DRAFT for Ballot Only Note to Balloters: This draft third edition ballot is open for comments on only the track changes sections, not the entire document. Changes that were accepted without comment during ballot resolution of the first and second ballots are also not open for comments on this ballot. Any changes outside of the track changes shown will be score-carded for future consideration, unless they are purely editorial. In accordance with the guidance recorded in the previous API 580 T/G meeting at the New Orleans Standards meeting, the primary changes in this third edition draft T relate to changing some recommended elements of the RBI work process to requirements, i.e. changing some “shoulds” to “shalls”; plus the addition of a new section up front that summaFrizes where those changes are in the document. All new “shalls” in this ballot were accepted in the second ballot and are no longer open for review in this ballot. When you review and comAment in the API Ballot website, please be sure to clearly mark the section number and paragraph that you are commenting upon or your comments may be lost. R D E E T T I M M O C 2 API RECOMMENDED PRACTICE 580 Foreword ....................................................................................................................................................................... 5 Introduction .................................................................................................................................................................. 7 1 Purpose ...................................................................................................................................................................... 8 1.1 General ................................................................................................................................................................. 8 1.2 Required Elements in RBI .................................................................................................................................. 9 1.3 RBI Benefits and Limitations ........................................................................................................................... 11 1.4 Using RBI as a Continuous Improvement Tool ............................................................................................. 12 1.5 RBI as an Integrated Management Tool ......................................................................................................... 12T 2 Scope ................................................................................................................................................................. 13 F 2.1 Industry Scope .................................................................................................................................................. 13 2.2 Flexibility in Application ................................................................................................................................... 13 A 2.3 Mechanical Integrity Focused .......................................................................................................................... 13 2.4 Equipment Covered .......................................................................................................................................... 13 R 2.5 Equipment Not Covered ................................................................................................................................... 14 2.6 Target Audience ................................................................................................................................................ 14 D 3 Normative References ...................................................................................................................................... 14 4 Terms, Definitions, Acronyms, and Abbreviations ............................................. .......................................... 15 4.1 Terms and Definitions ........................................................................................E.............................................. 15 4.2 Acronyms and Abbreviations .......................................................................................................................... 19 E 5 Basic Risk Assessment Concepts .................................................................................................................. 20 5.1 What is Risk? ..................................................................................................................................................... 20 T 5.2 Risk Management and Risk Reduction ........................................................................................................... 21 5.3 The Evolution of Inspection Intervals/Due Dates .......................................................................................... 21 T 5.4 Overview of Risk Analysis ............................................................................................................................... 21 5.5 Inspection Optimization ..................................................I................................................................................. 22 5.6 Relative Risk vs Absolute Risk ....................................M.................................................................................... 24 6 Introduction to Risk-Based Inspection ........................................................................................................... 24 6.1 Key Elements of an RBI Program ....................M................................................................................................ 24 Consequence and Probability for RBI 16 6.3 Types of RBI Assessment ................................................................................................................................ 26 6.4 Precision vs Accuracy ...................................................................................................................................... 31 6.5 Understanding How RBI Can Help to MOanage Operating Risks .................................................................. 31 6.6 Management of Risks ....................................................................................................................................... 33 6.7 Relationship Between RBI and OCther Risk-Based and Safety Initiatives ................................................... 34 6.8 Relationship with Jurisdictional Requirements ............................................................................................. 36 7 Planning the RBI Assessment ......................................................................................................................... 36 7.1 Getting Started .................................................................................................................................................. 36 7.2 Establishing Objectives and Goals of an RBI Assessment .......................................................................... 37 7.3 Initial Screening ................................................................................................................................................ 39 7.4 Establish Operating Boundaries ..................................................................................................................... 44 7.5 Selecting a Type of RBI Assessment .............................................................................................................. 45 7.6 Estimating Resources and Time Required ..................................................................................................... 45 8 Data and Information Collection for RBI Assessment .................................................................................. 47 8.1 General ............................................................................................................................................................... 47 8.2 RBI Data Needs ................................................................................................................................................. 