Inspection Management

ORBIT RBI Software

Panos Topalis

Agenda
Introduction to DNV Software
Risk Based Inspection (RBI) - ORBIT RBI Software
ORBIT+IDS (Inspection Management)
Discussion

Version

Slide 2

Process PlantsObjectives and Challenges

Objective: Operate safely and profitably
-

Prevent/reduce leaks.
Meet HSE Requirements
Maintain high availability and throughput.
Minimize shut downs.
Extending shut down intervals
Reduce Insurance Costs

Challenges
-

Old Plants
Large, complex units
Integrated Feed Systems
Many degradation mechanisms
Raw material price
Massive amount of data

Need to manage in a proactive and systematic way

Guiding Principle: Maintenance on the basis of risk

Version

Slide 8

Software Offering For the Process Industry

Performance
Forecasting

Frequency
Analysis

Consequence
Analysis

Impact and
Risk Analysis

/ RAM
Analysis

Asset
Integrity
Management
Software

ORBIT+IDS
MAROS

LEAK

TARO

RiskSpectrum

PHAST

PHAST Risk

Silverpipe
ORBIT RBI
AIMS Structures

RISK MANAGEMENT

Version

Slide 12

DNV Integrity Management for Onshore and

Offshore Facilities
Process Facility
ORBIT+ IDS+RBI
Refineries
Gas Plants
Petrochemicals
Chemicals
LNG Plants
Terminals
Others

Onshore & Subsea Pipeline

SilverPipe

Satellite Topsides

Offshore
Topside
ORBIT+
IDS+RBI
Offshore
Structure
Sesam
Structure
Integrity

Sub sea

Version

13

Slide 13

ORBIT+ IDS
- Risk-based Inspection Management PDCA for Equipments

PLAN

What: Tag / Element

What: Tag / Element

Details,

Why:

Damage

When: Next Due Date

When: Assessment Date

Inspection

Customized Interface

Where: Process Unit

Where: Process Unit

PLAN

Resource Plan

Damage

(SAP-PM)
Inspection
Prepare for
the survey
Planning
&

Risk the
Evaluate
process
Assessment

Where: Process Unit

What: Tag / Element

Packaging

Why:

Equipment Master

Damage

When: Next Due Date

Data (SAP-PM)
Standard
Interface

Implement
Facility
plans and
Databank

Risk-based

Inspection
Execution

Who:

Inspector

How:

Insp. Method

DO

Inspection Management
When: Insp. / Maint. Dates
What:

Insp. Maint. Details

How:

Eqn. Status

Inspection
Analyse
survey
Task
results
Approval

Follow up
Action

When: Work Request / Order Date

What:

Work Order Details

How:

Status

What:

Finding

How:

Effectiveness

What Next: Recommendations

CHECK

ACT
Standard Interface

Maintenance
Work (SAP-PM)

Inspection

When: Insp. Date

What:

Finding

How:

Effectiveness

What Next: Confirmed / Revised

Recommendations

16

When: Insp. Date

Customized Interface

Resource Recording
(SAP-PM)

Benefits of using ORBIT+ IDS

Managers

Integrity
Engineer

Inspectors and
Contractors

IT
Support

17

Risk and job overview for all types of equipment

Traffic lights on facility hierarchy and integrity barriers

Managing risk by KPI

RBI on Web or offline

Combining risk-based and regular inspection scheduling

Flexible work packaging and task assignment

Easy inspection preparation

Easy inspection result recording and reporting

Generate and monitor maintenance notifications

Fully web-based system, easy deployment and support

Open web-services for integration

Logical data views and report templates for external enhancements

RBI History
Probabilistic risk analysis techniques
- Started in the nuclear industry (1970s)

Quantitative risk assessment (QRA) in the Process Industries

- Canvey Island and the Rijnmond Report (1980s)

Software tools for QRA

- Eg DNV-Technica develops SAFETI and PHAST risk assessment tools (1980s)

ASME RBI principles overview document in 1991

API develops Risk Based Inspection Methodology (mid-1990s)
-

Version

DNV main API sub-contractror

API Base Resource Document 581 (2000)
API RBI software
API RP 580 (2002)

Slide 23

Risk Based Inspection Driving Factor

Risk is not equally distributed among the individual pieces of
process equipment.
A large percent of the total unit risk is concentrated in a small
percent of the equipment.
% of Total Risk Vs % of Equipment Items
Plant Unit, ~500 Total Items

% of Total Risk

100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

% of Equipment
Version

Slide 24

Managing Risk Using RBI

Cost
reduction

Risk, Traditional Strategy

Risk
Reduction
Both

Risk, RBI Strategy (more effective)

Inherent Risk
EFFORT = EURO, USD, RUB, RMB,NOK

Version

Slide 25

So what are the real Benefits of RBI Implementation ?

