How do you use risk-based inspection (RBI) to optimize mechanical integrity and reliability?

RBI is Risk Based Inspection methodology which is used in various industries like Oil and Gas, Semiconductors, Chemicals etc. to optimize inspection and maintenance activities by focusing resources on high-risk components or areas of a facilities. The risk based approach enables industries to optimize their inspection intervals and create recommendations based on the damage mechanisms. This approach takes into consideration various aspects like operating and design parameters, stream conditions, financial aspects etc. to arrive at a risk. This risk will further be used to recommend and schedule inspections. There are various RBI methodologies such as API 581, RBI+, EN-16991, NR-13 etc.

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.” Ref. API-580-2016.

How I do it is that I collect the documents pertaining to the particular equipment for which we were going to perform an RBI on. This included General Arrangement Drawings, U-1A forms, Data Sheet etc. This allows me to get the input data for the strategy. Simultaneously, I make sure that I have the past inspection history record available with me in order to decide the condition of the equipment. I use AsInt Asset Strategy Development for drafting my equipment strategy. Once that's done, I make sure that there are several cold eye review sessions with the different teams involved. The final FIN and SHE Risk is calculated and is shared with site. Also there are several recommendations generated from my end as well based on Damage Mechanisms.

RBI has following key elements a) management systems for maintaining documentation, personnel qualifications, data requirements, consistency of the program, and analysis update. b) documented method for POF determination. c) documented method for COF determination. d) management systems for maintaining documentation, personnel qualifications, data requirements, consistency of documented methodology for managing risk through inspection, process control, and other mitigation activities.

RBI relies on risk analysis, enabling informed decision-making. This data-driven approach helps in better understanding the risk and making more strategic choices regarding inspection scheduling, tasks and maintenance plans. RBI evergreening enables a continuous improvement cycle, allowing organizations to refine and enhance their inspection and maintenance strategies over time.

RBI serves as a pivotal activity that not only facilitates financial savings and optimized inspection intervals for assets but also stands out as one of the most effective methods to ensure the safety of field personnel. Employing a systematic approach and incorporating a diverse set of factors in probability of failure calculations, a robust RBI equipment strategy has consistently proven to be a valuable asset for individuals working in the field.

- Identification of risk drivers - Improve equipment and system reliability - Manage risk at equipment & component level - Overall Facility Risk Reduction - Acceptance / understanding of the current risk drivers - Provision for other applicable risk mitigation activities (such as) • Establishing and maintaining IOWs • Reducing the POF with Insp. • Using RBI as a continuous improvement tool

Implementing risk-based inspection processes focused on identifying and monitoring essential components has proven to be critical to maintaining system integrity and averting breakdowns. We may identify components based on their probable failure likelihood and consequence severity by thoroughly analysing risk variables ranging from corrosion and fatigue cracks to thermal stresses and obstraction concerns. The inspection resources are then directed to high-risk locations. This decreases the probability of catastrophic occurrences and the associated financial, safety, and environmental consequences. RBI optimisation is currently considered best practice in the industry. It maximises dependability and safety when used consistently.

How I do it is that I collect the documents pertaining to the particular equipment for which we were going to perform an RBI on. This included General Arrangement Drawings, U-1A forms, Data Sheet etc. This allows me to get the input data for the strategy. Simultaneously, I make sure that I have the past inspection history record available with me in order to decide the condition of the equipment. I use AsInt Asset Strategy Development for drafting my equipment strategy. Once that's done, I make sure that there are several cold eye review sessions with the different teams involved. The final FIN and SHE Risk is calculated and is shared with site. Also there are inspection recommendations from my end as well based on the analysis.

Main Challenges During Re-assessment/- Inspection Team Cooperation In IM module data update. - Detailed updates in Inspection Summary and updated on actions taken against findings oberserved in Inspection. - Inspection Update & create Recommendation and Target date on (Re-coating , Temporary Repair updates , other mitigation performed against findings). Which support RBI team to follow up the actions and RBI expects to give Next Inspection insterval based on Asset Condition and maitain the ingrity.

Some of the major challenges today are: - Poor data documentation - Calibration issues for thickness readings - Difficulty in tracing the risk - Ineffectiveness of the RBI tool to manage bulk data