RBI - Inspection Management-Orbit Onshore_W_tcm144-512440

8/9/2019 RBI - Inspection Management-Orbit Onshore_W_tcm144-512440

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Inspection Management –ORBIT RBI Software

Panos Topalis



Version Slide 8

Process Plants-Objectives and Challenges

Objective: Operate safely and profitably

- Prevent/reduce leaks.

- Meet HSE Requirements

- Maintain high availability and throughput.

- Minimize shut downs.

- Extending shut down intervals

- Reduce Insurance Costs

Challenges

- Old Plants- Large, complex units

- Integrated Feed Systems

- Many degradation mechanisms

- Raw material price

- Massive amount of data

Need to manage in a proactive and systematic way

Guiding Principle: Maintenance on the basis of risk



Version Slide 12

RISK MANAGEMENT

Software Offering For the Process Industry

Performance

Forecasting

/ RAMAnalysis

FrequencyAnalysis

ConsequenceAnalysis

Impact andRisk Analysis

AssetIntegrity

ManagementSoftware

PHAST RiskPHASTLEAK

RiskSpectrum

•ORBIT+IDS

•Silverpipe

•ORBIT RBI

•AIMS Structures

MAROS

TARO



Version Slide 1313

DNV Integrity Management for Onshore andOffshore Facilities

Satellite Topsides

Sub sea

Onshore & Subsea Pipeline

SilverPipe

Offshore

Structure

Sesam

StructureIntegrity

Offshore

Topside

ORBIT+

IDS+RBI

• Refineries

• Gas Plants• Petrochemicals

• Chemicals

• LNG Plants

• Terminals

• Others

ORBIT+ IDS+RBI

Process Facility



• RBI on Web or offline

• Combining risk-based and regular inspection scheduling

• Flexible work packaging and task assignment

IntegrityEngineer

• Risk and job overview for all types of equipment

• Traffic lights on facility hierarchy and integrity barriers

• Managing risk by KPIManagers

Benefits of using ORBIT+ IDS

17

• Easy inspection preparation

• Easy inspection result recording and reporting

• Generate and monitor maintenance notifications

Inspectors andContractors

• Fully web-based system, easy deployment and support

• Open web-services for integration

• Logical data views and report templates for external enhancements

ITSupport



Version Slide 23

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 (mid-1990’s)- DNV main API sub-contractror

- API Base Resource Document 581 (2000)

- API RBI software

- API RP 580 (2002)



Version Slide 24

Risk Based Inspection “Driving Factor”

% of Total Risk Vs % of Equipment ItemsPlant Unit, ~500 Total Items

0%

10%

20%30%

40%

50%

60%

70%

80%

90%

100%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

% of Equipment

% o

f T o t a l R i s k

•Risk is not equally distributed among the individual pieces of

process equipment.

•A large percent of the total unit risk is concentrated in a small

percent of the equipment.



Version Slide 25

Managing Risk Using RBI

Risk, RBI Strategy (more effective)

Risk, Traditional Strategy

Inherent Risk

EFFORT = EURO, USD, RUB, RMB,NOK

Risk

Reduction

Cost

reduction

Both



© Det Norske Veritas AS. All rights reserved.Slide 26

So what are the real Benefits of RBI Implementation ?

Risk ranking and prioritization of inspection and maintenance activities

Optimise spending on maintenance and inspection

May significantly alter the inspection strategies to become more “efficient”

May provide substantial cost savings

May contribute to reducing operational risks

Improved communication between operations, inspection and maintenance

Provides RBI database for easy future inspection scheduling, updating andrisk control

Improves the mechanical integrity system and provides means to measure

the effectiveness of inspection



Version Slide 28

ORBIT Onshore Features

Suitable for RBI of chemical plants, refineries, onshoreinstallations

Semi-qualitative screening analysis enables rapid identificationof high risk items

Detailed likelihood calculation as a function of time, using limitstate equations

State-of-the-art consequence modelling using PHAST models Extensive database of more than 1700 construction materials

