTD-Vol.
41)

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Summary of ASME RBI Documents

18

Based on research efforts, ASME Standard PCC-3, Inspection Planning Using

Risk-Based Methods
ASME PCC-3 provides guidance to owners, operators, and designers of pressurecontaining equipment for developing and implementing an inspection program
The risk analysis principles, guidance, and implementation strategies presented
in PCC-3 are broadly applicable

Specifically developed for applications involving fixed pressure containing equipment and
components

Not intended to be used for nuclear power plant components; see ASME BPV, Section XI

Sister Document to API 580 Risk-based Inspection developed for the refining and petrochemical
industry

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Benefits of RBI
19

Risk Reduction Typical

risk reduction when
shifting from interval
based to risk-based
inspection planning is 60%
to 80%

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Benefits of RBI
20

Cost

Reduction Typical inspection activity reduced 20 - 40%

One user indicates that 65% of equipment was limited by the maximum inspection
interval (time-based API 510 approach)

Another user estimates a 9:1 payout of the RBI program

Turnaround

scope reduction

One mid-west refiner shows a 10% reduction in turnaround duration

In accordance with API website A petrochemical manufacturer reduced

plant turnaround costs by $2.5 million in one year by implementing an
industry-developed risk-based inspection methodology for process equipment

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Benefits of RBI
21

Improvement in inspection effectiveness

One User tracks percentage of finds

After 4 years of RBI program, finds went from 2% to 25%
A find is defined as an inspection activity that finds what they were expecting
A higher number implies that you are not wasting time with unnecessary inspections
Stresses the importance of a good Damage Review

Risk drivers are clearly identified (COF versus POF Driven) in

prioritized lists
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Benefits of RBI
22

Users have identified catches or near misses using RBI; CUI is classic example

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Whats Next
23

API RP 581 3rd Edition was released in April 2016

Significant changes to API 581 include:

Thinning Damage Factor

HTHA Module

Removal of 10,000 sq. ft. limit on Level 1 COF pool fires

Effect of changes will be analyzed, may result in adjustments to risk targets

API 581 Task Force continues to plan technology improvements, E2G

continues to manage API RBI 581-compliant software

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Closing Thoughts
24

As plant equipment ages, owners need to fully understand the damage

mechanisms driving risk and to know when, where, and how to inspect
equipment to maintain safety and integrity
RBI has evolved over the last 25 years to guide this process, and many plants

have found RBI to be useful for optimizing inspection activity and reducing
plant risk
The development of API 580 and API 581 technology has been and continues to

be the result of industry collaboration

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Thank You!
25

Valerie Magyari
Principal Engineer Consultant
The Equity Engineering Group, Inc.
20600 Chagrin Blvd. Suite 1200
Shaker Heights, OH 44122 USA
Phone: 216-658-4744
Email: vlmagyari@equityeng.com

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