RBI Concept

IJK & team RBI Concept
Risk Base Inspection (RBI)

Concept
In Jumanda K
[email protected]
0818 0205 4292
Introduction
• RBI: Risk Based Inspection
Inspeksi Berbasiskan Resiko
• RBI:
• Sebuah metode untuk menilai tingkat Resiko pada fasilitas dan
perpipaan
• Sebuah metode untuk membuat rencana inspeksi (inspection
plan) berdasarkan tingkat resiko, bukan semata-mata berdasarkan
waktu (TBI/Time Base Inspection)
• CODE: API 581: Risk Based Inspection;

Based Resource Document
IJK & team RBI Concept 2
1
PURPOSES
The purposes of a (RBI) program are as follows
a. To provide the capability to define and measure risk,
creating a powerful tool for managing many of the
important elements of a process plan;
b. To allow management to review safety, environmental
and business-interruption risks in an integrated, cost-
effective manner;
c. To systematically reduce the likelihood of failures by
making better use of the inspection resources; and
d. Identify areas of high consequence that can be used for
plant modifications to reduce risk (risk mitigation).
Focus Of Risk Assessment

• In the past, the focus of risk assessment has
been on-site safety-related issues.
• Presently, there is an increased awareness of
the need to assess risk resulting from:
a. On-site risk to employees.
b. Off-site risk to the community.
c. Business interruption risks.
d. Risk of damage to the environment.
2
APPLICATIONS OF RBI
• Optimization Procedures
• Database Improvements
Optimization Procedures
Risk reduction
Risk using RBI
Cost reduction
3
Uninspectable Risk
The uninspectable factors for loss of containment include,
but are not limited to, the following:
a. Human error.
b. Natural disasters.
c. External events (e.g., collisions or falling objects).
d. Secondary effects from nearby units.
e. Deliberate acts (e.g., sabotage).
f. Fundamental limitations of the inspection method.
g. Design errors.
h. Previous unknown mechanisms of deterioration.
Other Uses For RBI

• Table 1-1 shows how the risk of loss of containment relates
to the various categories that may contribute to a failure.
• Loss of containment occurs only when the pressure
boundary is breached.
• As the figure demonstrates, however, failure of any of the
equipment categories or human factors can act as a
precursor to the failure of the pressure boundary.
• A power failure or an instrument malfunction can result in
a process upset.
• If appropriate action is not taken by the process operator,
conditions can be reached that will result in a breach or
failure of the pressure envelope.
• It follows, therefore, that damage prevention efforts should
be coordinated across all these areas.
4
DEFINING AND MEASURING RISK

• Figure 1-2 displays the risk associated with the
operation of a number of equipment items in a process
plant.
• Both the likelihood and consequence of failure have
been determined for ten equipment items, and the
results have been plotted.
• The points represent the risk associated with each
equipment item.
• Ordering by risk produces a risk-based ranking of the
equipment items to be inspected.
• From this list, an inspection plan can be developed that
focuses attention on the areas of highest risk.
5
The Relationship
between Inspection and Risk
• Given that the “risk” of an accident has two
components, likelihood and consequence,
• Inspection, an activity intended to limit risk must
reduce one or both of the risk components.
• We gain substantial insight into the relationship
between inspection and risk by recognizing which
component of risk a particular inspection activity
is intended to reduce.
AN ANALOGY
• Automobile Accident
6
7
RBI Levels of Analysis

• Level I (Qualitative): screening tool that quickly highlights the
high-risk equipment that users may wish to assess in greater
detail.
• Level II (Semi-Quantitative): a step closer to being a

quantitative analysis than Level I, and it is a scaled down
approach of Level III. Provides most of the benefit of Level III
analysis, but it requires less input than Level III.
• Level III (Quantitative): quantitative approach to RBI providing

the most detailed analysis of the three levels.
API 581 RBI Risk Matrix

High
Medium High
Likelihood category
Low
Medium
Consequence category
8
QUALITATIVE
RBI ANALYSIS
Level 1
API 581 RBI Level 1