Risk ranking and prioritization of inspection and maintenance activities
Optimise spending on maintenance and inspection
May significantly alter the inspection strategies to become more efficient
May provide substantial cost savings
May contribute to reducing operational risks
Improved communication between operations, inspection and maintenance
Provides RBI database for easy future inspection scheduling, updating and
risk control
Improves the mechanical integrity system and provides means to measure
the effectiveness of inspection

Det Norske Veritas AS. All rights reserved.

Slide 26

ORBIT Onshore Features

Suitable for RBI of chemical plants, refineries, onshore
installations
Semi-qualitative screening analysis enables rapid identification
of high risk items
Detailed likelihood calculation as a function of time, using limit
state equations
State-of-the-art consequence modelling using PHAST models
Extensive database of more than 1700 construction materials
(ASME)
Incorporates database of more than 1500 chemicals (DIPPR),
100 chemicals with detailed data
Easy addition of new materials or chemicals for detailed RBI or
screening RBI
Version

Slide 28

Modules
Qualitative-Screening Approach
Internal Thinning
Stress Corrosion Cracking (SCC)
External Damage
Brittle Fracture
Fatigue
High Temperature Hydrogen Attack (HTHA)
Linings
Pressure Relief Valves
Consequences with PHAST lookup tables or direct input
Inspection Planning, Optimisation, Cost Benefit Analysis and Final Approval

Version

Slide 29

Typical Reports

Version

Slide 31

Typical Reports
Risk matrices for
- Current Date
- Future prior to inspection
- Future post inspection

Executive summary with risks per equipment type and damage mechanism, risk
variation with time with / without inspection
Inspection plans showing what equipment items to inspect, for what type of
damage, when to inspect and what approach to use
Cost Benefit Analysis/ Risk benefit analysis
Equipment summary sheet
Detailed risk breakdown including business interruption, equipment damage and
personnel safety contributions

Version

Slide 32

ORBIT Other Features-Strengths

Database
- Enterprise Oracle version for corporate deployment
- MS Access version for extra flexibility

Multi-language. Currently:
-

English
French
Chinese
Russian
Spanish (2012)

Compliant with national legislations

- Recognised by Dutch Government for inspection planning
- Conforms to french Guides Plan dInspection
- Methodology presented to DRIRE

Managed by software professionals

- Dedicated software support service
- In-house continuous development with long term view
- User Group meetings and user advisory group

Interface with ORBIT+IDS & other inspection management software

packages
Version

Slide 33

DNV RBI Experience

More than 300 RBI projects completed to
date for downstream and upstream
applications where API/ DNV RBI
methodology and software have been
used.
The applications include:
Refineries
Petrochemical and chemical plants
Gas processing plants
Offshore topsides
Pitting corrosion at
channel of lube oil ccoler/seal
oil cooler for R601A/B & R603

Preferential
corrosion
in weld HAZ
3-5 mm

603
P-8"-611D1306-(N40A)

CD

To
A601

P-14"-601-D1306-(N40A)

M601B
CD
P-2"-857-D1306-(N40A)
DR-2"-603-1306-(N40A)

OFF GAS
FROM TCOT
P-20''-600-D3106-(N40A)

601

M613
CD

DR-2"-601D1306-(N40A)

P-3"-827-D1306-(N40A)

M603
M603
RP
CD
P-6"-604D3307-(N40A)

TO P601A/BC/D

610

T602
Pitting &
LTA

P-8"-605D1306-(N22A2)

RP

R601A

P-8"-606D3102-(NA22A2)

P-12"-607-D3307-(N40A)

P-3"-625-D1306-(N40A)

P-6"-608-D3102-(N40A)

SIMPLIFIED PROCESS
FLOW DIAGRAM
FOR GPP-1 LPGU
FRONT END
DAMAGE TYPES AND
LOCATIONS OF
REPLACED PIPING/
EQUIPMENT

612

DR-1"-606-D1306-(N40A)
613

FUEL GAS
TO M116

P-14"-609D1306-(N22A2)

