1、 THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION Risk Based Inspection A Guide to Effective Use of the RBI Process PUBLICATION No 206 : 2006 Copyright 2006 The Engineering Equipment and Materials Users Association ISBN 0 85931 150 3 10-12 Lovat Lane London EC3R 8DN Telephone: +44 (0)20 762
2、1 0011 Fax: +44 (0)20 7621 0022 E-mail: saleseemua.org Website: www.eemua.org EEMUA Publication 206 A guide to effective use of the RBI process - EEMUA THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATIONThe Engineering Equipment and Materials Users Association (EEMUA) was formed in London in 1
3、983 by the amalgamation of the Engineering Equipment Users Association (EEUA) with the Oil Companies Materials Association (OCMA). Members are drawn mainly from process plant operating companies in the oil and gas sector, chemical and allied industries, and from the energy and power generating secto
4、r, plus companies that specialise in providing engineering services to support such organisations. Membership is open to companies of all sizes that share the common interest of users of engineering equipment and materials and that meet the admission criteria. EEMUA Member Companies at the time of p
5、ublication include: ABB Engineering Services, AstraZeneca, BASF, BP, Chevron, ConocoPhillips, Dow Corning, E.ON, ExxonMobil, Foster Wheeler Energy, Huntsman Petrochemicals, Hydro, Innospec, Johnson Matthey, Royal Vopak, RWE npower, Shell, Syngenta, Total. Objectives of the Association are: - To prov
6、ide a structure and organisation within which Member companies can cooperate and collaborate on non-competitive matters. - To encourage and facilitate the development and application of common user best practices, standards and specifications. - To keep members informed of forthcoming changes to leg
7、islation, regulation and standards likely to impact their businesses. - To provide a route through which Member companies can participate in the work of national and international Standards organisations. - To represent the users view on engineering issues to legislative, regulatory and other bodies
8、, to suppliers and the rest of industry. EEMUA supports the British Standards Institution, works with other institutions, associations, Government departments, regulatory authorities and the Confederation of British Industry, and also has links with other standards-making bodies such as the American
9、 Society of Mechanical Engineers and the American Petroleum Institute. EEMUA activities may lead to the production of Association publications. These are prepared primarily for Members use, but may be offered for sale as well. Such publications may also be submitted by EEMUA, normally through the Br
10、itish Standards Institution, as the bases for appropriate national, European or international standards. A list of EEMUA publications is given at the end of this publication. The full list is also on the Associations website at www.eemua.org, together with on-line shopping facilities. To enquire abo
11、ut Membership, write to infoeemua.org or call +44 (0)20 7621 0011. iiEEMUA Publication 206 A guide to effective use of the RBI process - EEMUA ABOUT THIS PUBLICATION Legal Aspects In order to ensure that nothing in this publication can in any manner offend against or be affected by the provisions of
12、 the UK Restrictive Trade Practices Act 1976, the recommendations which it contains will not take effect until the day following that on which its particulars are furnished to the UK Office of Fair Trading. As the subject dealt with seems likely to be of wide interest, this publication is also being
13、 made available for sale. Any person who encounters an inaccuracy or ambiguity when making use of this publication is asked to notify EEMUA without delay so that the matter may be investigated and appropriate action taken. It has been assumed in the preparation of this publication that the user will
14、 ensure selection of those parts of its contents appropriate to the intended application and that such selection and application are correctly carried out by appropriately qualified and competent persons for whose guidance the publication has been prepared. EEMUA does not, and indeed cannot, make an
15、y representation or give any warranty or guarantee in connection with material contained in its publications, and expressly disclaims any liability or responsibility for damage or loss resulting from their use. Any recommendations contained herein are based on the most authoritative information avai
16、lable at the time of writing and on current good engineering practice, but it is essential for the user to take account of pertinent subsequent developments and/or legislation. All rights, title and interest in this publication shall belong to EEMUA. All rights are reserved. No part of this publicat
17、ion may be reproduced, stored in a retrieval system, or transmitted in any form or by any means: electronic, mechanical, photocopying, recording or other. Infringement of copyright is not only illegal, but also reduces the Associations income thereby jeopardising its ability to fund the production o
