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เร่ือง

“Risk Based Inspection for Boilers ”

7 มถุินายน 2557

นําเสนอโดย

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Lloyd’s Register International (Thailand) Ltd.

Chamni Mosagul

Operation Manager,

ASME Authorized Inspector and Supervisor (AI, AIS)Energy, Inspection Business,

Lloyd’s 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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ให้ความสนใจใน ความเส่ียงทีส่ามารถตรวจสอบได้

ผลเสียหายทีเ่กดิขึน้

มผีลต่อความปลอดภัยถึงขั้นเสียชีวติชีวติเน่ืองจากการร่ัวไหลของสารอนัตราย

มผีลต่อความปลอดภัยถึงขั้นเสียชีวติชีวิตเน่ืองจากความดนัภายในส่งผลกระทบต่อส่ิงแวดล้อม

สินค้า - ผลติภัณฑ์เสียหาย

Risk Matrix in RBI

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Reliability Based Mechanical IntegrityCriticality 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 ($104 )

• 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

Addressing 12% of Fixed Equipment Items

As-Found Risk

After Risk Mitigation

Calculated as the mid value consequence multiplied by the likelihood

Risk Distribution

10 1 10 0 0 0 033 2 1 10 3 18 122 3 0 6 3 12 125 4 5 0 0 17 3

100 5 27 0 0 65 8E D C B A

190 43 16 6 112 13

Initial Risk Study

Risk Distribution

3 1 3 0 0 0 013 2 2 6 0 5 025 3 4 10 3 8 035 4 6 0 3 21 5

114 5 28 0 0 78 8E D C B A

190 43 16 6 112 13

Industry Best Practice Case Study #3U. S. Refinery – Piping in All Units

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ContractInspection Resources

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การกระทาํโดยเจตนา

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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

Subject Matter Expert 3

Subject Matter Expert 4

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 impact

•Maintenance 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

Pro

bab

ilit

y R

anki

ng

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

Suggestedinspection plangenerated by

system

API 573

(Insp. of Fired

Boilers/heaters

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Data collection step

Evaluate Risk level for each Component/item