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Estimated annual cost of metallic corrosion in United State alone was between US$300 and US$350 billion. 40% of the mentioned cost could have been avoided using the current

or existing technologies and by applying or implemented the proven best practices.

The National Institute of Science and Technology

Dangers, Losses and Damage of Corrosion

Pipeline Explosion Lights Up East Texas Sky~ a pipeline leaking natural gas exploded after a car drove over that leak, which was part of the Texas Gas Gathering Company .

Petro China Refinery Explosion Injures 30~ More than 30 people were hurt following an explosion at Petro China Co.’s Fushun refining complex in northwestern Liaoning province, the official Xinhua News Agency said, without citing anyone. No deaths were reported.

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Corrosion and Corrosionist

Corrosion is the disintegration of an engineered material into its constituent atoms due to chemical reactions with its surroundings

He is a man who walks down those mean, corroded streets. A man you seldom know because when he makes your day -- which he does every day -- you won’t know him.

~ In the most common use of the word, this means electrochemical oxidation of metals in reaction with an oxidant such as oxygen.

~ Formation of an oxide of iron due to oxidation of the iron atoms in solid solution is a well-known example of electrochemical corrosion, commonly known as rusting.

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Corrosion Control and Monitoring

Minimum requirements for corrosion control:* External Corrosion Control1. Buried DOT regulated pipelines will be coated and cathodically protected* Internal Corrosion Control1. Known corrosion rate based on historical data.2. Corrosion rate from a national standard data base.3. Data collected from laboratory prototype testing.* Above Ground External Corrosion Control1. Coat with an approved system with resistance to the soil and internal fluid temperature

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API 580 – Provides with the basic elements for developing and implementing a risk-based inspection (RBI) program for fixed equipment and piping in the hydrocarbon and chemical process industries. These API Inspection codes and standards allow an owner/user latitude to plan an inspection strategy and increase or decrease the code-designated inspection frequencies based on the results of a RBI Assessment.  

API 581 –Provides quantitative procedures to establish an inspection program using risk-based methods for pressurized fixed equipment including pressure vessel, piping, tanks, pressure relief devices, and heat exchanger tube bundles.

maXRBI Based on API 580 / 581

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In general, Risk is calculated as a function of time as follows:

In API RBI, the consequence of failure is assumed to be independent of

time, therefore:

The Probability Of Failure used in API RBI is

The Consequence of Failure or loss of containment for a pressurized component is expressed as an impact area (ft2) or in financial terms ($) . Final consequence areas are determined as a probability-weighted area of each of the individual event outcome areas

API 580/581 Risk Analysis

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maXRBI UsageIBM MAXIMO delivers best-of-class asset lifecycle and maintenance management for all asset types on a single platform. providing insight for all of your enterprise assets, their conditions and work processes, for better planning and control.

maXRBI is a MAXIMO RBI Software add-on application to monitor and analyze Risk, Consequence and Probability of failure due to corrosion.

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maXRBIUsage of maXRBI application is divided into four Major Stages

Preparation Stage

Data Recording and Documentation

Stage

Data Analysis Stage

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Inspection Planning

Asset Registration for Corrosion

InspectionField Inspection

and Data Gathering

Work Order Generation

Preventive Maintenance (Work Type = “ INSP ” )

Inspection Program Job Plan

Field Inspection and Data

Gathering

Inspection/Testing (NDT /NDE) Application

maXcorrosionist (Asset) Application

NDT/NDE Log Tab Risk Assessment)

Risk Assessment (Quantitative Data)

maXcorrosionist (Asset)

Application

Inspection Planning Application

Inspection Planning

Optimize PM and Job Plans

Inspection/Testing (NDT /NDE) Application

NDT/NDE Recording Log Tab

NDT/NDE Recording Log Tab

maXRBILog-on to MAXIMO.

User name maxadmin

Password maxadmin

Start Center will be launched.

Access maXRBI , under maXRBI Module.

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maXRBI (Preparation Stage)List Tab of the application will be launched.

Search for the asset due for inspection. Inter a filtering string (ex. Asset number, description, location, parent, etc) to search. Press enter to allow the system to process the search and displays all matched records.

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6 Use the “Advance Search” option to look for the asset due for inspection. Enter specific filtering details and click “FIND” for the system to process the search.

maXRBI (Preparation Stage)

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Asset information will be displayed.

Corrosion Information

Installation Properties.

Drawings

General Information Details

maXRBI (Preparation Stage)

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Target Information

Equipment Details

maXRBI (Preparation Stage)The Operating Process tab is to display any information regarding the process details such as the fluid, operating temperatures and pressures, toxicity levels, etc.

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maXRBI (Preparation Stage)

The Sub-assemblies Tab displays children assets or assets within the Pipe group or Pipe Circuit.

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The meters tab

maXRBI (Preparation Stage)

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User can update the “Testing and Inspection Plans”.11

Correspondingly, Job Plan associated to the Preventive Maintenance record will be automatically displayed or updated.

How to use RBI Software: maXRBI (Preparation Stage)

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To start the Inspection Activity, user generates an INSP work order from the Preventive Maintenance Record due. Click the selector tool adjacent to the Inspection and Testing field to direct the page to Preventive Maintenance Application.

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maXRBI (Preparation Stage)

User generates an INSP work order from the Preventive Maintenance record due.

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maXRBI (Data Recording and Documentation Stage)

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Data Recording and Documentation

Stage

Field Inspection and Data

Gathering

Inspection/Testing (NDT /NDE) Application

NDT/NDE Recording Log Tab

maXRBI (Data Recording and Documentation Stage)

Types of RBI Procedure

• Qualitative Approach

• Semi-Quantitative Approach

• Quantitative Approach

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maXRBI (Data Recording and Documentation Stage)

After completing the on-site inspection and data gathering, the inspector uses “INSPECTION/ TESTING (NDT/NDE) APPLICATION”, to enter or document all gathered information into the application for analysis.

