Risk-Based Inspection

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Process Units API 580 Charlie Chong/ Fion Zhang
7.3.5 Systems within Process Unit Screening 处理单元细分下系统筛选 It is often advantageous to group equipment within a process unit into systems, loops, or circuits where common environmental operating conditions exist based on process chemistry, pressure and temperature, metallurgy, equipment design and operating history. By dividing a process unit into systems, the equipment can be screened together saving time compared to treating each piece of equipment separately. In case the risks of each piece of equipment in the system show a common sensitivity to changes in process conditions, then a screening can establish one single IOW with common variables and ranges for the entire system. Block flow or process flow diagrams for the unit may be used to identify the systems including information about metallurgy, process conditions, credible damage mechanisms and historical problems. 在工艺单元 ( 处理单元 ); 以相同工艺化学 , 压力和温度 , 冶金 , 装备设计和操作历史等 , 细分为工艺系统 / 环路有助于节省分析工作 . API 580 Charlie Chong/ Fion Zhang
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Risk-Based Inspection Downstream Se
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基于风险的检验 - 下
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API 580 Charlie Chong/ Fion Zhang R
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Foreword
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API 580 旨在补充 API 510, AP
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5 Basic Risk Assessment Concepts 5.
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10 Assessing Probability of Failure
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13 Risk Management with Inspection
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15 Reassessment and Updating RBI As
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Figures 1 Management of Risk Using
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Introduction This recommended pract
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RBI is synonymous 同义 with •
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Contents 1 Purpose 1.1 General 1.2
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It provides guidance to (1) owners,
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RBI 过程预期成果 : The e
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The RBI process 能够产生的
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任何其他风险缓解活
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RBI 过程预期成果 (1) 所
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RBI 过程预期成果 (2) 每
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RBI 过程预期成果 3) 任
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1.2 RBI Benefits and Limitations
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RBI Benefits and Limitations
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a) an acceptance/understanding of t
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a) an acceptance/understanding of t
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The RBI plans also identify equipme
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RBI is based on sound, proven risk
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inadequate designs or faulty equipm
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not effectively executing the plans
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lack of sound engineering or operat
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RBI should serve to guide the direc
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proven inspection technologies that
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综合管理工具配合其
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Contents 2 Scope 2.1 Industry Scope
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this RP is specifically targeted at
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2.2 Flexibility in Application 灵
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2.3 Mechanical Integrity Focused Th
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RBI 补足 HAZOP/PHA/RCM 作为
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2.4 Equipment Covered 覆盖设
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Process Piping- Pipe and piping com
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Storage Tanks- Atmospheric and pres
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Boilers and Heaters - Pressurized c
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2.5 Equipment Not Covered 不覆
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API 580 Charlie Chong/ Fion Zhang
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虽然主要观众为负责
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3 Normative References API 580 Char
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Societies/Organizations: 1. ASME In
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• AICHE 2, Dow’s Fire and Explo
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Contents 4 Terms, Definitions, Acro
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1.2 RBI Benefits and Limitations
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4.1.4 components 组成整件
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4.1.9 damage (or deterioration) mod
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4.1.14 event 事件 Occurrence of
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API 580 Charlie Chong/ Fion Zhang i
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4.1.18 Failure ……………… 1
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For RBI, the failure of concern is
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4.1.22 hazard and operability study
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4.1.26 management of change MOC 变
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4.1.29 process unit 工艺设备
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Reformer PFD Facility →Process un
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Facility →Process units → Syste
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4.1.30 qualitative risk analysis
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定性风险分析的结果
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4.1.31 quantitative risk analysis Q
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API 580 Charlie Chong/ Fion Zhang Q
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4.1.35 Risk 风险 - 事件的
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4.1.37 risk analysis 风险分
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concerns of stakeholders? API 580 C
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concerns of stakeholders? Himba wom
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4.1.41 risk communication 风险
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isk criteria 风险标准 Terms
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4.1.48 risk mitigation 风险缓
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4.1.53 System 系统 A collection
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4.1.55 toxic chemical 有毒化
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4.2 Acronyms and Abbreviations ACC
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5 Basic Risk Assessment Concepts AP
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5.1 What is Risk? 什么是风
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For example, in driving a car, peop
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Risk is the combination of the prob
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5.3 The Evolution of Inspection Int
