1

RBI: Risk-Based Inspection

Reassessment
by Lynne Kaley, P.E.
Materials/Corrosion and Risk Management Engineer
30 Years Refining, Petrochemical and Midstream Gas
Processing Experience
Leader in Risk-Based technology development for plant
applications
Project Manager of API RBI Joint Industry Project since
1996
Member of API committees for development of API 580
and API 581 recommended practices
Developer and Official Trainer for API 580/581 Public
Training course
Vice President and Principal Engineer with Equity
Engineering
3
Purpose of Presentation
Highlight key parts of API 581 and 581
API 510, 570 and 653 allowance for RBI
Overview RBI implementation steps
RBI Reassessment and & Updating
Discuss the role of the inspector in RBI
Sources
API RBI User Group Joint Industry Project
API 580
API 581
API 510, 570, 653
API 571
API RBI Software
Purpose
4
Presentation Overview
Introduction
API RBI Document Status
API 580 Overview
API 581 Overview
Risk Analysis
Probability of Failure
Consequence of Failure
Inspection Planning
Reassessment and Updating
Summary
5
Introduction
The API Risk-Based Inspection (API RBI) methodology
may be used to manage the overall risk of a plant by
focusing inspection efforts on the equipment with the
highest risk
API RBI provides the basis for making informed decisions
on inspection frequency, the extent of inspection, and the
most suitable type of Non-Destructive Examination (NDE)
In most processing plants, a large percent of the total unit
risk will be concentrated in a relatively small percent of
the equipment items
These potential high-risk components may require greater
attention, perhaps through a revised inspection plan
The cost of increased inspection effort may sometimes be
offset by reducing excessive inspection efforts in the areas
identified as having lower risk
6
Introduction
R
I
S
K
LEVEL OF INSPECTION ACTIVITY
Risk with Typical
Inspection Programs
Residual Risk Not
Affected by RBI
Risk Using RBI
and an Optimized
Inspection Program
Refocus Inspection Activities
Risk Reduction, for the same level of
inspection activity, optimization will
reduce the risk
7
Introduction
R
I
S
K
LEVEL OF INSPECTION ACTIVITY
Risk with Typical
Inspection Programs
Residual Risk Not
Affected by RBI
Risk Using RBI
and an Optimized
Inspection Program

Reduce Inspection Activities
Cost savings, for the same level of risk,
optimization using RBI will reduce
activity
8
Introduction
Calculation of Risk in API RBI
Involves determination of Probability Of Failure (POF) and
consequence of failure 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
9
API RBI Document Status
API RBI was initiated as a Joint Industry Project in
1992, two publications produced
API 580 Risk-Based Inspection (1st Edition May, 2002)
Introduces the principles and presents minimum general
guidelines for RBI
2nd Edition targeted for 2009
API 581 Base Resource Document Risk-Based Inspection
(1st Edition May, 2000)
Provides quantitative RBI methods for inspection planning
API 581 API RBI Technology (2nd Edition published
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
10
Overview of API 580 Contents
Foreword
Section 1 Purpose
Section 2 Scope
Section 3 Normative References
Section 4 Definitions and Acronyms
Section 5 Basic Risk Assessment Concepts
Section 6 Introduction to Risk Based Inspection
Section 7 Planning the RBI Assessment
Section 8 Data and Information Collection for RBI
Assessment
Section 9 Damage Mechanisms and Failure Modes
Section 10 Assessing Probability of Failure
Section 11 - Assessing Consequence of Failure
Section 12 Risk Determination, Assessment and
Management
11
Section 13 Risk Management with Inspection
Activities
Section 14 Other Risk Mitigation Activities
Section 15 Reassessment and Updating RBI
Assessments
Section 16 Roles, Responsibilities, Training and
Qualifications
Section 17 RBI Documentation and Record Keeping
Section 18 Summary of Pit RBI Pitfalls
Appendix A Damage Mechanisms Descriptions
Appendix B Screening Table for Damage Mechanisms
Appendix C Screening Table of Examination Methods
Bibliography
Overview of API 580 Contents
12
Section 1 Purpose
Using RBI as a Continuous Improvement Tool
Vehicle for continuously improving the inspection of
facilities and systematically reducing the risk associated
with pressure boundary failures
Reassessment tool that provides refreshed view of risks as
new data becomes available or when changes occur
Adjustment to risk management plans, as appropriate,
when changes occur
Identify gaps or shortcomings of commercially available
inspection technologies and applications
Identify opportunities for other risk mitigation approaches
to implemented.
