•Pressure 

Vessels P>04 bars & P*V>80
• Separator, Scrubber
•Process
Process Piping
Piping
•PSV
•Heat Exchangers 
H tE h
•Boilers 
•Storage tanks  
•PV : A container designed to withstand internal or external pressure
• PV can be dangerous, in use, they contain large amounts of stored energy 
b h l f
•This definition includes heat exchangers, air‐coolers, Separators Scrubbers, 
Process Piping
Process Piping

Over the past 100 years or so, industry has developed  a set of norms, which 
have the objective of assuring the integrity of PV
h f i h i i f Vi b i db
The system for assuring the integrity of PV is obtained by  :
1. Design appraisal
2. Using traceabe materials 
3. Applying proven NDT examinations
4. Doing a hydrostatic Pressure testing
•Perform official certification of PV: through internal and 
•Perform certification of PV: through internal and
external inspection 
•Carry out the baseline survey 
Most pipe in process plants has a regular periodicity of inspection 
It shall be inspected and tested in accordance to API 570
It shall be inspected and tested, in accordance to API 570

API‐570 is applicable for repair, alteration and re rating of METALIC 
PIPING th t
PIPING that are IN INSERVIVE.
IN INSERVIVE
It is developed for petroleum refining & chemical process industries, 
may be used where practical for other piping system

Which is the most commonly used technical to provide guidance of 
process piping inspection, it is one of the first area of a plant to be 
subject to Risk Based Inspection 
Inspection practices of Process Piping
The outline content of API 570
1 Inspection and testing practices 
1. Inspection and testing practices
2. Frequency and extent of inspections
3. Thickness calculations
4 Repair , alteration and re‐rating
4. Repair alteration and re‐rating
5. Inspection of buried pipelines 

The scope of API 570:
The scope of API 570:
Included: Excluded:
Almost any metallic piping system: •Water, steam
• Raw and finished oil products
p •Piping related to mechanical equipment 
• Raw and finished chemical products (compressor, pumps,..)
• Hydrogen, fuel and flare gas systems • Pressure vessel 
• Sour , waste systems etc  •Domestic sewers
•Everything <1/2 inch
•Non metallic piping 
The main technical content of API 570 covers the 11 
separate risk areas  shown below:

1. Injection points
2. Dead legs
3. CUI
4. Soil/Air interfaces
5. Erosion and erosion/corrosion
6. Environmental cracking
l k
7. Corrosion under linings
8. Fatigue cracking
9 Creep cracking
9. C ki
10. Brittle fracture
11. Freeze damage
• The frequency and extents of inspection depends on the form of 
degradation It affect the piping and consequence of the piping
degradation.  It affect the piping and consequence of the piping 
failure 
• API 570 defines three levels of piping class:
Cl
Class 1: Highest risk/consequence
Class 2 : Medium risk
Class 3 : Low risk

Class – 1 piping: Immediate emergency of a leak occurs.
– Flammable services
Flammable services
– Pressurized services that may rapidly vaporize
– Hydrogen sulphide (H2S) greater than 3% in a gaseous stream 
– An hydrous hydrogen chloride
An hydrous hydrogen chloride
– Hydro fluoric acid 
– Piping through public through ways and over water
• Class – 2: majority of unit process piping and selected off site 
piping 
i i
– Hydro carbons that will slowly vaporize
– Hydrogen, fuel gas and natural gas 
Hydrogen fuel gas and natural gas
– Strong acid and caustics (on site)
• Class
Class – 3: Flammable but do not significantly vaporize and not 
3: Flammable but do not significantly vaporize and not
located at high affectivity areas. 
– Hydrogen that will not significantly vaporize 
– Distillate and product line 
– Offsite acids and caustics. 
 Max Inspection Intervals
CLASS THK INSP
THK INSP EXT VISUAL
EXT VISUAL

1 5 5

2 10 5

3 10 10

Injection Point 3 by class

S/A Interface by class
 CUI Inspection EXTENT
CLASS NDE Follow up or INSUL
NDE Follow up or INSUL NDE AT Suspect  area
NDE AT Suspect area
Removal at a damaged areas piping with susceptible 
temp

1 75% 50%

2 50% 33%

3 20% 10%
 NSPEECTIION

INTRODUCTION TO
INTRODUCTION TO
RISK BASED INSPECTION
BASEED IN

(RBI)
RISK B

Prepared By: Abdelmajid BEN HAMED
 ASED
K BA
RISK ON
CTIO
D INSSPEC

PIPER ALFA: Fuite de gaz par percement

16
 RBI DEVELOPMENT

• Initially developed for Nuclear Industry
ON
• Probabilistic Risk Assessment (PRA’s) used following NRC
CTIO
Reactor Safety Study
(Wash‐1400) in 1975
D INSSPEC

