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RISKWISE™ Newsletter
Issue 2 - June 2001
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RISKWISE™ for Process Plant for NMOC, Japan TWI's RISKWISE™ Risk Based Inspection (RBI) software was recently applied at Nippon Mitsubishi Oil Company's (NMOC) Negishi Refinery, Japan's largest refinery in Yokohama. NMOC was created in the April 1999 merger of Mitsubishi Oil and Nippon Oil. Working with TLV Ltd, TWI undertook an RBI study on the naphtha hydrotreating unit. The objectives of the study were to optimise equipment inspection plans and identify suitable mitigation measures to reduce the risk of failure. The RISKWISE™ model converts failure likelihood to an estimated remaining life indicator (RLI) which is the basis for an inspection interval. The results of the NMOC study demonstrated the potential for incremental run length extension after selected equipment modifications. It also highlighted the scope for reduced shutdown inspection effort on a significant number of items, as well as suitable and cost-effective risk mitigation actions.  RISKWISE™ for Process Plant 'Risk Summary' screen A senior NMOC spokesperson commented: 'The software is very easy to use, so special training is not required. It enabled us to demonstrate the integrity of our plant using an advanced maintenance system. RISKWISE™ addresses not just those damage mechanisms known to be dominant in causing failure but also other damage mechanisms which may become active.' The features of RISKWISE™ include its user-friendly implementation process; its unique reliability-rule based evaluation to derive safe inspection intervals; and its risk mitigation module which allows users to assess actions to meet inspection interval targets.
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RISKWISETM for Pipelines in Arabian Gulf
The client's operations date back to the 1950s. The internal damage mechanisms addressed included CO2 corrosion, H2S corrosion, microbial corrosion, oxygen induced corrosion, HIC and stress corrosion cracking. All lines with an estimated remaining life indicator (RLI) of less than 5 years were selected as high risk lines for subsequent detailed fully-quantitative (probabilistic) RBI assessment. The output enabled the client to formalise a pipeline inspection and replacement plan with associated savings resulting from reduced business interruption, deferred capital spend and minimised liability uncertainties.
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HSE Best Practice for Risk Based Inspection
The document entitled 'Best practice for risk based inspection as a part of plant integrity management' discusses the best practice for application of Risk Based Inspection (RBI) in the context of plant integrity management. The intent is to provide guidelines for risk-based inspection planning, for pressure equipment and systems that are subject to the requirements for in-service examination under the Pressure Systems Safety Regulations 2000 (PSSR). It can apply to equipment and systems containing hazardous materials that are inspected as a means to comply with the Control of Major Accident Hazards Regulations (COMAH). The report considers the application, data requirements, team competencies, inspection plan (including NDT techniques and reliability) and overall management of the RBI process. An audit tool is given in the appendices in order to assist the evaluation of the RBI process. The report can de downloaded free of charge from the HSE's website at: http://www.hse.gov.uk/research/crr_htm/2001/crr01363.htm The UK's HSE and HSC (Health and Safety Commission) develop and apply science and technology to provide a sound, independent knowledge base to evaluate the risks to peoples heath and safety from work activities and the means to assess and control risks.
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API RP580 Update The 5th Draft of API RP580 is available to download from an API website: http://www.api.org/sci/documents/ RISKWISE™ for Pipelines and RISKWISE™ for Process Plant were designed to comply with the latest draft of RP580. Benefits of Using RISKWISE&8482;
RISKWISE™ incorporates a unique time dimension to risk assessment, which facilitates a semi-quantitative estimation of remaining life, i.e. the estimated Remaining Life Indicator (RLI), and hence a safe inspection interval. RISKWISE™ incorporates TWI's comprehensive knowledge of all damage and failure mechanisms. The software includes a Damage Mechanism and NDT Help program, thereby transferring know-how to the operator in a transparent manner. RISKWISE™ produces inspection plans in the form of a Written Scheme of Examination, in a customisable form (to meet the requirements of users and the local safety regulators).  RISKWISE™ for Process Plant and RISKWISE™ for Pipelines were developed specifically for application in refineries and petrochemical plants, and transportation pipelines. They therefore incorporate all the relevant degradation mechanisms. RISKWISE™ enables screening on the basis of risk or on the basis of recommended inspection periodicity. For high-risk items, the software directs the user to risk mitigation options via the Focus/Defocus process. RISKWISE™ has a plant asset and inspection database (PAID) which can be linked with the relevant module of computerised maintenance management systems (CMMS).
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Benefits of Using RISKWISE™
RISKWISE™ incorporates a unique time dimension to risk assessment, which facilitates a semi-quantitative estimation of remaining life, i.e. the estimated Remaining Life Indicator (RLI), and hence a safe inspection interval. RISKWISE™ incorporates TWI''s comprehensive knowledge of all damage and failure mechanisms. The software includes a Damage Mechanism and NDT Help program, thereby transferring know-how to the operator in a transparent manner. RISKWISE™ produces inspection plans in the form of a Written Scheme of Examination, in a customisable form (to meet the requirements of users and the local safety regulators). RISKWISE™ for Process Plant and RISKWISE™ for Pipelines were developed specifically for application in refineries and petrochemical plants, and transportation pipelines. They therefore incorporate all the relevant degradation mechanisms. RISKWISE™ enables screening on the basis of risk or on the basis of recommended inspection periodicity. For high-risk items, the software directs the user to risk mitigation options via the Focus/Defocus process. RISKWISE™ has a plant asset and inspection database (PAID) which can be linked with the relevant module of computerised maintenance management systems (CMMS).
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RBI and FFS Joint Industry Project As part of a significant joint industry project (JIP), TWI is carrying out a questionnaire-based survey to gain a better understanding of advanced plant life management practices and the practical needs of plant operators. The primary objective of this survey is to consolidate user experience through feedback on currently available risk-based inspection (RBI) and maintenance (RBM) practices and fitness-for-service (FFS) assessment procedures. This survey is open to sponsors and non-sponsors of our JIP. If you are not a sponsor of the JIP, TWI will nevertheless send you a complimentary copy of the summarised survey results in exchange for completing this questionnaire. Questionnaires can be obtained from TWI as an attachment to an e-mail. The questionnaire is contained in a Microsoft Excel spreadsheet, and will take you approximately 10 to 15 minutes to complete. Completed questionnaires should be returned to TWI as an attachment to an e-mail, by no later than Monday 30 November 2001. JIP proposal 'Study of Risk-based Life Management Practices and their Relationship to Fitness-for-service Assessment Methods', Group Sponsored Project Proposal GP/SID/1175-1, January 2000. (This is a pdf file 517kB).
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TWI's RISKWISE™ for Pipelines was used to assess the useable remaining life of in excess of 260 oil production and water injection lines for a major oil and gas producer in the Arabian Gulf.
Under a contract for the United Kingdom's Health and Safety Executive (HSE), TWI, working with Royal and Sun Alliance Engineering, has produced a report on Best Practice for Risk Based Inspection.
RISKWISE™ is highly user-orientated and its simplicity ensures rapid implementation. It accommodates plant experience and is not a 'black-box', which ensures operating personnel 'buy-in' and ultimately, own the new RBI inspection planning system.
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