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With advances in inspection approac
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RBI represents the next generation
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5.4 Overview of Risk Analysis 风
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e) determine credible failure mode
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Data → Damage Mechanism→ Damage
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A point is reached where additional
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typical inspection program Upper cu
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RBI Inspection lower risks can be a
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残余风险 API 580 Charlie Cho
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API 580 Charlie Chong/ Fion Zhang d
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API 580 Charlie Chong/ Fion Zhang d
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5.6 Relative Risk vs Absolute Risk
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API 580 RBI RBI is focused on a sys
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API 580 Charlie Chong/ Fion Zhang t
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6.1 Key Elements of an RBI Program
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6.2 Consequence and Probability for
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Combining the probability of one or
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Traditionally, organizations have f
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API 580 Charlie Chong/ Fion Zhang K
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The RBI procedure can be applied qu
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所选择的方法可以在
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Qualitative Approach-This approach
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QRA uses logic models depicting com
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QRA logic models generally consist
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The traditional QRA is generally co
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The QRA typically involves a much m
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Typically, most of the data used in
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When performing risk analysis acros
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6.4 Precision vs Accuracy 精度
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Risk presented as a precise numeric
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Therefore, it may be beneficial to
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Quantitative analysis uses logic mo
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Process variables that should be co
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Since risk is dynamic (i.e. changes
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Those changes might include such th
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The objective of RBI is to direct m
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The POF due to such deterioration i
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For those equipment items where ins
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6.6.3 Evaluation and Fitness-For-Se
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6.6.4 Other Risk Management 其他
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The relationship between RBI and se
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6.7.2 PHA A Process Hazard Analysis
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6.7.3 PSM Process Safety Management
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6.7.4 Equipment Reliability 设备
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Those benefits can include: a) appl
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7 Planning the RBI Assessment 评
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7.1 Getting Started 开始 This se
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At the conclusion of the planning p
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Page 302 and 303: 7.2 Establishing Objectives and Goa
Page 304 and 305: 7.2.3 Define Risk Criteria 定义
Page 306 and 307: 7.2.6 Meet Safety and Environmental
Page 308 and 309: e) removal of unnecessary insulatio
Page 310 and 311: The RBI assessment may identify ris
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Page 318 and 319: 7.2.9 Facilities End of Life Strate
Page 320 and 321: Typically, RBI is done on multiple
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Page 324 and 325: process units API 580 Charlie Chong
Page 326 and 327: System - CS Vessel 230psig, 230ºC
Page 328 and 329: 7.3.3 Facilities Screening 设备
Page 330 and 331: 石油和天然气加工和
Page 332 and 333: 石化和化工厂 API 580 Cha
Page 334 and 335: 液化天然气工厂 API 580
Page 336 and 337: facility level API 580 Charlie Chon
Page 338 and 339: 设施水平需要回答的
Page 340 and 341: (3) 是否有足够的资源
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Page 346 and 347: 7.3.4 Process Units Screening 工
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Page 352 and 353: 以设备细分为系统 - C
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Page 356 and 357: Catalytic Reforming 催化转化
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Page 360 and 361: Selection of equipment types to be
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Page 366 and 367: The operating conditions, including
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Page 380 and 381: 7.4.4 Operating Time Period 操作
Page 382 and 383: A strategy should be developed, mat
Page 384 and 385: 7.6 Estimating Resources and Time R
Page 386 and 387: 8 Data and Information Collection f
Page 388 and 389: Contents 8 Data and Information Col
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Page 396 and 397: Documentation of unique equipment a
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8.2.1 Data Needs for Qualitative RB
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通常 , 使用范围广泛
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8.2.3 Data Needs for Semi-quantitat
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Another potential source of scatter
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8.4 Codes and Standards—National
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Charlie Chong/ Fion Zhang
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8.5 Sources of Site-specific Data a
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Potential sources of specific infor
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d) MOC records; 设备变动管
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seismic activity records API 580 Ch
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9 Damage Mechanisms and Failure Mod
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9.1.1 Identification of Damage Mech
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) Considering the materials, method
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d) It is often possible to have two
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Understanding equipment operation a
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9.3 Failure Modes 失效模式 O
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9.4 Accumulated Damage 累积损
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c) a ranking of credible failure mo
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API 580 Charlie Chong/ Fion Zhang 1
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10.1 Introduction to Probability An