47 8.3 Data Quality ....................................................................................................................................................... 48 8.4 Codes and Standards—National and International ....................................................................................... 49 8.5 Sources of Site Specific Data and Information .............................................................................................. 49 RISK-BASED INSPECTION 3 9 Damage Mechanisms and Failure Modes....................................................................................................... 51 9.1 Introduction ....................................................................................................................................................... 51 9.2 Damage Mechanisms ....................................................................................................................................... 53 9.3 Failure Modes .................................................................................................................................................... 53 9.4 Accumulated Damage ...................................................................................................................................... 53 9.5 Tabulating Results ............................................................................................................................................ 54 10 Assessing Probability of Failure ..................................................................................................................... 54 10.1 Introduction to Probability Analysis ............................................................................................................ 54 10.2 Units of Measure in the POF Analysis ......................................................................................................... 55 10.3 Types of Probability Analysis ........................................................................................................................ 56T 10.4 Determination of POF ..................................................................................................................................... 57 F 11 Assessing Consequences of Failure .............................................................................................................. 61 11.1 Introduction to Consequence Analysis ...........................................................................................A............. 61 11.2 Types of Consequence Analysis ................................................................................................................... 63 11.3 Units of Measure in Consequence Analysis ................................................................................................ 64 R 11.4 Volume of Fluid Released ............................................................................................................................. 69 11.5 Consequence Effect Categories ................................................................................................................... 69 D 11.6 Determination of Consequence of Failure ................................................................................................... 74 12 Risk Determination, Assessment, and Management .......................................... .......................................... 77 12.1 Purpose .............................................................................................................E.............................................. 77 12.2 Determination of Risk .................................................................................................................................... 77 12.3 Risk Management Decisions and Acceptable Levels of Risk ............E....................................................... 80 12.4 Sensitivity Analysis ....................................................................................................................................... 81 12.5 Assumptions ..................................................................................T................................................................ 81 12.6 Risk Presentation ........................................................................................................................................... 81 12.7 Establishing Acceptable Risk Thresholds ..........................T........................................................................ 84 12.8 Risk Management ........................................................................................................................................... 85 I 13 Risk Management with Inspection Activities ................................................................................................. 85 M 13.1 Managing Risk by Reducing Uncertainty Through Inspection ................................................................. 85 13.2 Identifying Risk Management Opportunities from RBI Results ................................................................ 86 13.3 Establishing an Inspection Strategy Based Mon Risk Assessment ............................................................ 87 13.4 Managing Risk with Inspection Activities ................................................................................................... 88 13.5 Managing Inspection Costs with RBI ........................................................................................................... 89 O 13.6 Assessing Inspection Results and Determining Corrective Action ......................................................... 89 13.7 Achieving Lowest Life Cycle Costs with RBI .............................................................................................. 89 C 14 Other Risk Mitigation Activities ....................................................................................................................... 90 14.1 General ............................................................................................................................................................ 90 14.2 Equipment Replacement and Repair ........................................................................................................... 90 14.3 Evaluating Flaws for Fitness-For-Service ................................................................................................... 90 14.4 Equipment Modification, Redesign, and Rerating ...................................................................................... 90 14.5 Emergency Isolation ...................................................................................................................................... 91 14.6 Emergency Depressurizing/Deinventorying ............................................................................................... 91 14.7 Modify Process ............................................................................................................................................... 91 14.8 Establish Integrity Operating Windows ....................................................................................................... 92 14.9 Reduce Inventory ........................................................................................................................................... 92 14.10 Water Spray/Deluge ..................................................................................................................................... 92 14.11 Water Curtain ................................................................................................................................................ 92 14.12 Blast-resistant Construction ....................................................................................................................... 93 14.13 Others ............................................................................................................................................................ 