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RBI & API 580 Introduction
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INTRODUCTION TO RBI& API 580
RBI Training CourseModule 01
Scope of the Training
Introduction to RBI RBI Methodology Theory + with hands on exercises Likelihood calculation Consequence calculation
Case Study with the RBI software: refinery unit Data preparation Screening analysis Detailed analysis
Agenda
Start End
1 09:00 12:3012:30 13:30
2 13:30 15:003 15:00 17:00
4 09:00 10:305 10:30 12:30
12:30 13:306 13:30 17:00
7 09:00 11:008 11:00 12:30
12:30 13:308 13:30 17:00
9 09:00 11:0010 11:00 12:0011 12:00 12:30
12:30 13:3012 Other Features 13:30 16:00
Lunch
Plant inspection plans Creating inspection plans from the RBI guidelines.Reporting features / information output Extracting information from software
Model creation and data entry issues.Detailed analysis - Data entry
Day 1Introductions - Installations, Introduction to RBI
Detailed analysis - Data entry
Day 4
Lunch
Project Start up and Data Organization. Inventory groups and Corr circuits
Module
Other limit statesDay 2
Consequence theory and exercises
RBI Training Program. Breaks assumed during the day but not shown. Timing approximate.
Item Objectives
Lunch
Likelihood theory 2
Likelihood theory 3 Other likelihood models
Thinning: calculation principles and inspection updatingLikelihood theory 1
Other features
Establishing criteria and using the IP tool Inspection Planning using risk criteria
Consequence theory
Model creation and data entry issues.Screening Analysis Introduction Using the screening tool
Lunch
Day 3
INTRODUCTIONS(Name, Organisationtype of work, why interested in RBI,English )
Presentation Topics - This Session
RBI History API StandardsGeneral IntroductionThe benefits of RBIWhat RBI isHow RBI fits within existing plant systemsImplementing RBISome case studies
RBI History
Probabilistic risk analysis techniques Started in the nuclear industry (1970s)
Quantitative risk assessment (QRA) in the Process Industries Canvey Island and the Rijnmond Report (1980s)
Software tools for QRA Eg DNV-Technica develops SAFETI and PHAST risk assessment
tools (1980s)ASME RBI principles overview document in 1991 API develops Risk Based Inspection Methodology (1990s) DNV main API sub-contractror API Base Resource Document 581 (2000) API RBI software API RP 580 (2002)
RBI History
DNV develops ORBIT Onshore 1997-now Some Reasons:
Need for a RBI software for all onshore installations API 581 focuses on refineries
Improved consequence calculations with PHAST linkEnhancements in likelihood calculation
ORBIT uses equations for limit state implementationNeed for a robust software architecture & professional software development and maintenance
ORBIT is consistent with the API 580 RBI standard ORBIT and API 581 share philosophy/technology
API RBI development by Equity Eng. (2002-now)API RP 581 Update (2008)API RP 580 Update (2009)
API Inspection and FFS Standards
Existing RBI & FFS documents
API750
API510
API570
API653
API - BRD P 581RISK BASEDINSPECTION
MPCFITNESS FOR
SERVICE
RBIAPI RP 581
FFSAPI RP 579
WorkingDocuments
Research & referenceDocuments
NewDocuments
ASME
RBI API RP 580
Presentation Topics - This Session
RBI HistoryGeneral IntroductionThe benefits of RBIWhat RBI isHow RBI fits within existing plant systemsImplementing RBISome case studies
A Typical Plant
Loading facilities
Processing to give added value.
Storage and export
Typical Operating Objectives
Operate safely and profitably Maintain high availability and throughput. Minimize shut downs. Extending shut down intervals Prevent/reduce leaks.
Class question?
What are the typical plant objectives here?