• 1985 ASME formed Risk Analysis Task Force

1985  ASME formed Risk Analysis Task Force
• Task Force recommended research program
• 1991 published Risk Based Inspection ‐ Development of
Guidelines Volume 1
• API released Pub. 581 ‐ Base Resource Document on Risk
Based Inspection in 1996
Based Inspection in 1996
ASED

• API 580 – Risk Based Inspection Recommended Practices
(2002)
K BA

• API RECOMMENDED PRACTICE 581 SECOND EDITION, 
SEPTEMBER 2008
RISK

Prepared By: Syed Syahman Shahab
 WHAT IS RBI
PECTTION
N
– A systematic data analysis of equipment condition, to 
determine the associated risk with its operation
– Prioritise Inspection based on the Assessment of Risk
R BASSED INSP
RISK 
 WHAT IS RBI
ON
CTIO
• Method for prioritizing
equipment for inspection 
based on risk
based on risk
D INSSPEC

• Determines risk associated
with operation of specific 
items of equipment
• Identifies the key issues
driving the risk
driving the risk
ASED

• Decision making tool for
Inspection Planning
p g
K BA
RISK

Risk = Probability of Failure X Consequence of Failure 
 The principles of RBI
PECTTION
N
The principles of RBI :
• It considers the consequences and 
likelihood of failure
R BASSED INSP

• Identifies the highest‐risk equipment
Identifies the highest risk equipment
• Quantifies the risk 
• Reflects the risk in the Written Scheme 
of Examination  

The three fundamental approaches are 
pp
known as the qualitative ,quantitative and 
semi quantitatively approaches :
RISK 

•Uses engineering judgment and experience  •Based on pre‐set risk parameter 
as the bases for the analysis of POF & COF  (logic models to calculate the POF 
•The results are dependent on the  & COF 
background  and expertise of the analysts  •
 The main steps of an RBI analysis 
1. Data Gathering by listing the equipment

2. Evaluate each with regard to consequence and 
probability of failure : 
a) Inspection History Review 
b) RBI Specific Input (Inspection Records, Piping 
circuit, Corrosion Loop)
3. Criticality Analysis by compiling Risk Matrices

4. Review results

5. Decide new inspection periods or practices 
 RBI Concept
p
ASSESS
IDENTIFY THREATS/ INSPECTION
HAZARDS HISTORY
to EQUIPMENT

(Pipework, Vessels etc)

SUSCEPTIBILITY to
FAILURE MODE
THREAT

MITIGATION
MEASURES to
REDUCE
SUSCEPTIBILITY

LIKELIHOOD of CONSEQUENCES of
FAILURE FAILURE

REMAINING LIFE or
RISK FACTOR
INSPECTION GRADE

INSPECTION
SCHEME
Standards and Codes linked to RBI
Standards and Codes linked to RBI

• API Risk‐Based Inspection
– API 580 & 581

• API In‐Service Inspection Recommended Practices (RP)
– API 510, 570, 576, 653, 574, 572,577, 578

• Equipment Design, Fabrication, and Repair
– ASME Section VIII, Division 1, 
– ASME B31 3
ASME B31.3
– ASME B16.5
– ASME V
– ASME IX
ASME IX

23
 Inspection History
API RP 570 
& 510
& 510

Quantitative Qualitative

Calculate time to failure based on wall

Calculate time to failure based on wall  Effectiveness and results of
Effectiveness and results of 
thickness measurements.  inspections are graded. IP 
guidelines set out 
Maximum inspection interval 
Maximum inspection interval = ½ 
½ recommended maximum
recommended maximum 
remaining service life intervals based on inspection 
grade
 PECTTION
N TYPE OF DATA GATHERED
TYPE OF DATA GATHERED
• P&ID, PFD
P&ID PFD
• G.A. Drawings
Schematic Drawings
Schematic Drawings
R BASSED INSP

•
• Inspection Records
• Equipment Database
Equipment Database
• Process Data Book
• Maintenance Reports
Maintenance Reports 
• Site verification
RISK 
 DATA MANAGEMENT PROCESS
ON 1 Data Gathering
1. D G h i
• PFD
ASED
K BA
RISK CTIO
D INSSPEC
• P&ID
 DATA MANAGEMENT PROCESS
Cont…
 Inspection Record
• G.A Drawing
Evaluate each with regard to consequence and probability of 
failure ( Corrosion Loops)
 DATA MANAGEMENT PROCESS
Cont…
ON
3. Criticality Analysis (by using RBI)
Criticality Analysis (by using RBI)
ASED
K BA
RISK CTIO
D INSSPEC

 Creating new vessel 
 DATA MANAGEMENT PROCESS
Cont…
ON
3. Criticality Analysis (by using RBI)
Criticality Analysis (by using RBI)
ASED
K BA
RISK CTIO
D INSSPEC

