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Risk Based Inspection

(RBI) solutions
Improve integrity, reduce costs through
more effective inspection

Risk
Assessment

Opportunity Competency
Assessment Assessment

pRIME

Training & Value

Development Creation

Risk
Management
2 R B I S O L U T I O N S I M P R O V E I N T E G R I T Y, R E D U C E C O S T S T H R O U G H M O R E E F F E C T I V E I N S P E C T I O N

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Risk Based Inspection (RBI)

What is RBI? How to select an appropriate RBI

RBI is a well proven approach for determining the
methodology
optimum inspection plan for plant equipment. It
RBI methodologies
uses a risk-based methodology to reduce risk,
Across industry there are two different
improve efficiency and lower the total costs of
approaches to RBI; qualitative and quantitative.
inspection.

The quantitative approach

RBI has proven to be an effective tool for the
A highly data driven methodology that is focused
optimisation of inspection strategies for vessels
upon theoretical corrosion rates. The assessment
(columns, heat exchangers, filters, boilers,
calculates the remaining safe operating life of the
furnaces etc.), storage tanks, pipework, relief
equipment and the output is typically in
streams, civil structures, sumps and bunds.
numerical form, without visible analysis or action
plans. The adoption of this approach can limit the
Benefits of RBI
benefits of RBI because:
-- Reduced likelihood of loss of containment
-- Reduced inspection cost by specification of
-- Operating excursions or cleaning routines are
appropriate inspection techniques and
not considered
extending inspection intervals where
-- Inspection data is not always available or
appropriate
validated
-- Improved reliability and plant availability
-- Corrosion rates are not verified
-- Legislative compliance
-- Written Schemes of Examination (WSE) are not
updated
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RBI risk matrix: reducing the operating risk envelope.
RBI risk matrix: reducing the operating risk envelope The qualitative approach
5 A more holistic view to determine what to
inspect, where, how and when. It identifies the
4
n
actual operating and maintenance conditions for
ion
cttio the assessed equipment, including upset and
uc
Rred
Likelihood

k
3 sisk start-up / shutdown conditions. It delivers an
RRi
auditable risk assessment that enables the
Before RBI
2
After RBI
generation of a WSE that will optimise plant
availability, reduce costs and improve equipment
1
integrity. ABB’s RBI+© programme uses a
1 2 3 4 5
qualitative team-based methodology and unique
Consequence
software to ensure that the full benefits from RBI
are realised.
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RBI+© methodology

Our experience Which items should we review? Where do we

ABB provides technical and engineering services start?
to improve performance in the areas of ABB offers an initial ‘criticality and opportunity
compliance, operations and engineering to screening process’ which assesses the likelihood
customers in the chemical, petrochemical, oil and and consequence of equipment failure and the
gas, power, pharmaceutical, metals and customer cost effectiveness of the current inspection
industries worldwide. regime. This enables equipment to be ranked in
order of criticality or by the size of opportunity
ABB has over 20 years experience of carrying out for improvement.
RBI reviews and has applied the RBI+©
methodology to over 100,000 equipment items. Normally no further study of low ranking
Our operating history and functional expertise equipment is necessary, enabling resources to a
enables us to provide authoritative advice and targeted to areas that will benefit the most. It is
solutions across the range of our clients’ assets also an effective way of recording and
(gives us the leading edge capability across all demonstrating that all items have been assessed
assets). for both Health Safety and Environment (HSE)
and business risk and comply with the relevant
— legislation.
The RBI process.

RBI+© methodology
Items benefiting from a full RBI study are then
assessed by a multi-discipline team using ABB’s
RBI+© methodology. A fundamental part of ABB’s
Implement Collect or process is a collaborative review involving the
inspection plan refresh data client’s operations and maintenance personnel
assisted and lead by ABB’s functional specialists
(by operations, maintenance and functional
specialists from ABB and client teams).