Typical Plant Issues
Challenges Old Plants Large, complex units Integrated Feed Systems Many degradation mechanisms Raw material price
PROCESS CORROSION- Continuously degrading integrity
Corrosion Principles
Corrosion rate is measured as weight loss per unit area and is expressed in mils per year (mpy) or mm/y.Corrosion Rates can be affected by: Passivity forming protective surface films (including
corrosion inhibitors, paints and coatings) Oxygen content Flow velocity/rates Temperature pH effects (Low and High) Contaminants/intermediates
Some Corrosives Found In The Process Industry
WaterOxygenNaphthenic AcidPolythionic AcidChloridesCarbon DioxideAmmoniaCyanides
DepositsHydrogen ChlorideSulfuric AcidHydrogenPhenolsDimer and TrimeracidsOther
Low Temperature Corrosion
Below 500F (
Low Temperature Corrosion
From Process chemicalsFrom Process contaminantsNot caused by clean hydrocarbonsCaused by inorganic compounds such as water, hydrogen sulphide, hydrogen chloride, sulphuric acid, salts, etc.
High Temperature Corrosion
Above 500F (>260C)No water presentResult of a reaction between metal and process ions (such as oxygen O-, sulphur S, etc.)
High Temperature Corrosion
Important due to serious consequencesHigh temperatures usually involve high pressures.Dependent on the nature of the scale formed General thinning Localized thinning (pitting) Inter-granular attack Mixed phase flowMetallurgical changes
Situations Leading To Deterioration
Normal operation, upset, startup /shutdown conditionsMaterial/Environment condition interactionsMany combinations of corrosive process streams and temperature/pressure conditions.In the absence of corrosion, mechanical and metallurgical deterioration can occur.Weather effects .
Forms Of The Damage
General loss due to general or localized corrosionPitting attackStress Corrosion Cracking (SCC)Metallurgical ChangesMechanical damageHigh Temperature Hydrogen Attack (HTHA)
Damage types occur with specific combinations of materials and environmental/ operating conditions
SOHIC in soft base metal. Stress-Oriented Hydrogen Induced Cracking
In contrast to general corrosion, SCC is very hard to detect visually even when it has progressed to an extreme condition.
Stress Corrosion Cracking Detection
Types of Stress Corrosion Cracking
Chloride stress corrosion cracking (Cl-)NitratesCaustic stress cracking (NaOH)Polythionic acid stress corrosion crackingAmmonia stress corrosion cracking (NH4)Hydrogen effects (in steel)Sulfide stress corrosion cracking SSC, hydrogen induced cracking HIC, stress oriented hydrogen induced cracking SOHICHydrogen cyanide HCNOthers
High Temperature Hydrogen Attack (HTHA)
Carbon and low alloys steels exposed to hydrogen above 430F (221C)Hydrogen Partial pressure above 200 psi (>14 bar)Dissociation of molecular hydrogen to atomic hydrogen
H2 -> 2 H+Atomic hydrogen permeation into the steelReaction of atomic hydrogen with carbon in steelFormation of methane at discontinuitiesAPI 941 recommended for new installation
Longitudinal Weld
Magnification: 500x Etch: 2% Nital
High Temperature Hydrogen Attack
Metallurgical And Environmental Failures
Temper embrittlementLiquid metal embrittlementCarburizationMetal dustingDecarburizationSelective leaching
Grain growthGraphitizationHardeningSensitizationSigma phase885 F embrittlement
Mechanical Failures
Over pressurizationBrittle fractureCreepStress ruptureThermal shockThermal fatigue
Incorrect or defective materialsMechanical fatigueCorrosion fatigueCavitation damageMechanical damageOverloading
Conclusions
There are many causes of equipment failures in the process industry.Many are common and well documented.Other, less common deterioration mechanisms are not well documented.Deterioration is the result of metal and environment/ operating conditions combinations.These combinations vary somewhat in different process units.Detection and characterization of the different forms is a challenging and critical activity.
Tools exist to assist to assess the severity of corrosion or determine the appropriate materials of construction For Example:
NaOH Chart
These Tools Are Generally Used By Experienced Corrosion Engineers.