(ASME)

Incorporates database of more than 1500 chemicals (DIPPR),100 chemicals with detailed data

Easy addition of new materials or chemicals for detailed RBI orscreening RBI



Version Slide 29

Modules

Qualitative-Screening Approach

Internal Thinning

Stress Corrosion Cracking (SCC)

External Damage

Brittle Fracture

Fatigue

High Temperature Hydrogen Attack (HTHA)

Linings

Pressure Relief Valves

Consequences with PHAST lookup tables or direct input

Inspection Planning, Optimisation, Cost Benefit Analysis and Final Approval



Version Slide 31

Typical Reports



Version Slide 32

Typical Reports

Risk matrices for

- Current Date

- Future prior to inspection

- Future post inspection

Executive summary with risks per equipment type and damage mechanism, riskvariation with time with / without inspection

Inspection plans showing what equipment items to inspect, for what type ofdamage, when to inspect and what approach to use

Cost Benefit Analysis/ Risk benefit analysis

Equipment summary sheet

Detailed risk breakdown including business interruption, equipment damage and

personnel safety contributions



Version Slide 36

Success Stories

Dow Chemicals

- Using ORBIT in 16 sites

- User group and technical steering group

Total Petrochemicals (former Atofina)- Selected ORBIT in competition with other RBI software

- Deployed already in 4 sites, planned for more sites

Borealis

- Deployment in 6 sites: Austria, Belgium, Germany, Sweden, Norway,Finland

Equate, RBI implemented in Kuwait petrochemical installation

Kuwait Oil Company

- RBI and Inspection Software (ORBIT Onshore and ORBIT+IDS)- Inspections conducted/managed for 5000 equip. & 50000 pipes

- 21 Gathering Centres and 3 Booster stations,



Evidence of Benefits from the Use of ORBIT



Version Slide 38

ORBIT Onshore Worldwide Continuous Success Story:Dow Chemicals

http://www.dnv.com/resources/publications/dnv_forum/archive/DowChemicalCo.asp



Version Slide 39

Dow Chemicals

Chemical company with sites / joint ventures worldwide

RBI Implementation in more than 15 sites

- Europe, US, South America, Asia Use of ORBIT Onshore & DMI since 2000

- In-house RBI experts

- Currently operating with minimum DNV assistance

Risk based inspection instead of periodic inspection Quoted(*) Benefits of the RBI program:

- Improved reliability

- Eliminated low-value work

- 40% inspection cost reduction

Dow quote 100 million USD savings/year

* http://www.dnv.com/resources/publications/dnv_forum/archive/DowChemicalCo.asp



Version Slide 42

RBI – Risk in Detailed Analysis



Version Slide 46

Undesirable Consequences in RBI

HEAT from flames destroys equipment, injures people

PRESSURE WAVE from explosions knocks down structures andpeople, causes flying objects

TOXIC cloud, for some duration, causes toxic exposure injuries



Version Slide 50

Risk Target and Inspection Planning

InspectionTarget

R i s k / D a m a g e F a c t

o r ( D F )

Predicted Risk

Increase

Now

Time to next

inspection

Highly Effective

Risk / DF

1st

Turnaround

Fairly Effective

2nd

Turnaround

Time



Version Slide 55

API and ORBIT

DNV develops successive versions of API 581 and API-RBI, 1993-2002

DNV develops ORBIT RBI 1997-now

- Some Reasons:

- Need for a RBI software for other than refineries

- Improved consequence calculations with PHAST link- Need for a robust software architecture & professional software

development and maintenance

ORBIT is consistent with the API 580 RBI standard

ORBIT and API 581 share a lot of technology



Software Demonstration



Version Slide 63

ORBIT Overview

•Screening or

•Detailed

Analysis

•Designed for All Types of Process Plants.

•Designed to Be Subdivided Easily IntoPlant Units, Areas, Zones, Corrosion

Circuits Etc.

• Looks Like Microsoft

Outlook.

• Intuitive To Use.

