RISK-BASED
INSPECTION
The Steps to Effective Asset Integrity Management
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Safety-focused and cost-effective, Risk-Based Inspection
(RBI) as an inspection scheme targets threats to the
integrity of critical energy assets. An essential part of Asset
Integrity Management, the methodology enables teams in
complex processing industries to find the answers related
to inspection activities, six of which will be addressed in this
paper to help facilitate improved reliability of global energy
access.
Why Risk- It is critical for inspection teams to know where to focus based on the available
inspection resources and budget, when to perform the inspections, and which
Based inspection technique is the most suitable to help to identify the actual state of
an asset. Risk-Based Inspection (RBI) provide confidence and serves as a tool for
Inspection? future inspection planning. This in turn facilitate better decision-making, which
ultimately is reducing loss of containment events at the facility.
RBI is a systematic tool for managing risk by prioritising equipment for inspection
activities. It is a sound and proven asset integrity methodology and an excellent
tool for prioritising and optimising inspection activities, identifying and
understanding risk drivers, and creating effective risk mitigation strategies.
In an operating plant or installation, a relatively large percentage of risk is
associated with a small percentage of the equipment items. Typically, 80% of
the risk of equipment and piping systems failure is associated with only 20% of
equipment. RBI allows the shifting of inspection and maintenance resources to
provide a higher level of coverage on the high risk items and an appropriate effort
on lower risk equipment. The Pareto Principle of 20/80 fits well for this purpose.
120
100
FREQUENCY OF FAILIURE
CUMULATIVE %AGE OF
ASSET RISK
80
60
40
Asset Asset Asset Asset Asset Asset Asset Asset
20
NUMBER OF ASSETS
Figure 1: The Pareto
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Risk-Based RBI is an asset integrity management methodology that uses relative risk as the
basis for prioritising and managing the efforts of an inspection program, including
Inspection recommendations for monitoring and testing. It provides focus for inspection activity to
specifically address threats to the integrity of the asset and the equipment’s capacity to
Methodology operate as intended, resulting in improved process safety and asset reliability.
The risk is calculated by combining probability of failure (POF) and consequence of failure
(COF) for individual assets.
Risk = Probability of Failure X Consequence of Failure.
Effective risk assessment should be a reasonable, logical, organised process that contains
at least two key steps:
1. Determine how significant the risk is, and
2. Determine whether the risk is acceptable to the asset owner.
The RBI procedure can be applied qualitatively, quantitatively, or by using aspects of both
(semi-quantitatively depending upon the depth of the assessment and details of the data).
Each approach provides a systematic way to screen for risk, identify areas of potential
concern and risk drivers, and develop a prioritised list for more in-depth inspection or
analysis. Each approach develops a risk ranking measure to be used for evaluating the POF
and the potential COF separately.
By targeting high-risk areas, a recommended inspection plan (inspection effectiveness)
can be implemented on complex systems to minimize unplanned shutdown(s), improving
the integrity of the facilities by reducing the loss of containment.
The American Petroleum Institute (API) has published two recommended practices,
API RP 580, Elements of a Risk-Based Inspection Program, and API RP 581, Risk-Based
Inspection Methodology. API RP 580 details basic minimum and recommended elements
for developing, implementing, and maintaining an RBI program while API RP 581 provides
quantitative procedures to establish an inspection program using risk-based methods for
pressurised fixed equipment.
ASSIGN/UPDATE
INSPECTION PLANNING
DAMAGE MECHANISMS
EXECUTE
ACQUIRE/UPDATE ASSESS RISK
PROCESS MONITORING INSPECTIONS
DATA
RISK RANKING RISK MITIGATION
REVIEW RESULTS
Figure 2: Risk-Based Inspection (RBI Analysis Process
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How Do You Risk reduction over time can be achieved by effectively implementing and maintaining the
RBI assessment. Turnaround inspection planning optimisation and postponing internal
Reduce Risk? pressure vessel inspections by focusing on high areas are two of the activities that RBI can
help to reduce risk over time. A conceptual result of this methodology is illustrated by the
lower curve in Figure 3. The lower curve indicates that with the application of an effective
RBI program, lower risks can be achieved with the same level of inspection activity. This is
because through RBI inspection activities are focused on higher risk items and away from
lower risk items.