They can also be implemented in software as corrosion evaluation supplements
Determining Equipment Integrity
Requires information about the level of degradation:
Monitoring (Fluid corrosivity) and Inspection (Wall condition)
MONITORING POSSIBILITIES
Monitoring Fluid Composition/Quality
Pressure, Temperature, pHContaminants when relevant
Fluid corrosivityCorrosion probes (e.g. Weight loss, electrical resistance, linear polarization)
Function of protective systems e.g. inhibitor injection
Inspection: Pressure boundary condition checks, e.g. Visual examination Thickness measurements Other checks
Non Destructive Examination
- Inspection
Selecting Inspection method. Factors to consider
Type of defect General metal loss Localized metal loss Pitting Cracks Metallurgical changes
Location of defect On the outside wall of an item The inside wall Within the body of the wall Associated with a weld
Selecting Inspection method. Factors to consider:
Material of construction Magnetic Non magnetic Operating at high temperatures Insulated
Equipment geometry: May be hard to access May require extensive activity e.g. scaffolding,
entry preparations, to perform the inspectionMany considerations when determining how to inspect.Also, need to justify the need for inspection.
NDE MethodsAmerican Society for Nondestructive Testing (ASNT)
Acoustic Emission Testing (AE) VolumetricEddy Current Testing (ET) Surface/ VolumetricInfrared/Thermal Testing (IR) SurfaceLeak Testing (LT)Magnetic Particle Testing (MPT) SurfaceNeutron Radiographic Testing (NR) VolumetricPenetrant Testing (PT) SurfaceRadiographic Testing (RT) VolumetricUltrasonic Testing (UT) VolumetricVisual Testing (VT) SurfaceMagnetic Flux Leakage (MFL)
Penetrant Testing
Penetrant solution is applied to the surface of a pre-cleaned component. The liquid is pulled into surface-breaking defects by capillary action. Excess penetrant material is carefully cleaned from the surface. A developer is applied to pull the trapped penetrant back to the surface The penetrant spreads out and forms an indication. The indication is much easier to see than the actual defect.
Magnetic Particle Testing
A magnetic field is established in a component made from ferromagnetic material. The magnetic lines of force or flux travel through the material, and exit and reenter the material at the poles. Defects such as cracks or voids are filled with air that cannot support as much flux, and force some of the flux outside of the part. Magnetic particles distributed over the component will be attracted to areas of flux leakage and produce a visible indication.
Radiography Testing
X-rays are used to produce images of objects using film or other detector that is sensitive to radiation. The test object is placed between the radiation source and the detector. The thickness and the density of the material that X-rays must penetrate affect the amount of radiation reaching the detector.This variation in radiation produces an image on the detector that shows the internal features of the test object.
Ultrasonic TestingHigh frequency sound waves are sent into a material by use of a transducer. The sound waves travel through the material and are received by the same transducer or a second transducer. The amount of energy transmitted or received, and the time the energy is received are analyzed to determine the presence and locations of flaws. Changes in material thickness, and changes in material properties can also be measured.
Ultrasonic Principles
Straight Beam(Longitudinal Wave)
Angle Beam(Shear Wave)
Ultrasonic Presentations
TOP VIEW(C-SCAN)
END VIEW(B-SCAN)
SIDE VIEW(D-SCAN)A-SCAN
Risk Based Inspection
Presentation Topics
General IntroductionThe benefits of RBIWhat RBI isHow RBI fits within existing plant systemsImplementing RBISome case studies
The Value of RBIWhat is the first duty of Business?
The first duty of business is to survive, and the guidingprinciple of business economics is not the maximisation of profit - it is the avoidance of loss.
Peter Drucker
The Key Benefits of an RBI Study
Identify the high risk itemsUnderstand the risk drivers and develop mitigation plansFocussed inspection plans which: Increase safety and reduce risk Help to improve reliability Often results in cost benefits due to:
Reduced turnaround time and/orA reduction in the number of items to be inspectedThe associated maintenance costs e.g access arrangements
Normally an overall reduction in risk and cost savings from the inspection activity.
Presentation Topics
General IntroductionThe benefits of RBIWhat RBI isHow RBI fits within existing plant systemsImplementing RBISome case studies
What Is RBI?
