International Journal of Advanced Biotechnology and Research (IJBR)

ISSN 0976-2612, Online ISSN 2278–599X,

Vol-8, Issue-2, 2017, pp448-453
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Research Article

Technical Inspection Engineering and Risk Based Inspection in order to

optimize inspection plans

Mohammad Rezaie Narimisaa,* and Manouchehr Rezaie Narimisa b

a
Ph.D. Crisis Management Ministry of Petroleum of Iran,
National Iranian Oil Refining & Distribution Company, Oil Refining Industries Development Company
b
Oil Industries Engineering and Construction Company (OIEC)-Iran,
Kamranieh, Pasha Zahri, Pirooz Alley, No 2, PO.BOX; 1937956751

ABSTRACT
In response to challenges such as stop or reduce production costs, aging equipment and more competition, different
technologies such as Risk Based Inspection, adjustment in terms of maintenance and repair services with a focus on
reliability, spread over 15-10 years. Risk Based Inspection methodology uses risk for prioritization and management
of inspection programs.In these way inspection resources on devices with the highest risk (probability and
consequence of failure) is concentrated.With this technology, prioritizing inspection equipment, optimization of
inspection as well as the method and time of inspection programs is possible.Risk Based Inspection consequence of
improving safety, reducing halt production and ultimately reduce the cost of production.In this paper the general
principles of the method, described its role in improving inspection programs.
Key words: Risk Based Inspection, inspection programs, probability of failure, the consequences of failure, safety

INTRODUCTION
With time and increasing the life of a plant, order to plan, justify and interpret the results of
maintenance requirements (Maintenance the inspection, testing and monitoring its use. In
Requirements) is important. In order to improve this way, unlike traditional methods of inspection,
safety and achieve optimal adjustment of but there is no fixed time interval defined for each
investment in maintenance is required. In order to device, and method of inspection specified time
reduce the costs and benefits of a systematic interval determined. Using a Risk Based
inspection program is required. [1] Risk Based Inspection while is avoiding frequent inspections,
Inspection (Risk Based Inspection) from the early the inspection features and capabilities focused on
90's response to the need for oil, gas and devices with higher risk. [2,3] In Figure 1. The
petrochemical equipment to manage risk and number and cost of accidents occurring in three
prioritize based on risk was developed. Risk different decades (1990-1960) in crude oil refining
Based Inspection a new approach in the and petrochemical industries are shown.
management of inspection and risk assessment in

Figure 1 The number and cost of accidents caused crude oil refining and petrochemical industry in three different decades
 Technical Inspection Engineering and Risk Based Inspection in order to optimize inspection plans

As it showed above, over time, the number of terms in the refining of crude oil and
accidents and increased costs caused by them petrochemical industry in the years 1960-1990 is
were increased. These results indicate that given. As seen in the figure is the highest share in
traditional technologies cannot guarantee the waste of material and mechanical damage. Risk
safety and management of industrial units is Based Inspection has the greatest impact on
functioning without incident. The emergence and mechanical damage.The Risk Based Inspection
development of risk-based inspection management determines and identifies design errors before the
is therefore realistic view of such matters. In establishment of effective incident.
Figure 2, the main causes of waste in percentage

