RISK-BASED INSPECTION STUDY AND

ITS CONTRIBUTION TO OPTIMIZE T&I

EXPENDITURE AT JNGLF PLANT

Presenter: Zakariya Al-Ashwan

© Copyright 2015, Saudi Aramco. All rights reserved.

Saudi Aramco: Public
Outline

• Introduction
• Risk Based Inspection (RBI) Technology
• Methodology
• RBI Study Results and Benefits for The Studied Unit
• Conclusion
• References

Saudi Aramco: Public

Introduction

• Ju’aymah NGL Fractionation Department

• Rerun Unit consists of Depentinizer, Red Vapor Pressure
(RVP), Decolorizer Systems
• Contain of pressure vessels, heat exchangers and piping.
• Last Rerun Unit T&I “2013” and business interruption cost
Saudi Aramco approximately $9.2 millions.
• Decision was made by JNGLFD Management to utilize RBI
Technology.

Saudi Aramco: Public

 Risk Based Inspection (RBI)
Technology

• To evaluate the integrity of operating equipment by managing

risk and damage factors.
• Based on scientific calculations and experience.

Saudi Aramco: Public

 Continue Risk Based Inspection (RBI)
Technology

Probability of Failure (POF)

“Susceptibility of damage mechanisms,
Risk = historical failures and equipment X
inspection history”

• Risk and damage factor limits.

• Saudi Aramco uses Area Risk Limit as 6 ft2/year and
Damage Factor Limit as 500

Saudi Aramco: Public

Methodology

• API-RBI methodology was used based on the API 581

publication, second edition, September 2008.
• API-RBI software, version 8.03.03.

Saudi Aramco: Public

 RBI Study Results and Benefits for the
Rerun Unit

• All possible damage mechanisms for the Rerun unit were identified.
• Rerun unit equipment and piping were divided to components and
classified as per their risk level.
• An inspection plan was established to show all Rerun unit
equipment and piping with specific needed inspections for specific
due dates as per their possible damage mechanisms and risk level.
(Similar effect to the below chart previously shown)

Saudi Aramco: Public

 Continue RBI Study Results and
Benefits for the Rerun Unit

• Year 2013 compared to year 2020 without inspection for evaluation

of T&I extension for 2 years.

This line in the figure

represent the limits. Area
Risk Limit as 6 ft2/year
and Damage Factor Limit
as 500

Saudi Aramco: Public

 Continue RBI Study Results and
Benefits for the Rerun Unit

• All 18 components were fin-fan tube banks, which are close to

reaching their life end. Fitness for service was conducted for
these components, which recommend to not extending the
T&I date for these components.
• The T&I date for other components can be extended by 2
years, which will result in saving approximately $3.4 millions
“T&I Cost & BIC.”
• This T&I extension will assure continuous operation and
product supply with less interruption time for a 7 year T&I
cycle instead of 5 years since the last T&I “2013.”

Saudi Aramco: Public

Conclusion

• The Ju’aymah NGLF Department conducted a quantitative

RBI study utilizing the API RBI program, API-571, API-580,
API-581 and SAEP-343.

• The RBI study was able to prove that extensive (overdoing)

inspection methods and the T&I cycle were used during the
last T&Is, which rises the T&I and business interruption
cost.

• The Ju’aymah NGLF Department succeeded in supporting

a deviation for Rerun Unit T&I by utilizing RBI Technology.

Saudi Aramco: Public

References
• Saudi Aramco, Risk Based Inspection “RBI” for Saudi Aramco
Facilities “SAEP-343,” Inspection Engineering Standards Committee,
2013.
• American Petroleum Institute “API”, Risk-Based Inspection “API-
580,” International Organization for Standardization “ISO,” 2009, 2nd
edition.
• American Petroleum Institute “API,” Risk-Based Inspection
Technology “API-581,” International Organization for Standardization
“ISO,” 2008, 2nd edition.
• American Petroleum Institute “API,” Damage Mechanisms Affecting
Fixed Equipment in the Refining Industry “API-571,” International
Organization for Standardization “ISO,” 2011, 2nd edition.
• Ju’aymah NGLF Department, Risk Based Inspection “RBI”
Assessment at JNGLF Plant R-84 Rerun Unit “SAER- S6536-13,”
Saudi Aramco, KSA, 2013.

Saudi Aramco: Public