A method/process for prioritizing equipment for inspection based on risk.It determines the risk associated with the operation of specific items of equipment and identifies the key factors driving the risk.A tool which demonstrates the value (or not) of performing specific inspection activities.It is a decision making management tool applied to the issue of Inspection Planning.
Equipment Types
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, floating heads, channels, and bundles).Pressure-relief devices.
Strategic Process Increasing reliability (revenue) Lowering cost Lowering risk
Integrated Methodology Risk factors
LikelihoodConsequence
Supports effective decision making
Risk Based Inspection
What Constitutes an Undesirable Event In RBI?
Failure is defined as a leak of the equipment contents to the atmosphere; breach of containment or LOPC Heat exchanger failures are channel or
shell leaks. Pump failures are due to seal leaks and
adjacent piping fatigue cracking.
RBI_Key_Concepts.vsd
Risk = Likelihood of Failure XConsequenceof Failure
GFF DFx
Age
DamageType/Rate
InspectionEffectiveness
Damage Area.
Equip. RepairOther repairs
InjuryBusiness Int.
x
Abbreviations: :
DF: DamageFactor
GFF: Generic FailureFrequency
Fi : Process, Mechanical& Universal Factor
Fdomino:Domino Eff.FactorMF: Management Factor
xMF Fp x Fm x Fu
RBI - Detailed Analysis
Components in the calculation of the risk
Fdomino x CoF
Common Damage Mechanisms in RBI
DamageMechanisms
InternalThinning
Stress CorrosionCracking
External Damage
Brittle Fracture
PipingFatigue
HTHA Lining PRVs
General HCl HT Sulfide .
& Nap. Acid HT H 2S/H2 H2SO 4 HF
Sour Water Amine HT
Oxidation
Caustic Amine SSC HIC/SOHIC Carbonate PTA ClSCC HSC-HF HIC/SOHIC-HF
Cl SCC
CUI
Damage factor CalculationMANUAL ACTIVITYEstimate the likely
damage state /severityConsider data source
Assess theinspection history(Effectiveness)
Inspection Effectiveness
Determine the Likelihood of being in oneof the different possible damage states:
1 No worse than predicted X %2 Up to 2x worse than predicted Y %3 Up to 4x worse than predicted Z %
Damage states
Calculate the failure frequency for eachstate using the relevant limit state
equation
Calculate the weighted failure frequencyfor the item based on the Likelihood of
being in the different states.Steps in Bayes_LoF
CALCULATING THE FAILURE FREQUENCY
Failures only occur when the rate of degradation is
higher than expected.
Undesirable Consequences in RBI
HEAT from flames destroys equipment, injures peoplePRESSURE WAVE from explosions knocks down structures and people, causes flying objectsTOXIC cloud, for some duration, causes toxic exposure injuriesENVIRONMENTAL DAMAGE due to spill (currently only included in AST RBI software)
Consequence Calculation
Physical Properties
Process Information
Equipment Damage Costs
Business Interruption Costs
Calculate Release Rate or Release Mass
Equipment Information
Safety Costs
Assessment of Incident Outcome
Damage Areas
Amount of Effort - RBI vs QRA
QRA*
RBI**
Likelihood Consequence
* Quantitative Risk Assessment ** Risk Based Inspection
Input Data For A Quantitative RBI Assessment
For some damage mechanisms, e.g. SCC, brittle fracture, fatigue, other data may be needed e.g. PWHT, Charpy test temp.
What has been looked for and what has been found
Is it operating as intended?
Identify all items
The main input data collectedItem
OD Tnom Matl Ins Press Temp Fluid Temp. Press Fluid Mechanism Severity/rate Done? Result?A Thinning,
SCC, Furnace, HTHA,..
BC
Inspection dataDesign Data Operating Data Damage mechanisms
What do we expect to find and what at what severity?
RBI Results?
Why -(Damage mech. &factor)
Where / How -(Item - Effectiveness - Material - Mechanism)
When -(Basis Inspection planning targets.)