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The probability of specific consequ
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The probability of specific consequ
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Guidance on determining the probabi
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weather extremes API 580 Charlie Ch
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operator error API 580 Charlie Chon
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sabotage API 580 Charlie Chong/ Fio
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sabotage http://en.wikipedia.org/wi
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For a qualitative analysis, the POF
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Two examples of this are listed in
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10.3 Types of Probability Analysis
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Another approach is used when inacc
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10.4 Determination of POF 确定
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Analyzing the effect of in-service
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Probability of Failure POF Damage T
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For many damage mechanisms, the rat
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equipment complexity, 设备的
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process and metallurgical variation
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inaccessibility for inspection, 难
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the inspector’s expertise 检查
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恶化率信息的来源包
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f) the phase of the fluid (liquid,
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10.4.3 Determine Failure Mode 确
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a) pitting generally leads to small
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a) pitting generally leads to small
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) stress corrosion cracking can dev
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c) metallurgical deterioration and
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d) general thinning from corrosion
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d) general thinning from corrosion
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API 580 Charlie Chong/ Fion Zhang e
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f) Deterioration rate under some ex
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10.4.5 Calculate the POF by Deterio
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11 Assessing Consequences of Failur
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API 580 Charlie Chong/ Fion Zhang h
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11.1 Introduction to Consequence An
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对环境的影响 API 580 Cha
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安全和健康的影响 /
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POF Managed by Inspector & Inspecti
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More or less complex and detailed m
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11.1.3 Other Functional Failures Al
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These other functional failures are
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11.2 Types of Consequence Analysis
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11.2.3 Quantitative Consequences An
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• failure mode and resulting leak
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评估故障结果的一些
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11.3.3 Cost 费用 , 价值 Cost
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The above list is reasonably compre
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Cost generally requires fairly deta
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11.3.4 Affected Area 受影响
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11.3.5 Environmental Damage 环境
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11.3.6 Categorizing Safety, Health,
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11.3.7 Other Considerations 其他
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In some cases, the volume released
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The cost of the lost fluid may be c
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11.5.6 Production (Business Interru
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The flammable events consequence is
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Boiling liquid expanding vapor expl
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Flammable Events (Fire and Explosio
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此风险评估通常着重
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11.5.4 Releases of Other Hazardous
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Liquid releases may result in conta
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The consequences of environmental d
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泄漏位置地形和可达
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泄漏位置地形和可达
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The fine component cost will depend
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The selection of a specific method
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API 580 Charlie Chong/ Fion Zhang D
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More rigorous methods for estimatin
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Site specific circumstances should
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11.5.7 Maintenance and Reconstructi
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Flammable Events (Fire and Explosio
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Consequence cost: Unscheduled Repai
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Consequence cost: Equipment replace
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Repair of small damage cost equipme
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The steps are as follows: 释放
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Figure 5—Determination of COF API
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用来估算后果的因素
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The following shows how a consequen
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11.6.3 Factors for More Rigorous Me
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12 Risk Determination, Assessment a
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12.1 Purpose 目的 This section d
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For example, after a loss of contai
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Personnel inexperienced in risk ass
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Figure 5—Determination of COF
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EXAMPLE: An equipment item containi
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API 580 Charlie Chong/ Fion Zhang F
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Typically, there will be other cred
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If probability and consequence are
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12.3 Risk Management Decisions and
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12.3.2 Using Risk Assessment in Ins
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It often is worthwhile to gather ad