93 15 Reassessment and Updating RBI Assessments ........................................................................................... 94 15.1 RBI Reassessments ....................................................................................................................................... 94 4 API RECOMMENDED PRACTICE 580 15.2 Why Conduct an RBI Reassessment? ......................................................................................................... 94 15.3 When to Conduct an RBI Reassessment .................................................................................................... 96 16 Roles, Responsibilities, Training, and Qualifications ................................................................................... 96 16.1 Team Approach .............................................................................................................................................. 96 16.2 Team Members, Roles, and Responsibilities .............................................................................................. 97 16.3 Training and Qualifications for RBI Application ......................................................................................... 99 17 RBI Documentation and Recordkeeping ...................................................................................................... 100 17.1 General .......................................................................................................................................................... 100 17.2 RBI Methodology .......................................................................................................................................... 101 T 17.3 RBI Personnel ............................................................................................................................................... 101 17.4 Time Frame ................................................................................................................................................... 101 F 17.5 Basis for the Assignment of Risk ............................................................................................................... 101 17.6 Assumptions Made to Assess Risk ................................................................................................A........... 102 17.7 Risk Assessment Results ........................................................................................................................... 102 17.8 Mitigation and Follow-up ............................................................................................................................. 102 R 17.9 Applicable Codes, Standards, and Government Regulations ................................................................. 102 18 Summary of RBI Pitfalls ...................................................................................................D.............................. 103 18.1 General .......................................................................................................................................................... 103 18.2 Planning ................................................................................................................ ........................................ 103 18.3 Data and Information Collection .....................................................................E............................................ 103 18.4 Damage Mechanisms and Failure Modes .................................................................................................. 103 18.5 Assessing POF ........................................................................................E..................................................... 104 18.6 Assessing Consequence of Failure ........................................................................................................... 104 18.7 Risk Determination, Assessment, and Management .................T.............................................................. 105 18.8 Risk Management with Inspection Activities ............................................................................................ 105 18.9 Other Risk Management Activities .......................................T...................................................................... 106 18.10 Reassessment and Updating RBI Assessment ...................................................................................... 106 18.11 Roles, Responsibilities, Training, and QualificationIs for RBI Team Members .................................... 106 18.12 RBI Documentation and Recordkeeping ...............M.................................................................................. 107 Figures 1 Management of Risk Using RBI .......................M................................................................................................ 24 2 Risk Plot ............................................................................................................................................................. 26 3 Continuum of RBI Approaches........................................................................................................................ 27 O 4 Risk-Based Inspection Planning Process ...................................................................................................... 31 5 Determination of Consequence of Failure ..................................................................................................... 75 6 Example of Calculating the ProbCability of a Specific Consequence ........................................................... 79 7 Example Risk Matrix Using Probability and Consequence Categories to Display Risk Rankings .......... 83 8 Risk Plot when Using Quantitative or Numeric Risk Values ........................................................................ 84 Tables 1 Three Levels of POF ......................................................................................................................................... 55 2 Six Levels of POF .............................................................................................................................................. 56 3 Six Level Table .................................................................................................................................................. 66 4 Three Level Safety, Health, and Environmental Consequence Categories ................................................ 68 5 Six Level Safety, Health, and Environmental Consequence Categories .................................................... 68 Bibliography ............................................................................................................................................................. 108 RISK-BASED INSPECTION 5 Foreword This recommended practice (RP) is intended to provide guidance on developing a risk-based inspection (RBI) program for fixed equipment and piping in the hydrocarbon and chemical process industries. It includes: a) What is RBI b) What are the key elements of RBI T c) How to implement an RBI program F d) How to sustain an RBI program A It is based on the knowledge and experience of engineers, inspectors, risk analysts, and other personnel in the hydrocarbon and chemical industry. R Shall: As used in a standard, “shall” denotes a minimum requirement in order to conform to thDe specification. Should: As used in a standard, “should” denotes a recommendation or that which is adv ised but not required in order E to conform to the specification. E This Standard RP is intended to supplement API 510, API 570, and API 653. These API inspection codes and standards allow an owner-user latitude to plan an inspection strategy andT increase or decrease the code designated inspection frequencies and activities based on the results of an RBI assessment. The assessment shall systematically evaluate both the POF and the associated conseqTuence of failure (COF). The POF assessment should be evaluated by considering all credible damage mechanisms. Refer to the appropriate code for other RBI assessment requirements. This Standard RP is intended to seIrve as a guide for users in properly performing such an RBI assessment. M The information in this Standard RP does not constituMte and should not be construed as a code of rules, regulations, or minimum safe practices. The practices described in this publication are not intended to supplant other practices that have proven satisfactory, nor is this publication intended to discourage innovation and originality in the O inspection of hydrocarbon and chemical facilities. Users of this Standard RP are reminded that no book or manual is a substitute for the judgment of a responsible, qualified inspector or engineer. C Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent. This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which this publication was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director. Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from 6 API RECOMMENDED PRACTICE 580 the API Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005. Suggested revisions are invited and should be submitted to the director, Standards Department, American Petroleum Institute, 1220 L Street, NW, Washington DC 20005, [email protected]. T F A R D E E T T I M M O C RISK-BASED INSPECTION 7 Introduction This Standard Recommended Practice (RP) contains both minimum program requirements to qualify for establishing inspection intervals based on RBI analysis versus rule-based (e.g. ½ life) requirements, and provides additional suggested guidelines on using risk analysis to develop an effective inspection plan. The use of risk based methodologies for inspection planning is not compulsory; they are optional, subject to the requirements and limitations of the other Inspection Codes (510, 570 and 653) and this StandardRP. Inspection planning is a systematic process that begins with identification of facilities or equipment and culminates in an inspection plan. T The output of an RBI assessment conducted according to this Standard RP is an inspection plan for each piece or group of equipment assessed, which should include the following: F A a) Identified risk drivers R b) Inspection methods that should be used D c) Extent of inspection (percent of total area to be examined or specific locations) E d) Inspection interval or next inspection date (timing) E e) Other risk mitigation activities T f) Residual level of risk after inspection and other mitigation aTctions have been implemented I The RBI plan produced according to the guidance herein, coMmbined with a comprehensive set of Integrity Operating Windows (IOWs) for each process unit and a rigorous MOC program should provide the basis for sound management of the integrity of fixed equipment in the refining and petrochemical process industry. M RBI is synonymous with risk-prioritized inspection, risk-informed inspection and with inspection planning using risk- based methods. O C 8 API RECOMMENDED PRACTICE 580 Risk-Based Inspection API STANDARD RECOMMENDED PRACTICE 580 THIRD EDITION, XXX, 2013 Risk-Based Inspection Downstream Segment API 580 T THIRD EDITION, XXX 2013 F A Risk-Based Inspection R D 1. Purpose 1.1 General E E The purpose of this document is to provide users with the basic minimum and recommended elements for developing, implementing, and maintaining a risk-based inspection (RBTI) program. It also provides guidance to owner-users, operators, and designers of pressure-containing equipment for developing and implementing an inspection program. These guidelines include means for assessTing an inspection program and its plan. The approach emphasizes safe and reliable operation through risk-prioritized inspection. A spectrum of complementary risk analysis approaches (qualitative through fully quantitative) Ican be considered as part of the inspection planning process. RBI guideline issues covered include an introduMction to the concepts and principles of RBI for risk management; and individual sections that describe the steps in applying these principles within the framework of the RBI process include: M a) Understanding the design premise O b) Planning the RBI assessment C c) Data and information collection d) Identifying damage mechanisms and failure modes e) Assessing probability of failure (POF) f) Assessing consequence of failure (COF) g) Risk determination, assessment, and management h) Risk management with inspection activities and process control RISK-BASED INSPECTION 9 i) Other risk mitigation activities j) Reassessment and updating k) Roles, responsibilities, training, and qualifications l) Documentation and recordkeeping T The expected outcome from the application of the RBI process should be the linkage of risks with appropriate inspection, process control or other risk mitigation activities to manage the risks. The RBI process is capable of F generating: A a) A ranking by relative risk of all equipment evaluated R b) A detailed description of the inspection plan to be employed for each equipment item, including: D 1. Inspection method(s) that should be used [e.g. visual, ultrasonic (UT), radiography, wet fluorescent magnetic particle E E 2. Extent of application of the inspection method(s) (e.g. percent of total area examined or specific locations) T 3. Timing of inspections/examinations (inspection intervals/due dates) T 4. Risk management achieved through implementation of the inspection plan I M c) A description of any other risk mitigation activities [such as repairs, replacements or safety equipment upgrades, equipment redesign or maintenance, IOWs, and controls on operating conditions M d) The expected risk levels of all equipment after the inspection plan and other risk mitigation activities have O been implemented C e) Identification of risk drivers 1.2 Required Elements in RBI This Standard RP contains both minimum program requirements to qualify for interval extension beyond rule-based (½ life) requirements and provides additional suggested guidelines on using risk analysis to develop an effective risk based inspection program. In general, the required elements / attributes of conducting an RBI analysis per this standard RP include the following: Work Process requirements (see Section 17): a) Management system to implement and sustain RBI program shall include: 1. Procedures covering iImplementation, mMaintenance & rReassessment 10 API RECOMMENDED PRACTICE 580 2. Roles / responsibilities, experience / training requirements 3. Documented assumptions and tTimeframe for RBI analysis applicability 4. Data requirements 5. Acceptable risk limits and thresholds T 6. Program audit requirements F b) Scope and boundary limits for RBI analysis shall be documented A c) Full reassessment conducted at a defined intervals R d) Team approach utilizing multiple discipline, qualified personnel D 1. Shall have a qualified corrosion specialist involved to identify damage mech anisms (see Section 16.2.4) E e) Data inputs shall be validated by qualified personnel (e.g. process eEngineer/operator to review operating parameters used), as described in Section 8.3 and 9.1.1 T 1.2.1 POF Analysis (Section 10): T a) Equipment design (pressures, temperature and mateIrials of construction) and current condition shall be considered (see Section 10.4.2) M b) All credible equipment operating conditions M(e.g. normal process, upset conditions, start-up, idle) shall be considered O c) Identify/consider all credible damage mechanisms for POF based on design and operating conditions C d) Identify/consider the prior inspection records where available (probability of identifying and detecting deterioration with inspection technique), as described in Section 10.4.4 1.2.2 COF Analysis (Section 11): a) All credible operating conditions (e.g. normal process, upset conditions, start-up, idle) shall be considered b) COF calculations steps shall identify and/or consider an estimate of the consequences (see Section 11.1). c) COF evaluations shall account for the following possible outcomes (see Section 11.5.1): 1. Flammable events (fire and explosion)