What -(Risk priority)
Item no.
Type From To Damage Mechanism
GFF DF LoF CoF Risk Insp. Type
Insp. Date
New DF
1 Pipe Thinning 30002 Vessel CUI 1003 Fin Fan Erosion 0.5
Calculation of the risk with a lookahead: Inspection Plan
54
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High RiskMedium-High Risk
Med. High Risk
Medium Risk
Low Risk
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Consequence CategoryA B C D E
The Presentation Of Risk
A B C D EConsequence of Failure
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How Will This Picture Change With Time?
Risk Increase Over Time
Likelihood of failure will increase over time because of time-dependent material degradation
A B C D EConsequence of Failure
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What is the effect of Inspection ?
A B C D EConsequence of Failure
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Steps Leading To The Inspection Plan
Risk CriteriaHigh Risk
Negligible risk
Unacceptable region
The ALARP or Tolerabilityregion(Risk is undertaken only ifa benefit is desired)
Broadly acceptable region(No need for detailed working todemonstrate ALARP)
Risk cannot be justifiedsave in extraordinary
circumstances
Tolerable only if risk reduction isimpracticable or if it cost is grossly
disproportionate to the improvementgained
Tolerable if cost of reduction would exceed the improvement
Necessary to maintain assurancethat risk remains at this level
Traditional Vs. Risk-Based Inspection PlanningTraditional
Inspection based on experience (usually by previous leaks and breakdowns)Inspection effort driven by Likelihood of failure
Reactive fire fighting, running behind the ball
Use of appropriate / Inappropriate NDT techniques
RBIInspection based on experience and systematic (risk) review
Inspection effort driven by risk, i.e. Likelihood of failure and consequences of failurePro-active planning and execution of inspections
Systematic identification of appropriate NDT techniques
Change inspection frequencies (when)Change inspection scope / thoroughness (what)Change inspection tools / techniques (how)
Inspection Program Options for Influencing Risk
RBI - Applications
Risk-prioritized Turnaround planning High safety/reliability impact = more attention (in order to
lower risk Less impact safety/reliability = less attention (in order to
lower costs) Result:
Lower equipment life cycle costsFewer incidents / outagesFewer unnecessary inspectionsHigher reliability
May also assess the impact of delaying a turnaround/ shut down
RBI - Applications
Special focus studies e.g.: Corrosion under insulation. Positive material identification. Hydrogen sulfide etc.
What if studies e.g. Assess the impact of process changes. Assess the impact of a different feed.
Can RBI Help To Prevent All Releases?
MechanicalFailure
43%Process Upset11%
Sabotage/Arson1%
Unknown14%Operational
Error21%
Design Error5%
Natural Hazard5%
About half of thecontainmentlosses in a
typicalpetrochemicalprocess plant
can beinfluenced by
inspectionactivities
Where Inspection Can Help
Source: Large Property Damage Losses in the HC-Chemical Industries - A thirty year review, 17th edition, J&H Marsh& McLennan.
THE SYSTEM FACTORS
"HARDWARE" "SOFTWARE" PEOPLE
Managing Risk - Considerations
Risk Exposures (Potential Losses)
Experienced Losses - Cause and Costs
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PercentageAvg. $ loss
Percentage 43 21 14 11 5 5 1Avg. $ loss 72.1 87.4 68.9 81 55.7 82.5 37.1
Mech. Fail.
Operator error
Unknown Process upsets
Natural hazards
Design errors
Sabotage/arson
Source: Large Property Damage Losses in the HC-Chemical Industries - A thirty year review, 17th edition, J&H Marsh& McLennan.
The Equipment Involved
Losses vs Equipment Type
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% of lossesAvg. $ loss
% of losses 33 15 10 8 8 7 5 5 5 2 2
Avg. $ loss 76.9 61.9 151.8 86.9 68.1 38.9 69.6 60.6 34.6 82.4 16.3
Piping Tanks Reactors
Towers
Pumps/Com
Drums
Heat exch.