P-2"-829-D3307-(N40A)

To
P602
A/B

P-6"-620D1306-(N40A)

P-8"-610D1306-(N22A2)

T601B

P-6"-613-D3102-(N22A2)

Floating Production

RT601B

607

RP
605

M602B

Vessels (FPSOs)

611

P-20"-916-D1306-(N40A)

Pipelines

P-8"-612D1306-(N22A2)

P-11/2"-831D3307-(N40A)

P-6"-613-D3102-(N22A2)

R601B

RT601A

606

P-8"-603
D1306-(N22A2)

RP
604

T601A

P-14"-602
-D1306-(N22A2)

P-3"-828-D1306-(N40A)

P611A/B

LEGEND
Cracks

602

M602A

P-8"-604D1306-(N40A)

CD

M601A

Corroded line

Pitting
General corrosion >0.5 mm < CA
Preferential weld corrosion
Pre-existing weld defect

CD
P-3"-621-D1306-(N40A)

TO M109

P-2"-832-D1306-(N40A)

DR-2"-602
-D1306-(N40A)

Gouge/Scratch

Version

P-11/2"-829-D1306-(NA40A)

CD

Coating damage

RP Replaced

Slide 34

Success Stories
Dow Chemicals
- Using ORBIT in 16 sites
- User group and technical steering group
Total Petrochemicals (former Atofina)
- Selected ORBIT in competition with other RBI software
- Deployed already in 4 sites, planned for more sites
Borealis
- Deployment in 6 sites: Austria, Belgium, Germany, Sweden, Norway,
Finland
Equate, RBI implemented in Kuwait petrochemical installation
Kuwait Oil Company
- RBI and Inspection Software (ORBIT Onshore and ORBIT+IDS)
- Inspections conducted/managed for 5000 equip. & 50000 pipes
- 21 Gathering Centres and 3 Booster stations,

Version

Slide 36

Evidence of Benefits from the Use of ORBIT

ORBIT Onshore Worldwide Continuous Success Story:

Dow Chemicals

Version

http://www.dnv.com/resources/publications/dnv_forum/archive/DowChemicalCo.asp

Slide 38

Dow Chemicals
Chemical company with sites / joint ventures worldwide
RBI Implementation in more than 15 sites
- Europe, US, South America, Asia

Use of ORBIT Onshore & DMI since 2000

- In-house RBI experts
- Currently operating with minimum DNV assistance

Risk based inspection instead of periodic inspection

Quoted(*) Benefits of the RBI program:
- Improved reliability
- Eliminated low-value work
- 40% inspection cost reduction

Dow quote 100 million USD savings/year

* http://www.dnv.com/resources/publications/dnv_forum/archive/DowChemicalCo.asp

Version

Slide 39

RBI Risk in Detailed Analysis

Version

Slide 42

Damage Mechanisms /Probability of failure (PoF)

Damage
Mechanisms

Internal
Thinning

HCl

Stress
Corrosion
Cracking

Caustic

External
Damage

Brittle
Fracture

Piping
Fatigue

HTHA

Lining

PRVs

General

HT Sulfide . Amine
CUI
& Nap. Acid SSC
HT H 2S/H 2 HIC/SOHIC Cl SCC
H2SO 4
Carbonate

Version

HF

PTA

Sour Water

ClSCC

Amine

HSC-HF

HT
Oxidation

HIC/SOHIC-HF

Slide 44

Undesirable Consequences in RBI

HEAT from flames destroys equipment, injures people
PRESSURE WAVE from explosions knocks down structures and
people, causes flying objects
TOXIC cloud, for some duration, causes toxic exposure injuries

Version

Slide 46

Risk Target and Inspection Planning

Risk / Damage Factor (DF)

Risk / DF

Inspection
Target
Fairly Effective

Highly Effective
Predicted Risk
Increase
Time to next
inspection

Now

Version

1st
Turnaround

Time

2nd
Turnaround

Slide 50

API and ORBIT

DNV develops successive versions of API 581 and APIRBI, 1993-2002
DNV develops ORBIT RBI 1997-now
- Some Reasons:
- Need for a RBI software for other than refineries
- Improved consequence calculations with PHAST link
- Need for a robust software architecture & professional software
development and maintenance

ORBIT is consistent with the API 580 RBI standard

ORBIT and API 581 share a lot of technology

Version

Slide 55

Software Demonstration

ORBIT Overview

Screening or
Detailed
Analysis
Looks Like Microsoft
Outlook.
Intuitive To Use.
Online Help.
Menus Or Buttons.

