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RiskWISE™ News Issue 3

RiskWISE™ News Issue 3

Riskwise News

RISKWISE™ for TotalFinaElf Belgium refinery

The principal aim of the project was to implement a pilot RBI programme. TWI's RISKWISE™ Risk Based Inspection (RBI) inspection planning software was used to demonstrate the benefits of Risk Based Inspection (RBI) for the management of pressure equipment.

Two TWI RBI engineers were deployed to Belgium on a part-time basis, to facilitate the process of producing inspection plans.

The equipment was subjected to a RISKWISE™ 'focus/defocus' session to optimise inspection plans for equipment with a low Risk of Failure (RoF) and to propose remedial actions for any equipment with a high RoF.

The RISKWISE™ risk model converts failure likelihood to an estimated Remaining Life Indicator (RLI) which is the only sound basis for deriving a safe inspection interval.

The findings of the work showed that an incremental increase in runlength (major inspection interval) was feasible for approximately 65% of the pressure equipment on the unit.

The RBI project indicated how significant operating cost (inspection and maintenance) savings during the 2004 turnaround could be made, if major inspections were deferred until 2008.

The proposals considered the constraints imposed by the need for major operations turnarounds, the recommendations of the process licensor and the Belgium safety regulating authority.

A benefit-cost analysis for this pilot project, in terms of operating cost savings and RBI system implementation costs identified significant potential savings.

The findings of the study confirmed TFE's general concerns about the potential corrosion under insulation attack.

Several key recommendations were also made by TWI following the pilot project, with a view to ensuring successful implementation of Risk Based Inspection (RBI) across the rest of the refinery.

Preliminary results of RBI user survey

TWI has completed an extensive survey to gain a better understanding of advanced plant life management practices and the practical needs of plant operators. The work is part of a long-term joint industry project (JIP) to consolidate user experience on currently available risk-based inspection (RBI) and maintenance (RBM) practices, as well as fitness-for-service (FFS) assessment procedures.

The survey was open to sponsors and non-sponsors of the JIP.

A small selection of preliminary results of the survey (concerned with RBI only) is presented below.

To obtain a complete set of survey results, please send a request by email to: julian.speck@twi.co.uk

Has your company previously implemented, or is your company considering implementing RBI/RBM?

The majority of all respondents' companies (69%) have 'previously implemented' RBI/RBM or are 'currently implementing' RBI/RBM. The fossil fuel power generation, nuclear power generation and oil & gas transportation sectors are the only sectors that have not previously implemented RBI/RBM. However, all sectors have indicated that they are currently implementing RBI/RBM. Oil & gas production (onshore and offshore) and multi-sectoral companies have progressed the furthest with RBI/RBM implementation. Petrochemical, oil and gas refining, fossil fuel power generation and chemical companies have the largest proportion of respondents considering implementation.

Use of RBI/RBM for several types of plant - ranking of plant by 'used and intend to use again'

General pressure vessels, process piping and shell and tube heat exchangers are expected to be the types of plant to which RBI/RBM is most often applied.

Structures, safety relief valves and pumps, turbines and compressors are expected to be the types of plant to which RBI/RBM is least often applied.

Use of three RBI/RBM methods - ranking of industry by 'used and intend to use again'

The oil and gas transportation and multi-sectoral companies appear to have made the most use of all RBI/RBM methods and intend to continue to do so in future. The petrochemical and oil refining sectors have made the least use of all of these methods.

RBI training to the new draft API RP580

TWI is helping companies wishing to develop their inspection management system to the American Petroleum Institute's new draft Recommended Practice 580 on RBI. This professional development programme is aimed at inspection, materials, corrosion and plant assessment engineers and anyone involved in managing the inspection and assessment of pressure systems using risk-based techniques. The course covers:

  • the theory of qualitative and quantitative risk analysis;
  • practical likelihood and consequence analysis;
  • preparing inspection plans and optimising inspection intervals;
  • implementing risk mitigation actions;
  • the elements of a competent RBI management system;
  • detailed RBI workshop study exercises.
All attendees will receive a comprehensive training manual and will be awarded a Certificate of Attendance at the end of this 2 day course.

For further information, please email: robert.gray@twi.co.uk