Unknown
Misc. VesselsHeater
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Presentation Topics
General IntroductionThe benefits of RBIWhat RBI isHow RBI fits within existing plant systemsImplementing RBISome case studies
Managing Integrity
Trained and Competent Staff
PlantIntegrity
Plant DesignOperating &MaintenanceProcedures
Data
Dataanalysis
Management SystemNormally fixed.
RBI projectprocedures. Data Integrity is
essential!
Trained staff areneeded.
Cannot beneglected!
Model For An MI System
SystemDocumentation
(Say what you do)
Documentation/Records
(Document the actions)
Actions(Do what you say)
FILING SYSTEM:
Asset RegisterDesign data
MI equipmentInspection dataOperational dataDeficiency data
Inspection PlansRepair information
Defect AssessmentsInspection due dates
TOP LEVELSYSTEM
DOCUMENTS
GENERALPROCEDURES:
WORKINSTRUCTIONS
STANDARDS
ESTABLISHSYSTEM
INSPECT
UPDATE/REVISE PLANS:
ASSESS THERESULTS
PLANNINGRBI
The Integrated PlanINSPECTION PLANNING
06_Inspection Planning RBI role.vsd
The InspectionPlan
Database
Corporate Philosophy
Local Legislation
Corporate Policy
Inspection Planning activity
i. Inspectii. Onsite assessment
iii. Detailed FfS ifneeded
Update database
Codes andStandards, RP's,
RAGAGEPM
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Data analysis
DesignInspectionOperation
Construction
DM'sAnomalies
Presentation Topics
General IntroductionThe benefits of RBIWhat RBI isHow RBI fits within existing plant systemsImplementing RBISome case studies
Typical RBI implementationDefine scope of RBI StudySet up RBI team and trainCollect DataIdentify inventory groups (For consequences)Identify Corrosion circuitsPerform Screening AnalysisSelect high risk equipment items for Detailed AnalysisPerform detailed RBI analysis Consequence data-Likelihood data Run risk assessment & Review the results Develop action criteria Discuss Orbit proposed inspection guidelines and run final
Translate into an actual inspection plan with scheduleImplement plan-perform inspectionsUpdate the model with latest inspections
Risk Target and Inspection Planning
Inspection Target
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Predicted Risk Increase
Now
Time to next inspection
Highly Effective
Risk / DF
1stTurnaround
Fairly Effective
2ndTurnaround
Time
Implementation Timeline (Tight Deadlines)
Equipment Data Collection
Risk Analysis and Prioritization
Inspection Program Improvements
Weeks 2 4 6 8
Effort Evergreen Level of Effort
Critical Success Factors
Defined objectives and planningA robust working process to assure efficiency and quality A good knowledge of the RBI theoryTrained competent staffA good understanding of the tools to be used.Evergreening the process.
Types of Analysis
A qualitative unit analysis (API 581 for Plant Units) Which unit or platform should be the first based on risk
A system screening analysis Which piping systems need to be included
A qualitative circuit based analysis A qualitative equipment analysisA semi-quantitative circuit based analysisA semi-quantitative equipment based analysisA fully quantitative equipment based analysis.
THE STEPWISE APPROACH
Will be of most benefit to a large facility just starting on the journey.
This course introduces the semi-quantitative approach but focuses on the quantitative.
These steps may beformal or informal.
System Screening- Determine which systems to be included
Semi-quantitative analysis of theincluded equipment
Quantitative analysis ofhigh risk items
FfS/ CBAof a few.
Facility Screening- Determine where to start the study
Vision for the RBI Services.vsd
Qualitative vs Quantitative - COST COMPARISON
For repeat analyses the quantitative approach is far more efficient.The benefits multiply with time
Method Est. total hours Hours onAccum. Hours "Value"
Data Coll. Analysis Insp. plan insp plan
Qual. 310 10% 40% 50% 155 na 40
Quant 500 60% 10% 30% 150 na 100
Qual. 310 10% 40% 50% 155 620 40
Quant 200 15% 15% 70% 140 700 100
Second time around:
Initial Analysis
Activity
Proportion of the time spent on activity:
ADVANTAGES OF THE QUANTITATIVE APPROACH
Not simply opinion based-easily reproducibleAccuracy-Time model The results of qualitative and semi quantitative studies are
frozen in time. In reality the risk will change as the equipment ages and as new data is available from inspection. The quantitative method incorporates this.
