OIL & GAS ASSET INTEGRITY & CORROSION MANAGEMENT

RBI SOFTWARE & INSPECTION MANAGER

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RBI SOFTWARE & INSPECTION MANAGER

SUMMARY RBI Risk Based Inspection…………….………………………………..3

RBI Software…………….……………………………………………………..5

Data Collection…………………………………….………………………….9

Risk Calculation..……………………………………………………………10

Inspection Plans……….……………………………………………………11

Mitigation & Reassessment……………………………………………11

Inspection Manager……………………………………………………….13

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RBI Risk Based Inspection Plant maintenance and inspection resources should be used preferentially on high-risk assets as they have the potential to cause serious disruption in plant operations or cause an unplanned shutdown. The priority treatment of high-risk assets must be balanced by providing sufficient maintenance and inspection for other lower-risk equipment to avoid the emergence or growth of problems over time. GazNeft Morgan’s approach recognizes that a relatively small percentage of plant equipment accounts for a very large percentage of disruption, shutdown and safety risk. Risk-based inspection (RBI) begins with identification of high-risk assets followed by assessment of equipment condition, evaluation of maintenance and inspection programs, study of operating protocols and estimation of life consumption of these priority assets. This process takes into account the likelihood and consequences of mechanical failure. This information is then used to modify and optimize inspection and maintenance programs, audit procedures, operating limits and safety information. Our solution includes the following aspects: - Inspection program optimization - Implementation of RBI software – a versatile, RBI solution framework and database management

system - Preparation of inspection and maintenance plans and manuals - Analysis of condition and failure data - Statistical analysis of inspection data - Extreme value statistical analysis - Detailed, risk based planning of shutdown activities and management of shutdown inspections - Materials engineering - Advanced inspection - Expert technical support - Experienced reliability engineers and shutdown managers - Structural integrity experts

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RBI Risk Based Inspection

In highly competitive market, it has become a priority for heavy duty industrial companies, particularly in the Oil & Gas sector, to avoid any unplanned shutdowns. Companies must therefore ensure that their equipment is safe, reliable and does not pose a risk to the surrounding environment.

What is Risk-Based Inspection (RBI)?

Risk-Based Inspection is a process that identifies, assesses and maps industrial risks which can compromise equipment integrity in both pressurized equipment and structural elements. RBI addresses risks that can be controlled through proper inspections and analysis.

It has been developed a user-friendly software tools integrating RBI as per API RP 581 and API RP 580 principles .

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RBI Software

RBI Software can evaluate the likelihood of the corrosion event (i.e. the corrosion factor) and the magnitude of the consequence corrosion event (the overall consequence factor).

The Corrosion risk is assessed by the combination on the risk matrix of the two factors mentioned above 5

RISK= PROBABILITY X CONSEQUENCE

RBI Software

RBI Software permits to evaluate the actual risk and the future risk providing a dedicated inspection plan.

All the matrices are interactive, the most critical equipment could be identified and directly found into database.

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RBI Software

The results from RBI Software are totally integrated into the system.

In the same interface there are information regarding RBI, details of the damage mechanisms involved as per API RP 571, inspection plan and inspection techniques recommended, 3D location of the equipment in the plant, the inspection history, technical datasheet, the activity plan, document management and any others.

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RBI Software

RBI software gives the support to store technical and inspection data, includes the algorithms for quantitative or semi-quantitative RBI approach and evaluation, creating a detailed inspection plan and managing tailored inspections on stream/off stream, analyzing the risk matrix and the risk ranking of the equipment/item, providing appropriate mitigation .

Archiving previous RBI analysis , Palladio-RBI makes the Reassessment effective.

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RBI Software-Data Collection

The Software is powerful for finding all the data mandatory for an efficient quantitative or semi-quantitative RBI study (operating manual, P&ID, technical drawings, piping class, fluid properties, design and process conditions, inspection history,…). The circuits are divided in corrosion loops/corrosion circuits with criteria of “similar damage mechanism”, operative conditions, design material etc ; the circuits are represented on P&ID drawings are built on the basis of conditions, fluid, materials and damage mechanisms.

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RBI Software-Risk Calculation

Probability of failure (POF) is calculated analyzing damage mechanisms with quantitative or semi-quantitative approach, as per API RP 581 principles.

𝐷𝑓−𝑡𝑜𝑡𝑎𝑙 = max[𝐷𝑓−𝑔𝑜𝑣𝑡ℎ𝑖𝑛 , 𝐷𝑓−𝑔𝑜𝑣

𝑒𝑥𝑡𝑑 ]+ 𝐷𝑓−𝑔𝑜𝑣𝑠𝑐𝑐 + 𝐷𝑓

ℎ𝑡ℎ𝑎 + 𝐷𝑓−𝑔𝑜𝑣𝑏𝑟𝑖𝑡 + 𝐷𝑓

𝑚𝑓𝑎𝑡

Consequence of failure (COF) is calculated considering the consequence of fluid flammable, toxic and non-flammable/non-toxic . The final value is the “Final consequence”.

Risk matrix has the value of consequence on the horizontal axis and the value of probability on the ordinate axis.

Each component will occupy a position in the matrix.

The multiplication between probability and consequence gives the actual risk value.

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RBI Software-Inspection plans

The software, following API RP 581 methodology, allows the user to perform an accurate RBI analysis, providing a dedicated inspection plan.

The variables that influence the risk are:

The time since the last inspection for each damage mechanism;

The inspection effectiveness for each damage mechanism.

It is necessary to define a limit risk value (Risk Target) not to be exceeded.

The results of the study are:

To find a date for inspection;

To find the inspection effectiveness (type of inspection, inspection locations and details).

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RBI Software-Mitigation & Reassessment

All the details of RBI study are stored into the software with the inspection, maintenance and technical data. The results are available for technicians to design or implement mitigation action over equipment.

The reassessment phase will consist of previous RBI data recovery and of changes that the equipment have undergone.

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Data Entry Mask Calculation Mask Inspection Planning

RBI Software-Inspection Manager

RBI Software is integrated into Inspection Manager.

Dynamic information from Inspection Manager are uploaded into RBI software.

Furthermore RBI outputs are stored into Inspection Manager database for their presentation through its dynamic interface ( i.e possibility to color 3D plant by RBI analysis). 13

RBI Software-Inspection Manager

The software supports all the inspection activity from the preparation phase to the consultation and management of deadlines.

Main features are:

Thickness preparing module;

Integrated inspection consultation;

Managing inspection deadlines and reports.

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Equipment 3D layout Graphical view of the thickness Register of Inspection Reports

RBI Software-Inspection Manager

After RBI analysis the user can create an operative module useful for inspectors.

It is quick to define the areas to be inspected and the use of 3D model allows to find them automatically.

The layout could be saved and used for any other inspection campaigns.

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RBI Software-Inspection Manager

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Integrated Inspection Consultation :

Inspection history can be found and analyzed in integrated manner, locating the critical zones, analyzing the corrosion trends .

Different types of inspection can be stored: thickness measurements, radiography, visual test, dye penetrant test, magnetic particles test and others.

RBI Software-Inspection Manager

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Managing inspection deadlines and reports :

All the deadlines could be managed through the activity plan.

In the Activity Plan there is an alarm function to highlight expiry dates and a planner to optimize the activities during the year.

In the Inspection Report Summary it is possible to manage the reports and the maintenance activities provided (Short and Long Term Actions).

Activity Plan Inspection Report Summary