Figure 3: Risk Reduction
RBI and Integrity Operating Windows (IOWs) are an important component of a comprehensive
mechanical integrity program. This is one of the best mitigations to reduce the risk to
Operating as low as reasonably practicable (ALARP). The parameters which possibly contribute to
damage rate can be monitored and damage rate can be minimized. IOWs are not a recent
Integrity concept. They have been around in different forms for several years. However, with the
Windows publication of the first edition of API RP 584 Integrity Operating Windows in 2014 and
second edition in 2021, focus has been increased on these concepts. The more recent first
edition of API RP 970 Corrosion Control Documents in 2018 also discusses the importance
of IOW programs as part of a complete Corrosion Management System. IOW development
should be integrated with the existing AIM Program, Risk Based Inspection (RBI), and
Corrosion Management Plan (CMP). Therefore, both RBI and IOWs go hand by hand to
ensure the integrity and hence improving the HSE.
Figure 4: Zones of Operation Including Target Range with Standard and Critical Limits
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Mitigating The major objective of RBI is to give direction to management for the decision-making
process of prioritising resources to manage risk. Inspection affects the uncertainty of
Risk the risk associated with pressure equipment, primarily by improving knowledge of the
deterioration state and predictability of the POF. Although inspection does not reduce risk
directly, it is a risk management activity that may lead to risk reduction. The impending
failure of pressure equipment is not avoided by inspection activities unless the inspection
triggers risk mitigation activities that change the risk.
RBI can be a good tool in determining the most appropriate line of action to mitigate
risk. The possible mitigations are focusing on inspections to increase confidence in the
actual damage state of the equipment, fitness for services requirements, any repairs
or replacements needed, lining installation, quality of coating, and corrosion inhibition
requirements.
Figure 4: Risk Mitigation
Cost The primary objective of an RBI assessment is not usually to reduce inspection costs,
however, it is normally a side effect of optimisation of inspection planning. When the
Benefits inspection program is optimised based on an understanding of risk, one or more of the
following cost reduction benefits may be achieved:
1. Elimination of ineffective, unnecessary, or inappropriate inspection activities.
2. Elimination or reduction of inspection for low-risk items.
3. Deployment of online or non-invasive inspection methods may be substituted for
invasive methods that require equipment shutdown.
4. Replacement of less effective, frequent inspections with more effective, infrequent
inspections.
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Figure 5: Cost benefits illustration
1. Current & Informed Risk 1. Relative Risk
2. Risk Drivers Identification 2. Conservative Model
3. Optimised Inspection Plan 3. No Functional Failure Calculation
4. Optimisation of Resources 4. Assessment on Asset Level
5. Management of IOW’s 5. Assumptions Taken
6. Cost Benefits
Figure 6: Benefits and Limitations
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Implement Penspen’s knowledgeable and experienced teams have provided consultancy services
to major companies across Oil and Gas, Power, and Engineering, Procurement and
RBI Construction worldwide for over 70 years. Paired with the necessary certifications,
memberships, and related industry expertise, our capable Asset Integrity teams can
Effectively provide outstanding solutions to help implement RBI effectively.
About Penspen is a global team of engineers who design, maintain, and optimise energy
infrastructure to improve access to energy for communities worldwide. We help meet the
Penspen world’s evolving energy needs by providing consulting, project, and engineering solutions
across the entire energy asset lifecycle.
For over 70 years, our teams have delivered more than 15,000 projects to in excess of 100
countries. By helping countries access lower carbon fuels and by extending
the useful life of existing energy infrastructure, we help to bring cleaner energy to millions
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and the US.
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Copyright 2024 Penspen Limited. All rights reserved.
Penspen and the logo are registered trademarks of Penspen Limited.
Penspen and the logo are registered trademarks of Penspen Limited.