Serve to guide the direction of inspection technology
development and promote faster and broader deployment
of emerging inspection technologies as well as proven
inspection technologies that are underutilized
13
Section 2 Scope
Target Audience
Primarily inspection and engineering personnel,
responsible for mechanical integrity and operability of
equipment
Not exclusively an inspection activity; requiring
involvement from engineering, maintenance and
operations
Requires commitment and cooperation of an entire
operating organization
Necessary for other stakeholders to be familiar with RBI
concepts and principles to the extent necessary in order to
understand the risk assessment process and accept
results
14
Section 15 Reassessment and
Updating RBI Assessments
RBI is a dynamic tool that can provide current and
projected future risk based on data and knowledge at
the time of the assessment
With time, changes occur that require updating and an
RBI assessment
It is important to maintain and update a RBI program
to assure the most recent inspection, process, and
maintenance information is included
The results of inspections, changes in process
conditions and implementation of maintenance
practices can all have significant effects on risk and can
trigger the need for a reassessment
15
Section 15 Reassessment and
Updating RBI Assessments
Reasons to Conduct an RBI Reassessment:
Deterioration Mechanisms and Inspection Activities
Process & Hardware changes
RBI Assessment Premise Change
Effect of Mitigation Strategies
When to Conduct an RBI Reassessment
After significant changes
After a set Time Period
After Implementation of Risk Mitigation Strategies
Before and After Maintenance Turnarounds
16
Section 18 Summary of RBI Pitfalls
Pitfalls that can lead to less than adequate results
(examples):
Poor planning unclear objectives, undefined operating
boundaries, inadequate management support or RBI
resources, unrealistic expectations
Poor Quality Data & Information Collection poor quality
data, failing to collect data needed
Damage Mechanisms and Failure Modes not properly
identifying and analyzing appropriate damage mechanisms
Assessing Probability of Failure incorrect assignment of
damage mechanisms or damage rates, poor assessment of
past inspection
Assessing Consequence of Failure incorrect assessment of
potential hazards or outcomes
Determination, Assessment and Management using black
box technology, inadequate use or documentation of
assumptions
17
Section 18 Summary of RBI Pitfalls
Pitfalls that can lead to less than adequate results
(examples):
Risk Management with Inspection Activities inadequate
inspection planning basis, inadequate planning for
inspection resources
Other Risk Management Activities not considering risk
management activities other than inspection
Reassessment and Updating RBI Assessment not
understanding the dynamic nature of risk over time, not
having a good link between RBI and MOC
Roles, Responsibilities, Training and Qualifications for RBI
Team Members inadequate skills, training, or experience,
or knowledge
RBI Documentation and Record-Keeping Not
understanding the need for proper documentation and
assumptions
18
API 510, Ninth Edition
RBI used to establish appropriate inspection intervals
for internal, on-stream and external inspection
Allow intervals other than 10 year inspection and -life
limits for internal and on-stream inspections
Allow intervals other than 5 year inspection limits for the
external inspections.