Determine The key steps of the process are:

optimum Review data

-- Gathering operating conditions and inspection
inspection plan history data
-- Team review of data
-- Identification of credible deterioration
mechanisms
Identify -- Analysis of HSE and business risks
Analyse risks deterioration -- Determination of the optimum inspection plan.
mechanisms The rationale for the proposed inspection
strategy is recorded
-- Generation of a WSE for each item under
consideration
-- Review as new data becomes available

The RBI+© methodology is compliant with API

580 RBI.
4 R B I S O L U T I O N S I M P R O V E I N T E G R I T Y, R E D U C E C O S T S T H R O U G H M O R E E F F E C T I V E I N S P E C T I O N

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RBI+© methodology - the benefits

The benefits of RBI+© compared to other —

methodologies:
-- Data used is specific to each item and validated
“After applying RBI+©, I now have
-- Actual operating conditions are understood and a greater understanding of my
assessed, displacing conservative assumptions
or occasionally over-optimistic assumptions
plant equipment and total
-- Expert knowledge is engaged to determine confidence in my inspection and
credible deterioration mechanisms
-- Team ownership of risk assessment and
operating policy.”
inspection strategies
Plant Engineer, Major Hazard
-- Auditable rationale for the extension of
Chemical Installation
inspection intervals and the adoption of non-
intrusive inspection strategies —
-- End product is a Written Scheme of
Examination unique to each item
“We have used ABB Inspection
-- Increased confidence in equipment integrity Services since August 2005
In most cases, a program of RBI+© reviews will
following a long period (since
deliver a significant reduction in the total cost of 1970) during which we provided
inspection.
our own inspection team. It was
—
Benefits of RBI+© to a new client over a three year period.
immediately obvious that ABB
Before RBI After RBI
Inspection cost Inspection cost brought a number of advantages
before RBI after RBI
Average inspection
53.4 months 79.2 months
to the table”
interval

Invasive inspection 151 73 £1,359,000 £657,000

Ammonia Mechanical Engineer,
Non-invasive
124 202 £186,000 £303,000 CF Fertilisers UK Limited
inspection

TOTALS £1,545,000 £960,000

SAVING compared to traditional inspection £585,000

Cost savings above do not include any benefits due to the increase in plant intervals or benefits of risk reduction

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RBI risk matrix.
 —
— Key features of the software

RBI+© software -- Deployable via web, intranet and Lotus Notes

The software can be accessed in various ways depending
on client and project requirements.

-- Secure
Risk
Assessment

The application is secured using tiered access, meaning

Opportunity Competency
Assessment Assessment

pRIME
that access and edit permissions can be set person by
Training & Value

person, module, by module. Data is secured through

Development Creation

Risk

encryption.
Management

Enhancement of RBI+© pRIME tool -- Access from anywhere

All RBI reviews undertaken by ABB have been delivered using The application can be accessed through a web browser or
the RBI+© pRIME (process Reliability and Integrity by using a local copy from the users PC.
Management Excellence) tool enabling an efficient and
-- Data capturing and review
robust assessment process. This software has now been
Several team members can work concurrently in capturing
further enhanced and is available for license as a standalone
the input data electronically to enable review during multi-
tool. Consequently, clients are now able to complete RBI
disciplinary meetings. Data from the different team
reviews in-house effectively and efficiently according to
members is transmitted through client and browser based
ABB’s recognised methodology.
applications and aggregated allowing individuals to work
separately. This allows the information to be reviewed by
In addition to the existing benefits of ABB’s RBI+©
specialist engineers outside of the immediate project
methodology the enhanced tool offers:
team.

-- More efficient RBI studies, using less operating team time -- Corrosion loops
-- Access to a large knowledge bank of best practice The software enables similar items of equipment with
guidance and equipment inspection data similar operating conditions and deterioration
mechanisms to be grouped together to form what are
pRIME toolkit sometimes called corrosion loops. This ensures that a
The RBI+© software is one element of ABB’s pRIME toolkit. range of and changes in process conditions are considered
pRIME is a methodology for managing asset integrity; consistently across the complete series of equipment
recognising symptoms, diagnosing causes, and affected. This also minimises the input requirements.
implementing corrective or improvement action. Adoption
-- Consistent workflow and management reporting
of the pRIME methodology will deliver a beneficial, cost
Each equipment item review is subject to a series of
effective, sustainable solution. All processes are risk based,
secure stage gates to ensure that all of the necessary input
ensuring that effort is concentrated on areas that will give
data has been collected, analysed and the
the highest return.
recommendations captured. This structured work process
— facilitates the tracking and reporting of project status by
RBI+© project dashboard. means of the progress dashboards.

