Risk Based Inspection Study Challenges - An EPC Contractor's Perspective

Abstract

1.0 Abstract In order to develop an effective inspection program for the early operational phase, Risk Based Inspection (RBI) study is included as a standard requirement in recent EPC Oil & Gas Projects. Conventionally, RBI study was managed by Operators, however nowadays EPC contractors are mandated to execute the same. This paper discusses the challenges faced by EPC Contractor during the execution of RBI study and provides an approach for timely completion of study. RBI study involves enormous data gathering and risk assessment to identify critical equipment, piping systems to optimize inspection programs and recommends inspection frequencies, locations and techniques. In addition, RBI study covers potential damage mechanisms identification, risk ranking and identification of potential hot spots for development of inspection program. RBI is normally performed based on risk assessment methodologies derived from International Standards such as API 580/581, DNV RP G101and applicable Operator guidelines. Specialized software is widely used for carrying out integrated activities involving failure probability, consequence assessment and inspection details. Finally, RBI inspection programs are integrated with Computerized Maintenance Management System. In order to execute RBI study successfully, a specialized third-party Consultant is normally engaged., Further alignment of all stakeholders including RBI study specialist is essential to address the following: - Timely availability of "As-built" data for study such as baseline inspection survey reports Agreement on design data versus baseline inspection data for RBI analysis Agreement on appropriate RBI approach: quantitative vs. semi-quantitative/qualitative Acceptance of RBI software Agreement on inspection program recommendations including hot spots, inspection intervals RBI study activities can be effectively initiated once the equipment fabrication records, piping isometrics, baseline reports and hydro-test data are available. In case of pipelines, inline inspection data should be the initial basis for the pipeline RBI assessment. EPC contractors normally face following challenges during RBI study execution: Delay in finalizing the study due to lack of "As-built" data Inconsistency between the outcomes of Corrosion Risk Assessment Study and RBI study performed by third party due to different corrosion modeling software Implications on selected material of construction as a result of RBI Study findings Ensuring compatibility of RBI templates with Operators CMMS. NPCC, as a large EPC company, has extensive experience in various Oil & Gas projects where RBI studies are developed in recent EPC projects and ensuring the integrity of the newly constructed assets. This paper attempts to address the challenges faced by EPC Contractor during execution of RBI studies; emphasizing the strategic considerations to be adopted for successful and timely completion of the study, providing benefits to the End users.