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
19
API 510, Ninth Edition
RBI assessment review should include review of
inspection history and potential for pressure-relieving
device(s) fouling
An RBI assessment can be done to exceed the following
inspection intervals for pressure-relieving devices:
a. Five years for typical process services
b. Ten years for clean (non-fouling) and noncorrosive
services
20
API 570, Second Edition
RBI assessment used to develop appropriate
inspection intervals for thickness and external
inspections (Table 6-1)
RBI assessment used to develop appropriate
inspection intervals for CUI inspection after external
visual (Table 6-2)
When using an RBI interval and inspection coverage,
RBI assessments shall reviewed at least at the
interval recommended in Table 6.1
The RBI assessments shall be reviewed and approved
by a piping engineer and authorized piping inspector
21
API 653, Third 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
22
API 580 Summary
Selection process for RBI approach
Type of process and technology (qualitative vs. quantitative)
Documented and structured implementations work process
Documented methodology and risk calculation procedure
Consistent approach
Procedure
Facilitator training Consequence analysis
Probability analysis
Corrosion/Materials review
Documented technical basis
Inspection Planning approach
Is there a risk mitigation plan
Follow through mechanism
Re-evaluation process and trigger
Link to MOC process
RBI Team Training
23
API 581 Document
Part 1 - Inspection Planning Using API RBI Technology
Calculation of Risk as a combination of POF and COF
Inspection Planning using time stamping
Presentation of results, Risk Matrix (area and financial) introduce
user specified POF and COF category ranges
Risk Calculations for Vessels, Piping, Tanks, Bundles and PRDs
Part 2 - Determination of Probability of Failure in an API RBI
Assessment
POF calculation
Part 2, Annex A - Management Score Audit Tool
Part 2, Annex B - Corrosion Rate Determination
Part 3 - Consequence Modeling in API RBI
COF calculation
Level 1 modeler with step-by-step procedure
Level 2 modeler providing rigorous procedure
Tank model consequence calculation
Part 3, Annex A - Detailed background of Level 1 and Level 2
consequence modeler
Part 3, Annex B SI and US Unit Conversion Factors
24
Risk Analysis
In general, risk is calculated as a function of time as
follows
The probability of failure is a function of time, since
damage due to cracking, thinning or other damage
mechanisms increases with time
In API RBI, the consequence of failure is assumed to be
independent of time, therefore
( ) ( ) ( ) R t POF t C t
( ) ( )
( ) ( )
R t POF t CA for Area Based Risk
R t POF t FC for Financial Based Risk
25
Risk Analysis
Risk ranking of
equipment at a
defined point in
time may be
shown using a
Risk Matrix
Priority for
inspection efforts
is often given to
components in
the HIGH or
MEDIUM-HIGH
risk category
26
Probability Of Failure
The Probability Of Failure used in API RBI is:
The time dependency of probability of failure is the
basis of using RBI for inspection planning
:




f MS
f
MS
POF t gff D t F
where
POF t the probability of failure as a function of time
gff generic failure frequency
D t damage factor as a function of time
F management systems factor
27
Probability Of Failure
Generic Failure Frequencies, gffs, are provided in API
RBI for distribution of hole sizes (small, medium, large
and the rupture case) for various types of pressurized
equipment (vessels, piping, tanks, etc.)
The gffs are based on industry data of vessel failures
and are intended to represent failure frequencies due to
fabrication flaws (and other non-service related
damage) prior to any exposure to the operating
environment
The probability of failure for a component is determined
by making adjustments to the gffs to account for
departures from industry data
Management Systems Factor, F
MS
Damage Factor, D
f
28
Probability Of Failure
Management Systems Factor, F
MS
Accounts for the influence of the facilitys management
systems in place (PSM, MOC, Mechanical Integrity, etc.)