-- Risk assessment according to client’s criteria

The assessment criteria for likelihood and HSE and
business consequences are configurable to the client’s
own risk assessment criteria.

-- Automated generation of reports

Summary and detailed reports of each RBI review project
program can be created in Word and Excel. The format of
these reports is configurable in the field on a project by
project basis.

-- Portfolios
Standard templates are available for each sector - oil and
gas, refinery, petrochemical, pharmaceutical and power.
These templates prompt assessment of relevant
deterioration mechanisms for each sector.

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To see how RBI+© pRIME software can benefit your business try our free demo at:
www.prime-toolkit.com
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Technical support

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pRIME integration overview.
Training
ABB can provide training on the RBI process and
how to get the most out of the RBI+© tool. We can
provide bespoke training onsite or at our offices.
Customer ERP / CRM pRIME users
Spreadsheet XML data files
Support
The software is easy to use. Our in-depth help
guides will provide the answers to most queries
and ‘how to’ videos will guide you through the
process. In addition, we offer free support via
telephone and email service.

Technical specification
XML data files
-- Compatible with Internet Explorer, Google
Chrome and Firefox
-- Compatible with IBM Notes
-- Compatible with Microsoft Word and Excel
XML web services pRIME Web -- Ability to produce custom detailed reports and
client browser charts
Web services -- Includes selective replication functionality
XML -- Can be installed on our servers or client servers
Email -- Available as a secure web based Software as a
IBM LEI Hosted ABB pRIME server* Service ( SaaS ) application
-- Available as an On-premises install or virtual
appliance
-- Available as a locally installed client solution
with optional cloud synchronisation
*On premises options also available
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Integrity management

RBI is one element of ABB’s ABB inspection services

-- Pressure equipment specification and design
integrity management offering. -- Independent design review
-- RBI+©
-- UKAS accredited inspection service
We can provide integrity -- Preparation of focussed schemes of
management support throughout examination
-- Fitness for purpose assessment
the plant life cycle. -- Repair specification
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-- Materials engineering and consultancy
ABB’s equipment life cycle approach. -- Civil and structural inspection and consultancy
-- Auditing and gap analysis against PSSR, PUWER
-- Asset life studies and plans

Integrity management services

Design -- Asset health check
assurance -- Asset life studies
-- Technical Due Diligence (TDD) assessment
-- Risk based approaches embracing safety,
maintenance, criticality and inspection
-- Competency and development training and
Decomm.
Inspection appreciation programmes
and demolition -- Integrity management solutions software

Other ABB capabilities

-- Inspection
-- Operations improvement
-- Process safety
Late life Asset -- Project services
operation management -- Technical engineering
-- Technical software
-- Technical training and competency
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ABB Limited ABB Limited
Daresbury Park The Deep Business Centre
Daresbury Tower Street
Warrington Hull
Cheshire HU1 4BG
WA4 4BT United Kingdom
United Kingdom Phone: +44 (0)1482 481160
Phone: +44 (0)1925 741111 E-Mail: [email protected]
E-Mail: [email protected]

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ABB Limited ABB Limited
Pavilion 9 The Shearer Building
Byland Way Earls Road
Belasis Business Park Grangemouth
Billingham Stirlingshire
Cleveland FK3 8XG
TS23 4EB United Kingdom
United Kingdom Phone: +44 (0)1324 494406
Phone: +44 (0)1642 372000 E-Mail: [email protected]
E-Mail: [email protected]

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ABB Limited
Hareness Road
Altens Industrial Estate
Aberdeen
AB12 3LE
United Kingdom
Phone: +44 (0)1224 592123
E-Mail: [email protected]

abb.com/consulting
abb.com/oilandgas
abb.com/chemicals
abb.com/service

Process safety/BRC034a/03/19

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