Figure 2. Causes of crude oil refining and petrochemical industry waste in percent
All the other techniques to Risk Based Inspection failure (Probability of Failure) method is very
and Safety were established based on risk. The accurate. [3]
output of these techniques for the input and output 2. Semi-quantitative method
Risk Based Inspection and Safety to improve risk- The risk assessment will be based on a clear set of
based techniques implemented by organizations is rules. For example, the predicted probability of
used. failure due to corrosion of the carbon dioxide wet
on the basis of the Standard Model De weardand
METHODOLOGY Milliams be determined. The accuracy of this
Process hazards analysis and risk-based method is affected by the quality of input data as
techniques and safety OSHA psm programs are an well as the inherent accuracy of the model. This
example. [3] API580 and API581 standards are method is a good way to Risk Based Inspection
three main methods of risk assessment.[3,4] and partly enjoys the benefits of both qualitative
-Qualitative Approach and quantitative methods. [3,5]
-Semi-quantitative method 3. Quantitative methods
-Quantitative methods This method is much more accurate than
1. Qualitative Approach qualitative approach and using it you may risk
Log data based on qualitative methods, descriptive calculated for each device or part of a pipeline.
information is available using the experience and Then, using the information available, the analysis
history. This method requires less detailed can be a comprehensive inspection determines a
information has, therefore, has its limits. This unit. Computer-based quantitative data to
method is generally used to prioritize important determine the probability of failure is history.
part of a unit or a unit used to study Quantitative What distinguishes qualitative and quantitative
Risk Based Inspection. Assuming correct input method in the input data and the accuracy of the
data, the method for determining the probability of data and the accuracy of the results is output.

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 Technical Inspection Engineering and Risk Based Inspection in order to optimize inspection plans

Figure 3 shows the outline of inspections based on assessment) done and finally develop and
risk and its relation to it. It is important to note implement risk-based inspection (Inspection Plan)
that drawing flowchart was general and it was not takes place.
based on the risk assessment methods Figure 3 shows the outline of inspections based on
(quantitative, qualitative or semi-quantitative). risk and its relation to it. To assess the probability
and consequence of failure, circuit design
RESULTS corrosion (Corrosion Loop Design) done. This
To assess the probability and consequence of design in an operational unit based on the type of
failure, circuit design corrosion (Corrosion Loop fluid, temperature, pressure and case material is
Design) done. This design in an operational unit formed. In Figure 4, a distillation unit in refinery
based on the type of fluid, temperature, pressure corrosion is circuits that each color represents a
and case material is formed. In Figure 4, a corrosion circuit. After determining the
distillation unit in refinery corrosion is circuits probability and consequence of failure, risk
that each color represents a corrosion circuit. After assessment and determine the degree of
determining the probability and consequence of deterioration Devices (Criticality risk assessment)
failure, risk assessment and determine the degree done and finally develop and implement risk-
of deterioration Devices (Criticality risk based inspection (Inspection Plan) takes place.

Figure 3. Schematic of risk-based inspection

Figure 4. A circuit corrosion of a refinery distillation unit

Risk Management is a risk assessment process Probability of Failure
and the development of risk control is an The possibility of failure in risk-based inspection,
acceptable value. Risk Reduction (Mitigation) is estimating the probability of one or more
only part of risk management. [3] mechanisms of degradation, is resulting in the
waste of materials and restrictions (Loss of

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 Technical Inspection Engineering and Risk Based Inspection in order to optimize inspection plans

Containment) . The evaluation of the degradation  Flammable Events

mechanisms that the device is sensitive to them  Toxic Releases
and places that have been undertaken over several  Environmental
different failure mechanisms, sensitive specified. Consequence
Types of corrosion mechanisms (internal,  Production Consequence
external, abrasion, corrosion fatigue, stress,  Maintenance and
welding, hydrogen sulfide wet) mechanisms creep Reconstruction Impact
damage hydrogen, softness at high and low Calculate Risk
temperatures as well as mechanisms The possibility of failure and the consequences of
sedimentation in evaluating the likelihood of failure are two basic parameters in determining
failure are examined. In general, the probability of the risk of a risk is determined by multiplying
failure is determined by considering the following them. [3,4,6]
two factors: Risk = Probability Consequence
1. D specific effect, risk calculation according
For each
egradation mechanisms and rate them as a to the following equation is determined:
result of working environment (internal and Risk of a Specific Consequence= (Probability of
external) devices. a Specific Consequence) (Specific
2. E
Consequence) Total risks calculated for each
ffectiveness of the Inspection Program,to particular outcome, will determine the overall
determine and monitor degradation risk. Most of calculated risks were highest
mechanisms (to replace or repair the damage. overall risk was almost time it. If the
[1,3] probability and consequence of failure is not
Consequence of Failure expressed as numerical values, probability and
The consequence of failure predicts the outcome consequence of failure risk by drawing on a risk
of a destruction device is evaluated. Assessing this matrix, is expressed.The following figure, a risk
factor can be done both quantitatively and matrix is a 3 × 3. If both are low probability and
qualitatively. Regardless of the method of consequence of failure is achieved the lowest
qualitative or quantitative, is the main factors that risk and with number 5 has been determined.
are considered in assessing the consequences of
failure as follow: [3,6]