• Metode Kualitatif yang digunakan dalam memeriksa risiko
operasi kilang dan petrokimia untuk proses berbahaya yang
berhubungan dengan integritas pressure equipment.
• Sebuah analisis kualitatif dilakukan pada level berikut :
a) Sebuah unit operasi, contoh: unit pengolahan minyak
mentah lengkap.
b) Sebuah wilayah besar atau bagian fungsional dalam unit
operasi,
Contoh: bagian vakum dari unit pengolahan minyak
mentah.
c) Sebuah sistem, (sebuah peralatan utama dan peralatan
tambahan)-contoh: sebuah pemanas atmosferik
termasuk alat penukar panas dan pompa.
9
Fungsi
• Prosedur kualitatif RBI memiliki tiga fungsi, yaitu:
a) Screening unit berdasarkan tingkatan analisis yang
diperlukan dan untuk memastikan kepentingan analisis
lebih lanjut
b) Penilaian tingkat risiko di berbagai unit, dan posisinya
dalam risk matrix.
c) Mengidentifikasi daerah yang berpotensi menimbulkan
resiko, dan kaitannya dengan program inspeksi yang
sesuai.
Tingkatan Unit Berdasarkan

Potensi Risiko
• Analisis kualitatif menentukan tingkatan risiko

dalam pengoperasian unit dengan
mengelompokkan dua elemen risiko yaitu
kemungkinan dan konsekuensi.
10
RISK RATING
RATING UNITS BASED ON POTENTIAL RISK
Consequence Category
Likelihood Category • Damage consequence category
RISK =
(Sum of factors affects the X (Fire & explosion risk)
likelihood of a large leak) • Health consequence category
(Toxic risk)
API 581 QUALITATIVE APPROACH

Equipment Factor (EF)
Damage Factor (DF)
Inspection Factor (IF)

Likelihood
Category Condition Factor (CCF)
Process Factor (PF)
Mechanical Design State Factor (SF)

Factor (MDF)
Damage Potential
Factor (DPF)
RISK
Chemical Factor (CF)
Damage Consequence Quantity Factor (QF)

Category
Autoignition Factor (AF)
Pressure Factor (QF)

Consequence
Credit Factor (CRF)
Category
Toxic Quantity
Factor (TQF)
Health Consequence Dispersibility Factor (CIF)

Category
Credit Factor (CRF)

Population Factor (PPF)
11
Kategori Kemungkinan
• Faktor yang membentuk kategori kemungkinan
sebagai berikut:
a. Jumlah peralatan (Equipment Factor, EF).

b. Mekanisme Kerusakan (Damage Factor, DF).
c. Ketepatan Inspeksi (Inspection Factor, IF).
d. Kondisi Peralatan saat ini (Condition Factor, CCF).
e. Sifat Proses (Process Factor, PF).
f. Desain Peralatan (Mechanical Design Factor, MDF).
URAIAN
a. Faktor Peralatan (EF) terkait dengan jumlah komponen dalam unit
yang memiliki potensi gagal. EF memiliki nilai maksimal 15 poin.
b. Damage Factor (DF) diukur dari risiko yang terkait dengan
mekanisme kerusakan dari unit. Mekanisme ini termasuk tingkat
korosi umum, retak, suhu rendah, dan degradasi suhu tinggi.
Faktor ini memiliki nilai maksimum 20 poin dalam penilaian secara
keseluruhan.
c. Inspection Factor (IF) terkait dengan ukuran efektivitas program
inspeksi saat ini dan kemampuannya untuk mengidentifikasi
kerusakan aktif atau mengantisipasi mekanisme dalam unit.
Mengkaji jenis inspeksi, ketelitian, dan pengelolaan pemeriksaan
program. Nilai maksimum untuk pemeriksaan faktor adalah 15
poin.
12
URAIAN
d. Faktor Kondisi (CCF), evaluasi dilakukan pada kondisi nyata
dan pemeliharaan peralatan dalam kondisi visual. CCF
memiliki nilai maksimum nilai 15 poin.
e. Process Faktor (PF) merupakan ukuran potensi suatu operasi
normal atau kondisi berlebih. Ini merupakan fungsi jumlah
shutdowns atau interupsi proses (Terencana atau tidak
terencana), stabilitas proses, dan potensi kegagalan alat
pelindung. PF memiliki nilai maksimum 15 poin.
f. Mechanical Design Factor (MDF) mengukur faktor keamanan
dalam desain unit. MF memiliki nilai maksimum 15 poin.
LIKELIHOOD CATEGORY
Sum of 6 factors: Likelihood Factor PoF
1. Amount of Equipment (EF)
2. Damage Mechanism (DF) 0 – 15 1
3. Appropriateness of
16 – 25 2
Inspection (IF)
4. Current Equipment
26 – 35 3
Condition (CF)
5. Nature of the Process (PF) 36 – 50 4
6. Equipment Design (MDF)
51 – 75 5
13
Consequence Category
• Terdapat dua hazards utama yang terkait
dengan operasi:
(a) risiko kebakaran dan ledakan, dan
(b) risiko beracun.
Damage Consequence Category

