Risk Based Inspection (RBI) Best Practice: The Technical Specification for Ensuring Successful Implementation

This Keynote Paper is written to help plant sites wishing to implement Risk Based Inspection (RBI) for the first time to enhance their equipment integrity management practice as well as for those plant sites not satisfied with their existing Risk Based Inspection (RBI) process at site and considering a change. It is also considered of immense value for plant sites wishing to set up a Risk Based Inspection (RBI) audit programme to review their existing RBI technology process and site practices and make the necessary improvements. The technical specification provided in this paper for ensuring successful implementation of Risk Based Inspection (RBI) is based on current knowledge of RBI technology, best practices, industry experience and feedback particularly from Inspection and Operations engineers at a variety of plant sites. Guidance is also provided to plant sites on key technical aspects which they must include when writing their Technical Specification for Risk Based Inspection (RBI) Project Tender enquiry, together with various criteria which must be satisfied when they finally evaluate and select the Risk Based Inspection (RBI) Service Provider. Any plant site following these guidelines will ensure achievement of its site strategic goals, whilst help minimise the serious inconsistencies exist between Risk Based Inspection (RBI) service providers with respect to the 5 critical aspects mentioned below. As a background, Risk Based Inspection (RBI) is a technology process which, when correctly implemented, is used to formally optimise the inspection efforts for each equipment item of plant within the boundaries of appropriately defined integrity operating limits, whilst minimising equipment failure risks caused by the relevant Damage Mechanisms (DMs). Risk Based Inspection (RBI) driven integrity management is relevant to static equipment, piping, storage tanks, pipelines and pressure relief valves operating in the oil, gas, petrochemical, fertilizer manufacturing & power generating plants. The management process is also evergreen as the initial Risk Based Inspection (RBI) study of each of these items requires reviews and updates after inspection or when operational changes are made. As such the integrity management responsibilities involve not just the Inspection Engineers but also the Operations and Process Engineers at a plant site. As Risk Based Inspection (RBI) is still a developing technology, there are various RBI methodologies are available in the marketplace, including API 581. Each has its own merits and weaknesses. As such, those companies who have already implemented Risk Based Inspection (RBI) at plant sites have reported varying outcomes from implementation. It is emphasized therefore, only through proper implementation of a robust and user-friendly Risk Based Inspection (RBI) technology process, the perceived substantial safety & financial benefits can be achieved by plant sites. As such, the following critical aspects must not be compromised as these are the ‘bottom line’ for implementing Risk Based Inspection (RBI) successfully. The plant site must ensure:1. Selected Risk Based Inspection (RBI) Technology is reliable (in assessing Probability of Failure [PoF] for each identified DMs and their Risks), incorporates best practices and is technically practical and user-friendly for Inspection Engineers at plant site. 2. Risk Based Inspection (RBI) Team Study of each item and each piping corrosion loop (PCL) is comprehensive, in particular the study process for identifying potential DMs & evaluating of PoF and risk profile, optimising inspection interval, defining inspection scope/method for each DM and defining integrity operating limits – there is no shortcut to this task, the study time must not be compromised. With respect to Risk Based Inspection (RBI) study data, ensure all damage causing chemicals including their actual compositions/temperatures at various locations in the plant are correctly established, including relevant past operational changes. Samples must be taken and analysed where such compositions are uncertain. 2/18 Risk Based Inspection (RBI) Best Practice: The Technical Specification for Ensuring Successful Implementation 3. In addition to Risk Based Inspection (RBI) Specialist Engineer and Corrosion Specialist, the Risk Based Inspection (RBI) Study Team includes Inspection, Operations and Process engineers from plant site. 4. Risk Based Inspection (RBI) Team Study Output is reliable, addresses all integrity related aspects (e.g. Optimum Inspection Interval, Integrity Operation Limits & Critical Maintenance Activities, etc) and matches site strategic goals. 5. Risk Based Inspection (RBI) software comprehensively supports 1-4, future updates of study and is fully auditable. With this mindset, following important aspects are discussed to provide an overall appreciation of the requirements:1. Industry Status on Risk Based Inspection (RBI) Technology 2. Plant Site Risk Based Inspection (RBI) Objectives and Project Deliverables 3. Risk Based Inspection (RBI) Implementation – Best Practice Risk Based Inspection (RBI) Technology 4. Risk Based Inspection (RBI) Implementation – Risk Based Inspection (RBI) Team Study and Study Time 5. Risk Based Inspection (RBI) Implementation – Study Output/Deliverables + example 6. Plant Site Management Commitment & Obligations 7. The role of supporting Risk Based Inspection (RBI) Software system 8. Writing a Technical Specification for an Risk Based Inspection (RBI) Project Enquiry 9. Selecting the Risk Based Inspection (RBI) Implementation Service Provider When the above important aspects are correctly addressed and followed, it has been shown to deliver the plant site Risk Based Inspection (RBI) strategic goals in terms of substantial improvement in safety, reliability and financial benefits:1. Enhanced integrity for each plant item (improved safety & reduction in lost production days) through better understanding of potential DMs and respective damage susceptible locations. 2. More focused inspection strategies with reliably optimised interval and inspection activities for each equipment item, based on identified ‘active’ and ‘potential’ DMs. Reduction in inspected items during each TA, through extended inspection intervals for items which are found to be over inspected. Replacement of intrusive inspections with nonintrusive methods for items where this is feasible. 3. Reduction in equipment failure risks due to better defined Integrity Operating Limits & Critical Maintenance Tasks. 4. Formally justified opportunities with recorded evidence to increase plant run-length time between TAs and optimise maintenance / inspection TA times. Reduction in unexpected deteriorations usually found during TA inspections which in turn lead to reduction in unplanned repairs, thus avoiding over-run of TA period. 5. Improved ‘working together culture’ between inspection, process and operation departments and proactive ‘asset care’ at plant site and improved self-assurance on equipment reliability. The Senior Management at plant site must therefore appreciate that, for implementing Risk Based Inspection (RBI) successfully at a plant site, it is the reliability of this technology process, its user-friendliness to inspection engineers plus the accuracy of the data, comprehensiveness of the team study and the people involved in this from the plant site which deliver the set objectives & goals and not the software. i.e. do not buy an Risk Based Inspection (RBI) software where the responsible plant inspection engineers cannot fully understand the Risk Based Inspection (RBI) technology behind it, as implementing such a technology can lead to an increase in equipment risk rather than a reduction in risk.