 Criticality Analysis 
 DATA MANAGEMENT PROCESS
Cont…
ON
CTIO
4. Review of Results
a) Review
Review and approval the results
and approval the results
D INSSPEC

b) To revise any deviation and to 
re‐enter
re enter parameter values for 
parameter values for
final risk run.
ASED
K BA
RISK
 DATA MANAGEMENT PROCESS
Cont…
ON
5. Preparation of Final RBI Report
p p
ASED
K BA
RISK CTIO
D INSSPEC

Sample results extracted from RBI database
 RBMI Software features
RBMI Software features
• The RBMI application meets all API 580 recommended practice 
Th RBMI li ti t ll API 580 d d ti
requirements for risk‐based inspection including inspection data 
management. RBMI also meets the latest API Standards 510 and 570 
requirements
• RBMI of LR Capstone is a Mechanical Integrity Management program and 
is a fully integrated Risk Based Inspection software package for:
‐ Fixed equipments (Pressure vessels, storage tanks, heat exchangers, fired 
heaters)
‐ Piping
‐ Relief devices
‐ Pipelines
‐ Structure
• The software manages the full cycle of RBI, including automatically 
generated dynamic inspection plans and automatic updating of risk after 
an inspection is completed.

35
 RBMI risk matrix
RBMI risk matrix

1 HIGH Consequence
A‐Catastrophic

Rankingg
B‐Very Serious
2 MED HIGH C‐Serious
D‐Significant
Probaability R
EE‐Minor
Minor
3 MEDIUM
Probability
1‐Very High
2‐High 4 LOW
3‐Moderate
4‐Low
5‐Very
5 Very Low
Low 5

E D C B A
Consequence Ranking
Consequence Ranking
36
 Probability of failure (PoF)
Probability of failure (PoF)

Probability
of Failure

Internal External Environment Creep Other Damage

Corrosion Corrosion Cracking (for fired heaters) Mechanisms

37
38
 Internal Threats
• I t
Internal Corrosion
lC i
– Sweet Corrosion
– Sour Corrosion / Cracking 
Mechanisms
– MIC (Microbiologically 
Induced Corrosion)
– Oxygen Corrosion
– Other potential mechanisms?
• E.g. Acetic Acid weld 
E g Acetic Acid weld
degradation

39
 External Threats

• External Corrosion
lC i
– Atmospheric Corrosion
– CUI (Corrosion Under Insulation)
– Chloride pitting of stainless steels
– Galvanic corrosion
– Other potential mechanisms?
Other potential mechanisms?

Ref: HSE Offshore External Corrosion Guide
 Consequence of failure (CoF)
Consequence of failure (CoF)

Consequence
of Failure

Safety Economics Environment

Burst Loss of Leak Clean Leak

Flammability Toxic Reactive
Model production inventory up cost volume

41
 Consequences of Failure
Manning  Fluid Type Toxicity
Temperature and  Levels Toxicity
Pressure
Flammabilityy

Safety Environment
Location
Failure 
Mode

Size of 
Flammability
Fluid Type Release
Temperature

Production
Commercial 
C i l
Criticality Loss of 
Production

Back up 
k
systems?
42
Example of Criticality

43
 ON WHY DO WE NEED RBI?
WHY DO WE NEED RBI?
 Reduce risk of high
Reduce risk of high
CTIO

consequence failures
• Manage risks associated
g
D INSSPEC

with inspection programs
Reduce Life
• Facilitates reallocation of Cycle Cost
resources from lower to
f l and Risk of
higher risk equipment Plant
• Optimization: Operation
p
ASED

– application of inspection
techniques
K BA

– cost‐effective inspection
and maintenance
RISK
 Inspection planning
Inspection planning
• Based on equipment type and risk rating
• Create inspection for each damage 
Create inspection for each damage
mechanism
• Provide : method, location, extent and 
P id h d l i d
frequency of the inspection
• Evaluate the condition monitoring
• Recommend the reduce/deletion or the 
R d th d /d l ti th
increase /change of the inspections.
45
Inspection planning
Inspection planning

46
 Inspection methods
Inspection methods

• The number of inspection methods has increased and 
are being used in the process industry
are being used in the process industry.
• The most used method of inspections in the industry 
still consist of a relatively few methods:
y
– Visual Inspections
– Ultrasonic Thickness Testing 
– di
Radiographyh
– Magnetic Particle Testing
– Penetrant testing
– Ultrasonic angle beam testing
– Acoustic Emission Testing

47
 ON
CTIO CONCLUSION

• RBI is becoming recognized by industry as a
cost effective methodology for the planning of
cost effective methodology for the planning of
D INSSPEC

inspection and maintenance activities
• RBI can be relatively simple to implement
RBI can be relatively simple to implement
using existing inspection data
ASED

Vi i d di d d i ll
• Vision to standardized and integrate all
inspection planning tools could be realized
K BA

faster
RISK