Assumes that the probability that accumulating damage will
be discovered through inspection is directly proportional to
the quality of the facilitys PSM program
Damage Factor, D
f
The damage factor quantifies the degradation expected
from the operating environment and includes degradation
due to corrosion/erosion, environmental cracking, hydrogen
attack, embrittlement and fatigue
The total damage from multiple mechanisms is based on
the principal of superposition
Identification of active damage mechanisms is a
critical component of an API RBI analysis
29
Probability Of Failure
Methods for determining damage factors are provided
in API 581 covering the following damage mechanisms
min ,
:
( / )
thin elin extd scc htha brit mfat
f total f f f f f f f
thin
f
elin
f
extd
f
scc
f
D D D D D D D D
where
D damage factor for thining corrosion erosion
D damage factor for equipment lining
D damage factor for external damage
D dama
htha
f
brit
f
mfat
f
ge factor for stress corrison cracking
D damage factor for high temperature hydrogen attack
D damage factor for brittle fracture
D damage factor for mechanical fatigue
30
Consequence of Failure
Instantaneous Gas Continuous Gas
Instantaneous Liquid Continuous Liquid
Pool Fire, Safe
Dispersion
Jet Fire, Pool Fire,
Safe Dispersion
VCE, Flash Fire
Jet Fire, Toxic Exposure
Safe Dispersions
VCE, Flash Fire, Fireball,
Toxic Exposure,
Safe Dispersions
31
Consequence of Failure
Methodology
Determine Fluid
Properties
Select Hole Sizes
Calculate Release
Rate
Establish inventory
groups and available
mass
Determine Release
Type (Continuous or
Instantaneous)
Assess Detection and
Isolation Systems
Determine
consequence areas
and associated costs
Calculate
Theoretical
Release Rate See
5.3 or 6.3
Estimate the Amount of Fluid
Available for Release
See 5.4 or 6.4
Determine if Release is
Continuous or Instantaneous
See 5.5 or 6.5
Assess the Impact of
Detection and Isolation
Systems
See 5.6 or 6.6
Calculate Flammable
Consequence Area
See 5.8 or 6.8
Calculate Toxic
Consequence Area
Section 5.9 or 6.9
Calcualte Final
Probability-Weighted
Consequence Areas
See 5.11 or 6.11
Fluid Properties
at Storage and
Ambient
Conditions
See 5.1 or 6.1
Range of Hole
Sizes
See 5.2 or 6.2
Calculate Non-Flammable,
Non-Toxic Consequence
Area, See 5.10 or 6.10
Determine the Release Rate
and the Release Mass
See 5.7 or 6.7
Calculate Financial
Consequences
Section 5.12 or 6.12
32
Consequence of Failure
Final consequence areas are determined as a probability-
weighted area of each of the individual event outcome areas
Financial consequences are calculated including the costs
associated with:
Equipment repair
Downtime and associated production losses
Serious injury to personnel
Environmental impact
API RBI provides two levels of consequence modeling
1
..........
flam
pool jet VCE
n
flam
i
i
CA p CA p CA p CA
CA p CA
33
Inspection Planning
Risk increases with
time as component
damage increases
If multiple damage
mechanisms occur at
the same time, then
the principal of
superposition is used
to derive total risk
At some point in
time, risk reaches the
users specified risk
target
34
Inspection Planning
Inspection planning
involves recommending
the number and level of
inspections required to
reduce risk to acceptable
value at the plan date
Inspection effectiveness
is graded A through E,
with A providing the
greatest certainty of
finding damage
mechanisms that are
active and E representing
no inspection
Consider the following
three cases..
35
Inspection Planning
For many
applications, the
users risk target has
already been
exceeded at the time
the RBI analysis is
performed
Inspection is
recommended
immediately
36
Inspection Planning
When the risk is
determined to be
acceptable at the
plan date,
inspection is not
required
37
Inspection Planning
Based on the previous three cases, an inspection plan is
developed on a component basis
Equipment is modeled as a group of individual
components in API RBI
The final inspection plan for the equipment is based on
the results derived for the components
The inspection plan includes:
The date and timing of the required inspection,
The type of NDE (e.g., visual, UT, Radiography, WFMT)
based on the active damage mechanisms
The extent of the inspection (e.g., percent of total area
examined or specific locations)
Location of inspection (external or internal)
38
API RBI Document Overview
Part 1 - Inspection Planning Using API RBI Technology
Calculation of Risk as a combination of POF and COF
Inspection Planning using time stamping
Presentation of results, Risk Matrix (area and financial) introduce
user specified POF and COF category ranges
Risk Calculations for Vessels, Piping, Tanks, Bundles and PRDs
Part 2 - Determination of Probability of Failure in an API RBI
Assessment
POF calculation
Part 2, Annex A - Management Score Audit Tool
Part 2, Annex B - Corrosion Rate Determination
Part 3 - Consequence Modeling in API RBI
COF calculation
Level 1 modeler with step-by-step canned procedure
Level 2 modeler providing rigorous procedure
Tank model consequence calculation
Part 3, Annex A - Detailed background of Level 1 and Level 2
consequence modeler
Part 3, Annex B SI and US Unit Conversion Factors
39
RBI Implementation Process
40
RBI Work Process Steps
1. Define the Scope
2. Establish the Team
3. Create an Equipment List
4. Collect General Equipment Data
5. Collect Consequence Data
6. Collect Probability/Inspection Data
7. Develop an Inspection Plan and Risk Benefit
41
Step 1 - Define Scope
Define the physical and operational/process breaks
within the defined scope
Areas, Systems, Circuits defined for each unit studied
Smallest unit breakdown is Area
Do not break the Unit or Area in the middle of an
isolatable group.