18、f future publications. Consultation and Feedback EEMUA encourages comments on this publication from both Members and non-members of the Association. Comments should be sent on the standard feedback form, a copy of which is provided towards the end of this publication. An electronic version (MS-Word
19、document) of the form is available from EEMUA - e-mail your request for a copy to infoeemua.org, telephone your request to +44 (0)20 7621 0011, or download the form from the EEMUA website at www.eemua.org. Submit comments by e-mail (preferred) or post. Comments will be considered by the relevant EEM
20、UA Technical Committee and may be incorporated in future editions of the publication. New editions will be publicised on the EEMUA website. iiiEEMUA Publication 206 A guide to effective use of the RBI process - EEMUA ivEEMUA Publication 206 A guide to effective use of the RBI process - EEMUA Content
21、s Foreword.1 1. Assessing the requirements for risk-based inspection3 1.1 Is RBI for us? .3 1.2 Definition of systems and sub-systems4 2. RBI team and responsibilities6 2.1 Team composition6 2.2 Recording results .6 3. Assembly of the plant database 7 4. Analysis phase 9 5. How to develop an inspect
22、ion plan11 6. Achieving effective and reliable examination 12 7. Assessment of examination results and anticipated future service.14 8. The feedback loop.15 9. Audit and review of the integrity management process.16 10. Conclusion.16 11. References17 12. Related EEMUA Publications17 Feedback Form .1
23、8 EEMUA Publications Catalogue vEEMUA Publication 206 A guide to effective use of the RBI process - EEMUA viEEMUA Publication 206 A guide to effective use of the RBI process - EEMUA Foreword The British Health and Safety Executive (HSE) is interested in the application of the risk-based inspection (
24、RBI) process across industry. The EEMUA Committee of User Inspectorates (CUI) believes that, whilst the RBI process is seen as an important methodology for identifying and targeting inspection programmes, further guidance on good practice and its application is warranted. The EEMUA CUI therefore set
25、 up a Working Group with the objective of producing this document to give general guidance for those interested in applying or developing an RBI approach to inspection. This guidance has been produced predominantly for application on pressure systems and equipment, but it is considered that the guid
26、ance is also of use to all those involved in risk-based inspection of other mechanical plant. The basic premise is that the integrity of industrial plant, or other such asset, can be determined and monitored consistently by using risk-based methodologies. This EEMUA document has been developed to as
27、sist in the interpretation and use of the HSE Report CRR 363/2001 Best Practice for Risk Based Inspection as a Part of Plant Integrity Management. This HSE document incorporates as Appendix B an audit tool that allows users to assess their own RBI system. This is also the tool the HSE will use to as
28、sess Users RBI systems in the workplace. Mechanical integrity is maintained by operating industrial plant within defined limits and executing process monitoring, fabric maintenance and inspections with suitable techniques, location and frequency. The inspection techniques can be either non-invasive
29、or invasive and may be applied when the plant is in-service or out of service. The inspection intervals derived from the RBI procedure may be longer or shorter than the calendar-based inspection interval previously prescribed by legislation. In such cases, the results of the RBI study will need to b
30、e supported by a comprehensive audit trail to enable a third party to assess the engineering judgement that supports the proposed inspection plan. There is not an intention here to comment on, or place support with, any of the methods of RBI currently being used within industry. Both qualitative and
31、 semi-quantitative assessment are of value when used correctly. However, in either case: The selected process needs to be consistent in its application. The selected processes should be transparent and auditable. The team competency and the RBI assessment process has to lend itself to the identifica
32、tion of all potential and active degradation mechanisms applicable to each item of plant. The resulting inspection plan and interval needs to be such that the residual risk for each of the identified damage mechanisms is within defined acceptable limits. 1EEMUA Publication 206 A guide to effective u
33、se of the RBI process - EEMUA Inspections need to be both effective in locating defects and capable of identifying the likely damage mechanisms. The end result of the RBI process should be a complete and thorough inspection and process monitoring plan for an asset. The plan should result in: Increas