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在缺乏可信的输入值
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12.6 Risk Presentation 风险表
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Risk categories may be assigned to
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Probability of the associated conse
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12.6.3 Risk Plots 风险绘图 W
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Line of constant risk - acceptable
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Risk may be described in terms of d
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12.7 Establishing Acceptable Risk T
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12.8 Risk Management 风险管
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13 Risk Management with Inspection
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13.1 Managing Risk by Reducing Unce
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http://www.dnv.com/services/softwar
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Other damage mechanisms precipitate
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http://www.sv.vt.edu/classes/MSE209
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Hence the need for a establishing a
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13.2 Identifying Risk Management Op
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active and credible damage mechanis
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accessibility to expected damage ar
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API 580 Charlie Chong/ Fion Zhang a
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API 580 Charlie Chong/ Fion Zhang I
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In cases such as these, an alternat
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检验工艺的限制或可
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检验工艺的限制或可
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Inspection is only effective if the
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) Coverage - Different zones or are
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d) Procedures and Practices - Inspe
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The user can adjust these parameter
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POF 为风险关键因素 :
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检验如何降低检验费
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Unacceptable imperfections UW-51 (b
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What were the differences in inspec
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http://www.dnv.com/services/softwar
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14 Other Risk Mitigation Activities
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14.1 General 总则 As described i
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1. 14.2 Equipment Replacement and R
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Other Risk Mitigation Activities
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14.4 Equipment Modification, Redesi
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14.6 Emergency Depressurizing/De-in
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14.7 Modify Process 工艺修改
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14.8 Establish IOWs 建立操作
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14.10 Water Spray/Deluge 水喷 /
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14.13 Others 其他 a) spill detec
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15 Reassessment and Updating RBI As
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15.1 RBI Reassessments 重估 RBI
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It is important that the facility h
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Sections 15.2.2 through 15.2.5 prov
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API 580 Charlie Chong/ Fion Zhang I
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很多损伤机理带来的
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Process changes API 580 Charlie Cho
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Process changes API 580 Charlie Cho
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API 580 Charlie Chong/ Fion Zhang t
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RBI Assessment Premise Change Chang
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http://www.stoprust.com/23-risk-bas
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15.3.1 After Significant Changes
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15.3.2 After a Set Time Period 时
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15.3.4 Before and After Maintenance
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16 Roles, Responsibilities, Trainin
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16.2 Team Members, Roles, and Respo
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a) formation of the team and verify
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团队领导 API 580 Charlie Cho
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16.2.3 Equipment Inspector or Inspe
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腐蚀专家职责 : • 评
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16.2.5 Process Specialist 工艺
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16.2.6 Operations and Maintenance P
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16.2.7 Management 管理层 Manag
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16.2.8 Risk Analyst 风险分析
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16.3.2 Other Team Members 其他
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培训和资格 API 580 Charlie
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17 RBI Documentation and Record kee
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f) assumptions made during the asse
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17.2 RBI Methodology 方法学 Th
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17.3 RBI Personnel 评估人员
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Failure occurred Probability of Fai
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d) anticipated failure mode(s) (e.g
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17.7 Risk Assessment Results 风
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The methodology, process and person
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17.9 Applicable Codes, Standards, a
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18 Summary of Risk- Based Inspectio
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18.1 General 总则 The following
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期望 RBI 带来不实际的
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18.3 Data and Information Collectio
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18.4 Damage Mechanisms and Failure
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18.5 Assessing POF 评估故障
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18.6 Assessing COF 评估故障
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18.7 Risk Determination, Assessment
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18.8 Risk Management with Inspectio
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18.9 Other Risk Management Activiti
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18.10 Reassessment and Updating RBI
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18.11 Roles, Responsibilities, Trai
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18.12 RBI Documentation and Record
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Risk-Based Inspection

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