• Online Help.• Menus Or Buttons.



Version Slide 64

ORBIT List Views

Allows Easy Sorting andEditing of Large Amounts

of Data

A List-view: one of the

possible views of the

same study Database

ORBIT Li Vi



Version Slide 65

ORBIT List Views

“Drag and Drop” Facilities

for Sorting

Seven Pre-Installed List

Views



Version Slide 66

User List Views

Facility to Create User

Defined Views

Screening Analysis



Version Slide 67

Screening Analysis

Screening Analysis is a

semi-Quantitative

Method for Rapidlyidentifying high-risk

items from a large set of

Equipment Items.

NFPA

Ratings for

1600

Chemicals.

S i A l i



Version Slide 68

Screening Analysis

Likelihood By:

DamageMechanism

Method (for Long

Life Expectancy

Items) or -



Version Slide 69

Screening Analysis

Results Calculated Immediately As

•Likelihood rating (1 to 5)

•Consequence Rating (A to E)

•Overall Risk Ranking (Low to High).

- Statistical

Method (for

Shorter LifeItems).

Recommendat

ions Made.



Version Slide 71

Detailed Analysis

Extensive

Database of

Materials.

Select Exact Material

or Generic Type (E.G.

Carbon Steel)



Version Slide 72

Consequence Analysis

PHAST Is

DNV’s Widely

Used Software

for ConsequenceModelling

In Consequence Module

Define:

Consequence Method

(PHAST-Lookup or

Direct Input),

Chemical,

Vessel Shape.



Version Slide 73


Database of 1600

Chemicals. A subset

have lookup tables

Consequence Results

Determined:

Business Interruption Cost

Equipment Damage Cost

Safety Cost



Version Slide 74


SI, English, Metric or

User Defined Units of

Measure

C A l i



Version Slide 75


LinkEquipment

Items Into

Inventory

Groups

-

Automatically

Calculated or

Manual Input

Thinning Calculation



Version Slide 76

Thinning Calculation

Choice of Corrosion Rates:Measured,

Expert Opinion

Inspection History - Number

and Type: Used to Calculate

Probability That Corrosion

Rate Is Worse Than Measured,

or Estimated Rate.

Program Considers the Chance

of Corrosion Rate Being Higher

Than Measured or Estimated.

Localised or General

Corrosion



Version Slide 77

Thinning

Likelihood Factor = How many

times the Equipment Item Is More

Likely to Fail Than Generic.

Likelihood Factor for

Thinning Projected for a 5

Year Period.

Thi i



Version Slide 78

Thinning

Results Include:

Equipment Item Remaining

Life and Confidence in

Corrosion Rate (Based on

Inspections Undertaken).

E l D



Version Slide 79

External Damage

Estimated or Calculated

Corrosion Rates

Choice of Corrosion

Rates:

Measured,

Expert Opinion or

Calculated

SCC M d lli



Version Slide 80

SCC Modelling

In-built SCC

Causes:

•Caustic

•Amine•Carbonate

•SSC

•HIC/SOHIC

•Chloride

•PTA•HSC

•Ammonia

Calculated or

expert SCC

Susceptibilities

Results:•SCC Factor

SCC Modelling



Version Slide 81

g

SCC Factor Projected for a

5 Year Period.

Inspections



Version Slide 82

Inspections

Inspection History for Each

Equipment Item

Effectiveness Is Highly,

Fairly, Usually or Poorly -

DNV Templates Definitions

- Modified for Each Client

Inspection ImprovesConfidence in the

Estimated, Measured or

Calculated Corrosion Rate

or SCC Susceptibility

Other Modules



Version Slide 83

Other Modules

Other Modules:

•Brittle Fracture•Piping Fatigue

•HTHA

•Liners

•PRVs

Results: Risk Matrix Report



Version Slide 84

Results: Risk Matrix Report

Results: Equipment Summary Sheet



Version Slide 85

Results: Equipment Summary Sheet



END

RBI - Inspection Management-Orbit Onshore_W_tcm144-512440

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