34、ed reliability, safety and availability RBI is a proactive tool for identifying critical items of equipment. Better understanding of the probability and consequences of failure will lead to more effective means of control being practised. This will directly reduce the susceptibility to failure; and
35、as a result will directly increase the safety, reliability and availability of the asset. Reduced scope of work for shutdown inspection RBI provides the analysis for lengthening or shortening inspection intervals and / or reducing the maintenance and inspection scope of the less critical items. Addi
36、tionally, many equipment items may be monitored by in-service methods instead of the traditional out of service methods. This can result in shorter and / or less frequent shutdowns, which has several benefits. It reduces direct costs and allows higher unit availability. It will also eliminate the ri
37、sks associated with preparing, entering and reinstating items of equipment when the work is not essential. In cases where degradation is found, on-line monitoring can help to scope any remedial work that is necessary before the routine total plant maintenance shutdown. The RBI process selected must
38、be implemented in accordance with any regulations governing the particular industrial plant or system concerned. A number of standards and guidance documents are available and are listed in the reference section of this document. An audit trail showing all the decision processes has to be establishe
39、d and maintained. RBI can be used to manage both SHE (Safety, Health inspection reports that simply say “satisfactory as seen“ and lack detail, where there is poor control or knowledge of the process, or where there is no evidence of systematic documentation of repairs and process changes: these are
40、 all warning signs of deficient databases. 7EEMUA Publication 206 A guide to effective use of the RBI process - EEMUA An effective change-management system should also be in place, and tested by the RBI team. The change-management system should cover both equipment and process conditions. Without an
41、 effective change-management system, the quality and completeness of the data will be impossible to maintain. Where there are gaps or deficiencies in the plant database, the RBI team should evaluate the following before proceeding with an RBI assessment: Does the missing data make an RBI assessment
42、impractical? Can additional measures be taken to compensate for the missing data? Can inspections or testing be conducted to provide the missing data? Notes: Responsibilities and database 8EEMUA Publication 206 A guide to effective use of the RBI process - EEMUA 94. Analysis phase The duty holder or
43、 legally responsible person needs to assess ALL stages of the risk analysis. This may cover accident scenarios, deterioration mechanisms, definition of risks and uncertainties. The flow diagram in this Section (see next page) is based on the information provided to the RIMAP (Risk Based Inspection a
44、nd Maintenance Procedures for European Industry) project1and details the information flow in an RBI assessment and through its implementation. As with all stages of the RBI process, an auditable trail has to be established and documented. A process for peer review of the assessments has to be record
45、ed. An expert team will carry out most RBI assessments. These assessments will often be based on a qualitative risk-matrix approach. However, there are a number of other methodologies available for consideration. This publication does not endorse any particular method of assessment. All credible fai
46、lure scenarios need to be considered, and recorded. The record should contain sufficient detail to show which scenarios were considered. The assessment review should establish all mechanisms for damage or deterioration, and all failure modes. For each of the identified damage mechanisms applicable t
47、o an item, the analysis of failure probability and consequence, and hence risk for each credible failure scenario, has to be assessed using the selected RBI methodology approved by the site. Any amendments or changes need to be treated with the same rigour as the original assessment. There needs to
48、be a proven and demonstrated understanding of how any rankings have been made. An arbitrary decision process is not sufficient. The organisation that owns or manages the plant assets concerned has to decide and record what each level of risk means and what is acceptable. 1Risk Based Inspection and M
49、aintenance Procedures for European Industry (RIMAP) was a project partly financed by the European Commission Growth Programme, Contract Number G1RD-CT-2001-03008 and partly by industry partners. EEMUA Publication 206 A guideto effective use of the RBI process - EEMUA EEMUA Publication 206 - Guide to effective use of the risk-based inspection process - EEMUA Identifyequipment, defineboundariesGet history of equipment :-y Constructiony Operatingy Maintenancey InspectionSel
