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การอบรมสัมมนา
เร่ือง
“Risk Based Inspection for Boilers ”
7 มถุินายน 2557
นําเสนอโดย
สมาคมวศิวกรหม้อไอนํา้แห่งประเทศไทย
ร่วมกบั
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