Version

Designed for All Types of Process Plants.

Designed to Be Subdivided Easily Into
Plant Units, Areas, Zones, Corrosion
Circuits Etc.

Slide 63

ORBIT List Views

A List-view: one of the

possible views of the
same study Database

Allows Easy Sorting and

Editing of Large Amounts
of Data

Version

Slide 64

ORBIT List Views

Drag and Drop Facilities

for Sorting

Seven Pre-Installed List

Views

Version

Slide 65

User List Views

Facility to Create User

Defined Views

Version

Slide 66

Screening Analysis

NFPA
Ratings for
1600
Chemicals.

Screening Analysis is a
semi-Quantitative
Method for Rapidly
identifying high-risk
items from a large set of
Equipment Items.

Version

Slide 67

Screening Analysis

Likelihood By:
Damage
Mechanism
Method (for Long
Life Expectancy
Items) or -

Version

Slide 68

Screening Analysis

- Statistical
Method (for
Shorter Life
Items).
Results Calculated Immediately As
Likelihood rating (1 to 5)
Consequence Rating (A to E)
Overall Risk Ranking (Low to High).
Recommendat
ions Made.

Version

Slide 69

Detailed Analysis
Detailed Analysis - Comprehensive
Calculation Tool.

In General Data
Define:
Equipment Name,
Type, Location.
Service Date, Material,
Operating Conditions.
Type of Damage
Mechanism

Version

Slide 70

Detailed Analysis

Extensive
Database of
Materials.

Version

Select Exact Material

or Generic Type (E.G.
Carbon Steel)

Slide 71

Consequence Analysis

In Consequence Module
Define:
Consequence Method
(PHAST-Lookup or
Direct Input),
Chemical,
Vessel Shape.

PHAST Is
DNVs Widely
Used Software
for Consequence
Modelling

Version

Slide 72

Consequence Analysis

Database of 1600
Chemicals. A subset
have lookup tables

Consequence Results
Determined:
Business Interruption Cost
Equipment Damage Cost
Safety Cost

Version

Slide 73

Consequence Analysis

SI, English, Metric or

User Defined Units of
Measure

Version

Slide 74

Consequence Analysis

Link
Equipment
Items Into
Inventory
Groups
Automatically
Calculated or
Manual Input

Version

Slide 75

Thinning Calculation

Choice of Corrosion Rates:

Measured,
Expert Opinion

Inspection History - Number

and Type: Used to Calculate
Probability That Corrosion
Rate Is Worse Than Measured,
or Estimated Rate.
Version

Localised or General
Corrosion

Program Considers the Chance

of Corrosion Rate Being Higher
Than Measured or Estimated.
Slide 76

Thinning

Likelihood Factor = How many

times the Equipment Item Is More
Likely to Fail Than Generic.

Version

Likelihood Factor for

Thinning Projected for a 5
Year Period.

Slide 77

Thinning

Results Include:
Equipment Item Remaining
Life and Confidence in
Corrosion Rate (Based on
Inspections Undertaken).

Version

Slide 78

External Damage

Choice of Corrosion
Rates:
Measured,
Expert Opinion or
Calculated

Estimated or Calculated
Corrosion Rates

Version

Slide 79

SCC Modelling

In-built SCC
Causes:
Caustic
Amine
Carbonate
SSC
HIC/SOHIC
Chloride
PTA
HSC
Ammonia

Version

Calculated or
expert SCC
Susceptibilities

Results:
SCC Factor

Slide 80

SCC Modelling

SCC Factor Projected for a

5 Year Period.

Version

Slide 81

Inspections

Inspection History for Each

Equipment Item

Inspection Improves
Confidence in the
Estimated, Measured or
Calculated Corrosion Rate
or SCC Susceptibility
Version

Effectiveness Is Highly,
Fairly, Usually or Poorly DNV Templates Definitions
- Modified for Each Client
Slide 82

Other Modules

Other Modules:
Brittle Fracture
Piping Fatigue
HTHA
Liners
PRVs
Version

Slide 83

Results: Risk Matrix Report

Version

Slide 84

Results: Equipment Summary Sheet

Version

Slide 85

END