• unsur-unsur yang menentukan besarnya api
atau ledakan :
a. Faktor Kimia (CF)
b. Kuantitas Faktor (QF)
c. Faktor Kondisi (SF)
d. Auto-Ignition Factor (AF)
e. Factor Tekanan (PRF).
f. Credit Factor (CRF)
g. Faktor Potensi Kerusakan (DPF).
14
DAMAGE CONSEQUENCE CATEGORY

Sum of 7 factors: Flammable Damage
1. Inherent Tendency to Ignite Consequence Consequence
(Chemical Factor, CF) Factor Category (CoF)
2. Quantity That can be Released 0 – 15 A
(Quantity Factor, QF)
3. Ability to Flash to a Vapor (State
Factor, SF) 16 – 25 B
4. Possibility of Auto-ignition (Auto-
Ignition Factor, AF) 26 – 35 C
5. Effects of Higher Pressure
Operations (Pressure Factor, PRF)
36 – 50 D
6. Engineered Safeguards (Credit
Factor, CRF)
7. Degree of Exposure to Damage 51 – 75 E
(Damage Potential Factor, DPF)
Health Consequence Category

• Workbook kualitatif, berasal dari unsur-unsur
berikut yang dikombinasikan untuk menyatakan
tingkat potensi beracun bahaya dalam unit:
a) Kuantitas dan toksisitas (Toxic Quantity Factor,
TQF).
b) Dispersibility Factor (DIF).
c) Sistem deteksi dan mitigasi (Credit Factor, CRF).
d) Populasi penduduk (Population Factor, PPF).
15
HEALTH CONSEQUENCE CATEGORY

Sum of 4 factors: Health Consequence Health Consequence
Factor Category (CoF)
1. Quantity and Toxicity (Toxic
Quantity Factor, TQF) 0 – 15 A
2. Ability to Disperse Under
Typical Process Conditions
16 – 25 B
(Dispersibility Factor, DIF)
3. Detection and Mitigation
26 – 35 C
Systems (Credit Factor, CRF)
4. Population in Vicinity of Release
36 – 50 D
(Population Factor, PPF)
51 – 75 E
LEVEL RESIKO
• Tingkatan Kategori kemungkinan dan peringkat
tertinggi dari kategori konsekuensi kerusakan
atau kategori konsekuensi kesehatan digunakan
untuk menempatkan setiap unit dalam Matriks
resiko kualitatif ditunjukkan seperti pada Gambar.
• Bila hasil diplot pada matriks, memberikan
indikasi tingkat risiko untuk unit yang dievaluasi.
16
Risk Matrix
QUALITATIVE APPROACH
High
Medium High
Likelihood category
Low
Medium
SEMI-QUANTITATIVE
RBI ANALYSIS
Level 2
17
SEMI-QUANTITATIVE ANALYSIS
Likelihood Category Consequence Category

RISK = Technical Module Subfactor X - Damage consequence category
(TMSF) (Fire & explosion risk)
- Damage rate - Health consequence category
- Inspection effectiveness (Toxic risk)
Risk Calculation
Probability of failure Consequences

Calculations Calculations
Technical Module
Sub Factor (TMSF)
Flammable Toxicity Business
Consequence Consequence Consequence
18
TMSF CALCULATION
Internal/ YES Calculation of Thinning
External Thinning ? Factor
Thinning Factor
Material
NO
Stress Corrosion YES Calculation of SCC
Cracking ? SCC Factor Factor
Inspection NO
YES Calculation of Embrittlement
Embrittlement ? Factor
HTHA Factor
NO
YES Calculation of Furnace Tube
Furnace Tube?
Furnace Tube Factor Factor
NO
Mechanical YES Calculation of Mechanical
Fatigue? Mechanical fatigue Factor Fatigue Factor
NO
YES Calculation of Brittle Fracture
Brittle Fracture? Factor
Brittle Fracture Factor
NO
Equipment YES Calculation of Equipment
Linings? Equipment Linings Factor Linings Factor
NO
External
External YES Calculation of Corrosion
Corrosion ? External Corrosion Factor Factor
NO
Technical Module
Calculation of
Subfactor
Technical Module Subfactor
19
Risk Matrix for All Pieces of Equipment

Medium High High
Likelihood category
Low Medium
QUANTITATIVE
RBI ANALYSIS
Level 3
20
API 581
QUANTITATIVE ANALYSIS
LEVEL OF ANALYSIS
Each equipment item and pipe segment in a unit
FUNCTIONS
Prioritize the equipment based on its potential risk
To develop a comprehensive inspection plan for the unit
API 581
QUANTITATIVE ANALYSIS (cont’d)
Likelihood Category Consequence Category