Isolatable group is a group of equipment where inventory
can be isolated by remotely operated valves
Manual adjustment/estimate to inventory is required for
individual equipment items for study
42
Equipment Covered in RBI Study
Reactor
Column
Drum
KO Drum
Piping
(NS/Tube, Snd.)
Filter
PRD
Heat Exchanger
(SS/TS)
Finfan/Header
Storage Tank
Furnace
Pump
Compressor
43
Defining the Equipment
Included in the RBI Study
Area 1
A
B
C
D
E
F
G
H
System 2
System 1
System 3
Define Circuits
within each system
44
Step 2 - Establish the RBI Team
Facilitator/Project Manager
RBI Champion
Personnel with the following expertise:
Inspector
Metallurgy/Corrosion Engineer
Mechanical/Reliability Engineer
Process Engineer
Process Hazards
Team can be and often is a combination of plant and
consulting expertise.
45
RBI Time Frames & Schedules
An RBI implementation project is easily divided into
these main stages
First Stage data gathering and entry
Second Stage interpreting results, performing checks
and validation of data and assumptions
Third Stage prioritizing risks and inspection planning
development
46
List vessels and piping by unit and areas grouped by
corrosion groups of similar service
Use a spreadsheet (Access of Excel)
Identify the following:
Unit
Equipment ID
Equipment Description
Equipment Type
Component ID
Component Description
Component Type
Conduct Process overview discussion
This process familiarizes the team with the unit of
study
Step 3 - Create a Complete
Equipment List
A
C
B
D
Corrosion
Groupings
48
Hints for a Successful Study
Use a group facilitated approach
Provide process flow diagrams, populated with key data
Get people knowledgeable about the unit(s) involved
Consider maintenance and operational issues as well as
inspection history and findings
Group equipment logically, i.e. corrosion groups
Use existing electronic information whenever possible
And..Make conservative assumptions and
document them
Evaluate preliminary results and risk ranking
Identify variables driving risk
Update/Improve data, as necessary/appropriate
49
49
50
Step 4 - Collect General Data
Unit
Equipment ID
Equipment Description
Equipment Type
Component ID
Component Description
Component Type
Base Material of
Construction
Clad/Weld Overlay
Material of Construction
Service Start Date
Operating Temperature
Operating Pressure
Design Temperature
Design Pressure
Furnished Thickness
Corrosion Allowance
Diameter
Length
PWHT
Insulation Type
Heat Tracing
51
Process stream characteristics (fluid characteristics
representing behavior)
Fluid phase (inside equipment)
Toxic component of process stream
Toxic concentration (typically % of total process stream
composition)
Inventory calculated by program based on equipment
dimensions and fluid density
Detection, Isolation and Mitigation Systems
Material Balance is helpful for best modeling for Level 1
or Level 2 modeler
Step 5 - Collect Consequence Data
52
Step 6 - Collect Probability Data
Material of Construction (Code, Spec,
Grade and Year) for Base or Clad
materials
Clad, Weld overlay or Lining, as applicable
Insulation Type
Susceptibility Damage Mechanisms
Expected Damage (damage rate or
severity)
Concentration of contaminants
53
Probability Data - Thinning
Identify known in-service damage mechanisms
Identify if General or Localized behavior of thinning
corrosion (localized will affect < 10% of surface area)
Measure and/or Estimate thinning rates
Service Start Date or Date for current service
Furnished Thickness
Corrosion allowance
On-line monitoring
54
Determining Corrosion Rates
Performed at corrosion groups and circuits level
Defined as same active damage mechanism and similar
rate/severity
Determine damage rate based on:
Estimated Corrosion/Materials expert assessment
Measured From inspection history or equipment in
similar service
Calculated - determine estimates from damage
mechanism modules
*Rates for RBI generally range from 0 to 25 mpy
55
Probability Data - Cracking
Identify known cracking mechanisms
Susceptibility to cracking
Estimated - Corrosion/Materials expert assessment
