1_RiskBaseInspection

8/12/2019 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



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

1_RiskBaseInspection

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