What if studies, e.g.: New campaigns in swing plants If the study had been done qualitatively or semi
quantitatively, the effort would be much higher i.e. It is more efficient and powerful to use an analytical
approach
Presentation Topics
General IntroductionThe benefits of RBIWhat RBI isHow RBI fits within existing plant systemsImplementing RBISome case studies
Issue:
Should we change our feed to a cheaper but more corrosive alternative? What does this mean for our risks and inspection requirements?
EXAMPLE STUDY 1
Risk
Inspection Interval
Corrosive Conditions
Tolerable Risk
Maximum Tolerable Risk
Changed Inspection Frequency
Unacceptable Risk
Standard OperatingConditions
Example Study 1
Financial Risk Exposure
$34,793
$46,846
$26,421$15,000$25,000$35,000$45,000$55,000$65,000
0.1% 0.5% 0.8%Corrosive in the feed
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Example Study 1
Cost of Inspection
$0$50,000
$100,000$150,000$200,000$250,000$300,000$350,000
0.1% 0.5% 0.8%
% Corrosive in Process Feed
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Example Study 1
The study gave the facility the information on: The increased risk exposure The increased cost of inspection
They compared this with the cost benefits of the cheaper feed and made their decision.
Example Study 1
-$400,000
-$200,000
$0
$200,000
$400,000
$600,000
$800,000
$1,000,000
$1,200,000
$1,400,000
Unit 30 Unit 33 Unit 34 Unit 48 Unit 51
Current Inspection CostsCurrent Maintenance CostsTotal Current CostsRBI Inspection CostsRBI Maintenance CostsRBI TotalTotal Savings
Example Study 2
Inspecti
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Mainte
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Total
SavingsRBI
Current
$0$500,000
$1,000,000$1,500,000$2,000,000$2,500,000
$3,000,000
COST BENEFIT ANALYSIS Results for all Units
Example Study 2
Cost effective decision making for an older refinery with a limited inspection history.
Example Study 3
Using The Financial Risk Values
Total Risk vs. Risk RankRefinery Process Unit, Top 10% Risk Items
$0
$200,000
$400,000
$600,000
$800,000
$1,000,000
$1,200,000
$1,400,000
0 10 20 30 40 50
Risk Rank
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Assess The Cost Benefits Of InspectionTotal R isk vs . R isk Rank
Re finery Process Unit, Top 10% Risk Items,Same Ite ms, Each with 1 M ore Inspe ction
$0
$20 0,000
$40 0,000
$60 0,000
$80 0,000
$1 ,000,000
$1 ,200,000
0 10 20 30 40 50
Ris k Rank
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Total Risk = $4,100,000/yr,Savings = $7,400,000/yrCost = $250,000 (mostly piping, approximately $5,000 avg. insp. cost)
The Risk of the Lowest 10% Items
Total Risk vs. Risk RankRefinery Process Unit, Bottom 10% Risk Items
$0$200$400
$600$800
$1,000$1,200
$1,400$1,600
0 10 20 30 40 50
Risk Rank
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The Inspection Benefits HereTotal R is k vs . R is k R ank
R e fine ry Proce s s Unit, B ottom 10% R is k Ite ms ,Same Ite ms , Each with 1 M ore Ins pe ction
$ 0
$ 2 0 0
$ 4 0 0
$ 6 0 0
$ 8 0 0
$ 1 ,0 0 0
$ 1 ,2 0 0
0 1 0 2 0 3 0 4 0 5 0
Ris k Rank
R
i
s
k
,
$
/
y
r
Total Risk = $4,300/yr,Savings = $7,700/yrCost = $250,000 (mostly piping, approximately $5,000 avg. insp. cost)
END