Detected - Cracking history in this or equipment in similar
service
Calculated - Determine estimates from damage
mechanism modules
On-line Monitoring
56
Step 6 - Inspection Data
Summarize inspection history from records
Enter date of inspection and inspection results by
mechanism (e.g. thickness for thinning)
Grade effectiveness by damage mechanism
Start reviewing history with most recent inspection;
most reliable and applicable information for current
conditions
Refer to Inspection Effectiveness tables for guidance
Inspection Effectiveness tables can be customized for
each user company
Effectiveness Category Category Description
Highly Effective Inspection methods correctly identify the anticipated in-service
damage in nearly every case.
Usually Effective The inspection methods will correctly identify the true damage
state most of the time.
Fairly Effective The inspection methods will correctly identify the true damage
state about half of the time.
Poorly Effective The inspection methods will provide little information to
correctly identify the true damage state.
Ineffective The inspection methods will provide almost no information that
will correctly identify the true damage state.
Effectiveness Categories
The inspection effectiveness depends on the active mechanism. It is most
effective if the active mechanisms are identified before determining the
inspection effectiveness.
58
Inspection Planning
Methodology
Inspection reduces the expected Probability of failure
The Probability of failure due to such damage is a
function of four factors:
Damage mechanism and resulting type of damage
Rate of damage progression and escalation of risk
Probability of detecting damage and predicting future
damage states with inspection techniques
Tolerance of the equipment to the type of damage
Design errors, fabrication flaws, and malfunction of
control devices can lead to equipment failure
59
Options for Inspection Planning Approach
Fix when equipment fails or breaks
Conduct a full inspection on all equipment at fixed
intervals (primarily vessels, piping is often neglected)
Compliance based with the codes / law
Condition based approach (Probability of failure)
Risk based approach
Qualitative
Quantitative
Inspection Planning Module
60
An Inspection Plan includes consideration for:
Which equipment needs inspection
Identification of the mechanism(s) driving the
inspection
Interval for inspection
Locations and coverage required
Methods/Techniques to be used for inspection
In addition an inspection plan should include:
The acceptable limits for the inspection findings
Follow up with fitness for service analysis, if necessary
Inspection Planning Module
61
Objectives of an Inspection Program
Prioritization of equipment and piping for
inspection
To minimize downtime during turnarounds
Identify on-stream inspection candidates
To achieve more effective use of resources
Special Emphasis inspection programs
Assess the impact of turnarounds deferrals
Inspection Planning Module
62
Inspection Planning
Risk will increase until the date of inspection. The calculated
risk will decrease after RBI inspection plan is implemented.
Time
R
i
s
k
Criteria
Recommended
Inspection
Points
63
Inspection Planning
Two methods for Inspection Planning
Date Returns a recommended date for inspection based
on maximum Area or Financial Risk input and planned
inspection (number and effectiveness) for each damage
type
Plan Returns a recommended effectiveness for
inspection based on maximum Area or Financial Risk input
and date for inspection
64
Inspection Planning - Plan
Input required is date of inspection during planning
period
Enter Plan Time in Maximum Inspection Interval field
Local Target Risk Inputs can be used to override
Global Settings
Calculates Inspection necessary for the component to
remain below the Maximum Risk Target
Will generate the next (1) inspection and an effectiveness
of A, B or C
65
Inspection Planning - Plan
Risk
Time
Total Risk
RBI Date Plan Date Start Date
Target Risk
Cracking Risk
Thinning Risk
Insp
Insp.