Figure 5 .Risk matrix (to number isspecified high risk 1 and low risk with the number 5).
Obtain the optimum combination of distance and time of the inspection techniques; Risk Based Inspection
is one of the most important applications. By identifying the risk of each device, suitable inspection
techniques for each piece of equipment is determined. With a Risk Based Inspection, at the same value
search, the risk decreases. In Figure 7, risk management, using RBI and its effect on risk reduction

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 Technical Inspection Engineering and Risk Based Inspection in order to optimize inspection plans

compared to traditional inspection programs are shown. Due to the reduction of risks in RBI, inspection
activities focused on high-risk equipment.

Fig. 7 Risk Management Risk Based Inspection using.

Natural disasters, deliberate sabotage, destruction  Identification of

of unknown design errors and mechanisms, are potential damage mechanism
including factors that are causing this problem.  Identification of key process parameters
The ultimate goal is to determine the time of affecting degradation rates
inspection, is safe and compliant equipment  Potential Inspection and Maintenance cost
during operation. The Risk Based Inspection, with In addition to numerous advantages, Risk Based
a focus on according to the highest risk, better Inspection is limited in the following cases.[3,4]
communication between failure mechanisms and  Incorrect or inaccurate entry information.
efficiency of inspection on the appropriate  Improper design or installation errors related to
mechanisms, will be established. [3] equipment
RBI Benefits and Limitations  Incorrect process conditions
One of the main purposes of risk assessment is
 Incorrect implementation of inspection
efforts to reduce mechanical damage, cost and
programs
waste materials. In short the benefits of
 Lack of trained personnel or poor teamwork
establishing risk-based inspection are as follows:
 Lack of legislation related to processing
[1,3,5]
conditions and engineering information.
 Increased safety
 Sabotage
and equipment reliability
 Natural disasters and external events
 Prioritization of
 Unknown destruction mechanism
Inspection
 The inherent limitations of inspection methods
 Unplanned and
Planned shutdown
CONCLUSION
 Inspection
Risk Based Inspection methodology uses risk for
Effectiveness
prioritization and management of inspection
 Longer
programs. The inspection methods and resources
Inspection Interval
available on the devices with the highest risk
 Increased
(probability and consequence of failure) is
consistency in inspection
concentrated.
planning
With this technology, prioritizing inspection
equipment, optimization of the method and time

Mohammad Rezaie Narimisa, et al. 452

 Technical Inspection Engineering and Risk Based Inspection in order to optimize inspection plans

of inspection and inspection programs is possible. 3. API Recommended Practice 580, Risk-based
Risk Based Inspection consequence of improving Inspection, 1st edition, 2002.
safety, reducing halt production and ultimately 4. API Publication 581, Risk-based Inspection-
reduce the cost of production. Base Resource Document, 1st edition, 2000.
5. Reynolds J.T., The API Methodology for Risk
REFERENCES Based Analysis for the Petroleum and
1. Peterson R., Risk Based Inspection as Part of Petrochemical Industry, 1st Annual Symposium
an Overall Inspection Management Program, of the Mary Kay O’Connor Process Safety
Edmonton, Canada. Center, George Bush Presidential Conference
2. Tischuk J.L., Economic of Risk Based Center,Texas,1998.
Inspection and Maintenance, ERTC 6. Roberts I.P., Storage Tank Risk Based
Reliability, 2000. Inspection/Management, Tischuk International
Ltd., Aberdeen, Scotland.

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