1_riskbaseinspection
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Risk Based Inspection for Boilers
72557
Lloyds Register International(Thailand) Ltd.
Chamni Mosagul
Operation Manager,
ASME Authorized Inspector and Supervisor (AI, AIS)
Energy, Inspection Business,
Lloyds Register International (Thailand) Ltd.
7 June 2014
Risk Based Inspection for Boilers
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Risk Based Inspection(RBI)
Agenda
RBI Introduction
Time based vs Risk based inspection(RBI)
RBI Methodology
Boiler Deterioration Mechanism
Criticality assessment
RBI result implementation for inspection &
maintenance strategy
RBI Workshop (if time available)
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RBI Introduction
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What is Risk ?
Risk Has Two Components:-
Risk is a measure of BOTH
PROBABILITY of a failure
AND
CONSEQUENCE of a failure
What is RBI ?
Risk Based Inspection (RBI) is
a risk assessment and management process that is focused on
loss of containment of pressurized equipment in processing
facilities, due to material deterioration.
These risks are managed primarily through equipment inspection.
Referenced Code
API Recommended practice 580 (Risk Based Inspection)
API Recommended practice 581 (RBI Base Resource Document)
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Reliability Based Mechanical Integrity
Criticality Measures
Probability Ranking
Very High (1+ per yr.)
High (10-1 per yr.)
Moderate (10-2 per yr.)
Low (10
-3
per yr.)
Very Low (10-4 or less
per yr.)
Consequence Ranking
Catastrophic ( 107 )
Very Serious ( 106 )
Serious ( 105 )
Significant ( 10
4
)
Minor ( 103 )
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RBI Time based vs Risk Based Inspection RBI)
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Advantage of RBI comparing to Time Based inspection
Previous and existing resolution (Time Based)
Time based inspection and Maintenance:-
- Inspecting before knowing where to go
- Lower safety, reliability
- waste a lot of money to do unnecessary inspections
and maintenances cost
- Higher risk level
- Low level of assets performance management
- low Economical competitiveness capability level
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Alternative Technology RBI)
for assets performance management
Risk Based Inspection and Maintenance
- Inspectors can identify:-
- where the damage mechanisms are,
- how to inspect them, and
- how frenquently
- Inspection is about finding where the
problems are
before they find you. RBI helps we do that.
Alternative Technology RBI)
for assets performance management
Risk Based Inspection and Maintenance
- RBI is about doing the right things
- It is about getting to mechanical integrity
and safety,
- It is not about saving money, saving will
come after our facilities are safe and reliable.
- Inspection and Maintenance based on real-
time evaluated risk level
- Not doing unnecessary/waste inspection and
maintenance activities
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Alternative Technology (RBI)for assets performance management
- Maintain high safety level at Lowest risk
- Highest performance/lowest cost
- Maximize profit and economical
competitiveness capability
INSPECTION COSTS
RISK
Risk Using RBI
Risk with time driven asset
management program
The RBI processreducing costs, reducing risks and measuring value
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FCC Calculated Risk and Risk Reduction
90% Risk Reduction Achieved by
Add ressing 12% of Fixed Equipment Items
As-Found Risk
After Risk Mitigat ion
Calculated as the mid value
consequence multiplied
by the likelihood
Risk Distribution
10 1 10 0 0 0 0
33 2 1 10 3 18 1
22 3 0 6 3 12 1
25 4 5 0 0 17 3
100 5 27 0 0 65 8
E D C B A
190 43 1 6 6 1 12 13
Initial Risk Study
Risk Distribution
3 1 3 0 0 0 0
13 2 2 6 0 5 0
25 3 4 10 3 8 0
35 4 6 0 3 21 5
114 5 28 0 0 78 8
E D C B A
190 43 1 6 6 1 12 13
Industry Best Practice Case Study #3U. S. Refinery Piping in All Units
0
1,000,000
2,000,000
3,000,000
4,000,000
5,000,000
HFAlky
FCC
GasCon
#2Crude
#1Crude
MEASRU
#1Reformer
DistillateUnifiner
HDH
SatGas/Dehex
C5/C6Isom
FoulWaterSep
Hydrogen
C5/C6Desulf
Reformer#2
FuelGas
DDSHydrotreater
Flare,
OilSep,
BD
#2SRU
BOILER
SCOT
Units
As Found
As Left
CumulativeRisk-
$/Yr
Contract
Inspection Resources
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RBI Methodology
There are 3 methods commonly used:-
- Qualitative
- Quantitative
- Semi-Quantitative
RBI Methodology
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RBI Qualitative methodology
Corrosion engineer 1
Subject Matter Expert 2
Subject Matter Expert 3
Subject Matter Expert 4
Facilitator
Data collection
30 fields
per asset
Manual Inspection planning per asset
RISK Calculator
RBI Quantitative methodology
Data collection
130 fields
per asset
Manual Inspection planning per asset
RISK Calculator
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RBI Risk Modeling
Calculate Likelihood of Failure
(events per year)
Asset type, components
Degradation mechanisms
Failure modes
Age, usage, environment, etc
Asset condition (based on past and
future maintenance and condition
monitoring)
Calculate Consequence of Failure
(impact per event)
Safety, Health or Environmental impactMaintenance costs
Disruption to use
Reputation Public/Political
M&I Task Plan optimized to the
asset and the business
Includes industry best practices
May increased or decrease current
maintenance requirements
Will change with time
Consequence Ranking
ABCDE
1
2
3
4
5
ProbabilityRanking
HIGH
MED HIGH
MEDIUM
LOW
RBI Implementation step
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Semi - Quantitative methodology (Capstone RBMI)
Corrosion engineer
Asset
Perform
Plan
Evaluate
Update
RISK Calculator
RISK Calculator
Data collection
30 fields
per asset
Suggested
inspection plan
generated by
system
API 573
(Insp. of Fired
Boilers/heaters
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Data collection step
Evaluate Risk level for each Component/item