Target Date w/out
Inspection
Inspection History
67
Inspection Planning - Date
Input required is number of inspections planned and
effectiveness during planning period
Enter Plan Date
Local Target Risk Inputs can be used to override Global
Settings
Calculates Date component reaches Maximum Risk
Target with and without inspection
68
Inspection Planning - Date
Risk
Time
Total Risk
Inspection History
RBI Date
Target Date w/out
Inspection
Plan Date
Future Inspection
Start Date
Target Risk
Cracking Risk
Thinning Risk
70
71
72
73
RBI Reassessment & Updating
74
Reassessment and Updating RBI
API 580 highlights reasons for why and when an
assessment will be re-evaluated
Reasons to Conduct an RBI Reassessment:
Deterioration Mechanisms and Inspection Activities
Process & Hardware changes
RBI Assessment Premise Change
Effect of Mitigation Strategies
When to Conduct an RBI Reassessment
After significant changes
After a set Time Period
After Implementation of Risk Mitigation Strategies
Before and After Maintenance Turnarounds
75
Reassessment and Updating RBI
Additional Reasons for Re-evaluation
Changes in RBI technology or improvements that affect
the risk calculation
Changes in code that affect the recommendations
Changes in law or regulatory policies
Change in company risk policy
Process changes, includes debottlenecking, changes in
feed, changes in catalyst, changes in alloying, etc.
Considerations as learned from a failure in that plant or
another plant with a similar process
Extension of run length between turnarounds
76
TML/CML INSPECTION
PROGRAM TO RBI
ASSESSMENT TEAM
RBI ASSESSMENT &
INSPECTION PLANNING
RBI ASSESSMENT DATA
PLAN RBI INSPECTION
ACTIVITIES
DOCUMENT INSPECTION &
RESULTS
DATA FROM PLANT FILES
INSPECTION
RECOMMENDATIONS FROM
RBI
78
API RBI Analysis
Measured corrosion
rates and measured
thickness by circuit.
79
API RBI Inspection Planning
Inspection
recommendations
and due date.
Detailed inspection plans
include scope, damage
mechanism and
recommended inspection
effectiveness.
80
Inspection Results
Inspection results and findings should be compared to
expectations of damage
Thinning rate and type (general or localized)
Cracking inspection findings if cracking was found and
severity, if found
Where there any inspection findings that could impact
the RBI Assessment?
Are there any MOC considerations that could impact the
Risk Assessment?
Any new information or findings should be noted and
returned to the RBI analysis Team
81
Inspection Results into API RBI
Record actual inspection
effectiveness and
measured thickness to
be used in Risk
determination
Updated measured corrosion rate
also entered in Thinning Module
and Risk recalculated for next
interval recommendation.
82
Reassessment & Updating
Re-evaluation of Risk for equipment with inspection
findings were noted
Consider severity and type of damage compared to
expectations
Determine if the risk assessment needs to be modified
based on findings
Determine if MOC or process/debottlenecking requires
re-evaluation or further consideration
Recalculate Risk and begin inspection planning activity
Prompt User for new RBI Date (after latest inspection
date), Plan Date and notification of last RBI analysis
Date
83
Other Considerations
Damage mechanism screening using API 571
MOE link to identify key variables and ranges driving
damage notification system for exceeding or
operating outside of the set ranges
84
Summary
API RBI was originally developed in a Joint Industry
Project (JIP) sponsored by API, the JIP currently consists
of 47 companies with worldwide processing plant
facilities
Data input requirements minimal compared with output
value
API RP 581 2
nd
Edition, September 2008
API RP 580 2
nd
edition in Ballot process
Refer to API 580 when determining the need for
reassessment & updating for continuous improvement of
RBI program for managing risk
85
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Houston, TX 77058 USA
Phone: 281-480-0556 Fax: 281-480-2063
www.equityeng.com
Lynne Kaley, P.E.
Phone: 281-283-6502 email: lckaley@equityeng.com