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maXRBI(Data Recording and Documentation Stage)“INSPECTION/ TESTING (NDT/NDE APPLICATION” will be launched. Inspector can now create a new record of Inspection/ testing based on the inspected assets. Click on the “new record” icon to start.14

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maXRBI(Data Recording and Documentation Stage)Update information on the NDT/NDE Log Tab. Enter “Semi-qualitative” data on this tab for analysis. Click on the new row, and enter the asset inspected. Enter result of inspection.15

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maXRBI(Data Recording and Documentation Stage)Also has the option to input thickness readings from a data logger and also be imported from a xls file16

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maXRBI (Data AnalysisStage)Damage Factor and Degradation Mechanism

Damage Factor – An adjustment factor applied to the generic failure frequency to account for damage mechanisms that are active in a equipment.

The damage factor is determined based on the applicable damage mechanisms for the equipment, the inspection history and condition of the equipment.

In API RBI, the damage factors for the protected equipment are calculated as a function of time.

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maXRBI (Data AnalysisStage)

The mechanical integrity and functional performance of equipment depends on the suitability of the equipment to operate safely and reliably under the normal and abnormal (upset) operating conditions to which the equipment is exposed.

Risk: Combination of the probability of an event and its consequence. In some situations, risk is a deviation from the expected. When probability and consequence are expressed numerically, risk is the product.

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maXRBI (Data Analysis Stage)

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Data Analysis Stage

Inspection/Testing (NDT /NDE) Application

NDT/NDE Recording Log Tab

maXcorrosionist (Asset) Application

NDT/NDE Log Tab Risk Assessment

maXRBI (Data AnalysisStage)Access maXRBI Application again to do a Risk Assessment on the Inspection Result.17

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maXRBI (Data AnalysisStage)Risk Matrix Analysis

Risk presented as a precise numeric value (as in a quantitative analysis) implies a greater level of accuracy when compared to a risk matrix (as in a qualitative analysis)

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maXRBI (Data AnalysisStage)Risk Matrix Analysis

Risk Matrix: For risk ranking methodologies that use consequence and probability categories, presenting the results in a risk matrix is a very effective way of communicating the distribution of risks throughout a plant or process unit without numerical values.

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maXRBI (Inspection Planning Stage)

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Inspection Planning Risk Assessment

maXcorrosionist (Asset)

Application

Inspection Planning Application

Inspection Planning

Optimize PM and Job Plans

maXRBI (Inspection Planning)

3 different cases in inspection planning19

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A.) Example where the risk target is met before the plan date

B.) Example where the risk level is not met after inspection

C.) Example where the risk level is still above the risk target after inspection

maXRBI (Inspection Planning)

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Access the Inspection Planning application.

maXRBI (Inspection Planning)The inspection planning application helps plan for the next inspection dates. for the component or equipment. It provides the means to evaluate the optimal inspection effectiveness, inspection effort and inspection interval for the component based on the current risk information (Risk-Based Inspection Date).

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maXRBI (Inspection Planning)Inspection information allows user to see different risk results depending on the plan date and/or inspection details . It identifies recommended next inspection plan for the component based on the Risk Target. Risk target is defined as the level of acceptable risk defined for inspection planning. The risk target is in terms of area for area-based consequence analysis and in terms of financial limit for financial-based consequence analysis.

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maXRBI (Inspection Planning)

What-if Calculator allows users to change any of the parameters such as the inspection date, corrosion rate, any damage factor information to see risk results

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maXRBI (Systems)

Access the Systems application 23

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maXRBI (Systems)Inspection information allows users to associate assets to a System and view what the current Risk Rating (Financial Risk and Area Risk) of a systems based on the current risk information of equipments associated to the system. It displays system’s hierarchy of equipments/components and its Risk information.

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maXRBI (Management System Evaluation)

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1. Access from the Select Action menu of MaXRBI application.

2. Management System Evaluation window opens.

maXRBI (Management System Evaluation)

263. Click the portion of Facility’s Management System to Evaluate.

API 581 – Generic Failures for Equipment Types

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Comp. Damage Consequence Equation Constants

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Risk rank Summary Report which includes:◦ Likelihood and consequence

ranking for each equipment ◦ Risk ranking for each piping

section◦ Identified active damage

mechanisms Corrosion Rate Difference by

Service and Type Corrosion Inhibition and Corrosion

Rate Correlation Internal/External Inspection

Comparison

MaXRBI Reports

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Linear and Non-Linear Assets

Assets can have two categories: Linear and Non-Linear.Linear Assets have linear properties and often connect with each other by their relationship with the linear infrastructure itself.

A non Linear Asset occupy a defined space and can be tracked by their location or modeled as part of a parent-child hierarchy.

maXRBI supports both linear and non-linear assets.

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Subsea Corrosion?For subsea corrosion inspection, we use DVRi equipment from Net MC Marine.27

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maXRBI DocumentationD

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maXFilenet is the seamless combination of Maximo enterprise asset management applications and FileNet DMS capabilities. They form the solution for paperless business operations, secured and categorized attachments in Maximo records, and tracked documentation.

With maXFilenet, documents uploaded in the FileNet Workplace are automatically added to the Maximo document library, and, attaching them to Maximo records is as easy as the usual Maximo document-attaching way, offering versioning and tracking.

Managing attachments can be done in two ways, either through Maximo or FileNet. After every modification on documents, the two systems are updated with details for audit trail

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