RISK = Technical Module Subfactor X - Damage consequence category
(TMSF) (Fire & explosion risk)
- Damage rate - Health consequence category
- Inspection effectiveness (Toxic risk)
- Financial consequence category
21
API 581
Level III
Risk Matrix
Probability of failure Consequences

Calculations Calculations
Technical Module
Subfactor (TMSF) Flammable Toxicity Financial
Consequence Consequence Consequence
API 581 QUANTITATIVE ANALYSIS

Extract from RBI Database
Select a set of Hole Sizes
Estimate likelihood of Leak
Estimate Consequences
Risk = Likelihood x Consequences
All Consequences No
Completed ?
Yes
All Scenarios No
Completed ?
Yes
IJK & team Sum RBI

Risks for all Scenarios
Concept 44
22
API 581
Likelihood Analysis
Generic Failure Equipment Modification Management System
X X
Frequency Factor Evaluation Factor
Technical Module
Subfactor
Damage rate
Inspection
effectiveness
Universal Subfactor
Plant condition
Cold weather
Seismic activity Mechanical Subfactor
Equipment complexity
Construction code
Life cycle
Process Subfactor Safety factors
Continuity Vibration monitoring
IJK & team Stability RBI Concept 45
Relief valves
API 581
Fluid properties:
Estimate Range of Hole Sizes:
in equipment and at
Release Rate ¼”, 1”, 4”, rupture
ambient conditions
Determine if Release is Total mass

Continuous or Instantaneous available for
release
Determine if Fluid Disperses

as a Liquid or a Gas
ASSESS MITIGATION
FLAMMABLE TOXIC
CONSEQUENCE CONSEQUENCE
FINANCIAL
CONSEQUENCE
23
WORK FLOW SUMMARY

Data Collection
Qualitative Semi Quantitative

Analysis Quantitative Analysis
Analysis
Risk Matrix / Risk Matrix / Inspection

Risk Matrix /
unit or equipment plan
equipment
system
Screening Screening Screening

Level I Level II Level III
Terima Kasih
24

RBI Concept

Uploaded by

Copyright:

Available Formats

RBI Concept

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

RBI Concept

Uploaded by

Copyright:

Available Formats

IJK & team RBI Concept

Risk Base Inspection (RBI)

• CODE: API 581: Risk Based Inspection;

IJK & team RBI Concept 2

Focus Of Risk Assessment

IJK & team RBI Concept 4

IJK & team RBI Concept 5

Risk using RBI

IJK & team RBI Concept 6

Other Uses For RBI

IJK & team RBI Concept 8

IJK & team RBI Concept 9

DEFINING AND MEASURING RISK

IJK & team RBI Concept 10

IJK & team RBI Concept 11

IJK & team RBI Concept 12

IJK & team RBI Concept 13

IJK & team RBI Concept 14

RBI Levels of Analysis

• Level II (Semi-Quantitative): a step closer to being a

• Level III (Quantitative): quantitative approach to RBI providing

IJK & team RBI Concept 15

API 581 RBI Risk Matrix

IJK & team RBI Concept 17

API 581 RBI Level 1

IJK & team RBI Concept 19

Tingkatan Unit Berdasarkan

• Analisis kualitatif menentukan tingkatan risiko

IJK & team RBI Concept 20

IJK & team RBI Concept 21

API 581 QUALITATIVE APPROACH

Damage Factor (DF)

Inspection Factor (IF)

Process Factor (PF)

Mechanical Design State Factor (SF)

Damage Consequence Quantity Factor (QF)

Pressure Factor (QF)

Health Consequence Dispersibility Factor (CIF)

IJK & team RBI Concept 22

a. Jumlah peralatan (Equipment Factor, EF).

IJK & team RBI Concept 23

IJK & team RBI Concept 24

IJK & team RBI Concept 25

IJK & team RBI Concept 26

IJK & team RBI Concept 27

Damage Consequence Category

IJK & team RBI Concept 28

DAMAGE CONSEQUENCE CATEGORY

IJK & team RBI Concept 29

Health Consequence Category

IJK & team RBI Concept 30

HEALTH CONSEQUENCE CATEGORY

IJK & team RBI Concept 31

IJK & team RBI Concept 32

IJK & team RBI Concept 34

Likelihood Category Consequence Category

IJK & team RBI Concept 35

Probability of failure Consequences

IJK & team RBI Concept 36