Definisi RBI:
Menaikan Safety
Mengurangi Inspection dan Maintenance Cost
Memaksimalkan Produksi
Bisa diterapkan untuk peralatan baru maupun
peralatan lama/tua
Menghindari Catastrophic Failures
Mengganti Fixed Inspection Intervals ke
interval inspeksi berbasis tingkat resiko alat
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Non-pressurized equipment:
RISK
Probability
Consequence
X
of failure (PoF)
of failure (CoF)
Electrical systems.
Structural systems.
Machinery components (kecuali Pump casing dan
Compressor casings)
Likelihood / Probability of
Failure (PoF)
Perhitungan PoF diperoleh dari:
Historical Data
Calculation of degradation
Expert Assessment
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Tinjauan Consequence :
Safety: Loss of life due to Fire, Explosion, Toxic effects
Economic: Financial loss from lost production, Damaged
equipment, Rebuilding cost
Environmental: Damage to environment due to release
Reputation
Sekitar setengah
dari kehilangan
fluida proses di
dalam Refinary dan
Process Plant
dipengaruhi oleh
Aktifitas Inspeksi
yang melibatkan:
Tingkat Efektifitas
Jenis Inspeksi,
Cakupan Luas
Inspeksi, dan
Interval
Tujuan RBI
Prioritisasi Alat/Komponen
ber Resiko Tinggi
WHAT to inspect
Menentukan Jenis
Mekanisme
Kerusakan/Degradasi
WHEN to inspect
HOW to inspect
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Tujuan Inspeksi
Pendekatan Traditional
Pendekatan Risk-Based
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Tipe Alat.
Jenis Material Konstruksi.
Data rekaman Inspection, Repair, dan Replacement.
Komposisi Fluida Proses.
Inventory of fluids.
Kondisi Operasi.
Sistem Pengaman, Safety systems.
Sistem Deteksi, Detection systems.
Mekanisme Kerusakan, laju, dan severity.
Data Kepadatan Personel.
Data Coating, cladding, dan insulation.
Ongkos akibat Business Interruption.
Ongkos akibat penggantian alat.
Ongkos perbaikan Lingkungan yang tercemar.
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GIGO
GIGO
(Garbage In Garbage Out)
RBI
Assessment
32
API 581
Pendekatan Kualitatif
Analisa RBI Kualitatif
(Screening)
Tingkat Evaluasi
Unit2 di dalam satu Plant
Major Area atau Functional Section di dalam satu
Unit
Suatu Sistem
Kegunaan/Fungsi
Screening thd Unit2 di dalam satu Plant Site
Kategorisasi Tingkat RISK dari Unit2 dan
pemetaan RISK unit pada Risk Matriks
Identifikasi Area yang beresiko tinggi
API 581
Pendekatan Kualitatif
Likelihood
Category
Consequence Category
Category
RISK = Likelihood
(Sum of factors affects the
(lanjutan)
RISK
Damage Consequence
Category
Consequence
Category
Health Consequence
Category
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Likelihood
Factor
PoF
0 15
16 25
26 35
36 50
51 75
Flammable
Consequence
Factor
Damage
Consequence
Category (CoF)
0 15
16 25
26 35
36 50
51 75
3.
4.
Health Consequence
Health Consequence
Factor
Category (CoF)
0 15
16 25
26 35
36 50
51 75
API 581
Analisa KUANTITATIF
Tingkat Analisa
Setiap Equipment dan Pipe Segment di
dalam semua Unit
Kegunaan/Fungsi
Prioritisasi Equipment berdasarkan
Potensial Resikonya
Untuk menyusun Inspection Plan yang
komprehensif untuk setiap Unit
Analisa RBI
Kuantitatif
API 581
Analisa KUANTITATIF (lanjutan)
of
RISK= Probability
Failure
Consequence of
Failure
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Equipment
Modification
Factor
Management
System
Evaluation
Technical ModuleFactor
Subfactor
Universal Subfactor
Plant condition
Cold weather
Seismic activity
Process Subfactor
Continuity
Stability
Relief valves
Damage rate
Inspection
effectiveness
Mechanical Subfactor
Equipment complexity
Construction code
Life cycle
Safety factors
Vibration monitoring
TMSF
Damage Factors
Influenced by
Inspection Effectiveness
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c. Maintenance. d. Safety.
g. Engineering.
Semi Quantitative
Consequence of Failure (CoF)
Release Duration for Each Hole Size
Leak Type for Each Hole Size
Flammable/Explosive Consequence
Toxic Consequence
Environmental Consequence
Determined Unit
Volume Cleanup Cost
Business Interruption
loss /each hole size
Bussiness Interruption
Estimate
Release Rate
Hole sizes
Determine if Release is
Continuous or Instantaneous
Determine if Fluid Disperses
as a Liquid or a Gas
ASSESS MITIGATION
FLAMMABLE, TOXIC, BUSINESS, ENVIRONMENTAL
CONSEQUENCES
Total mass
available for
release
Cost of the
equipment
in the facility/ft2
Flammable
consequence
(area of
equipment lost)
Resulting downtime
due to damage
(days)
Unique equipement
failure
(Extended shutdown day)
Potential flammable
event to damage
neighboring critical
equipment
Bussiness
outage day
Loss/day (if the unit/facility shutdown)
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Financial Consequence
Medium High
Low
High
Risk
Limit
Medium
Consequence category
CoF
Categories
Consequence
Categories
Consequence Area
Risk Categories
IV
PoF
Categories
Consequence Cost
< 10
ft2
$ 0 $10 M
10 100 ft2
$10 M $ 100M
$100 M $1 MM
III
$1 MM $10 MM
12-16
>10000 ft2
> $10 MM
II
Quantitative
POF (/year)
One word
descriptor
Improbable
< 10-6
Remote
10-6 10-4
10-3
Significant
Medium
Low
5-10
PoF
Categories
10-4
High
17-25
Description
Rare
Probable
10-3 10-1
Frequent
> 10-1
I
1-4
Risk Management
Risk Management Process dimulai dan didasarkan
pada Risk Ranking dan Risk Limit dari setiap
alat.
Untuk alat dengan Risk yang Acceptable, maka
TIDAK diperlukan mitigasi atau tindakan penting
lainnya.
Untuk alat dengan Risk yang Unacceptable, maka
diperlukan mitigasi antara lain dengan:
Decommission: Apakah memang alat tsb betul2 sbg alat
utama dari operasi suatu unit ?
Inspection/condition monitoring: Apakah inspeksi dan
perbaikan dari hasil program inspeksi dapat diterapkan utk
mengurangi RISK hingga dapat level yang diterima ?
Consequence mitigation: Apakah tindakan yg diambil dapat
mengurangi konsekuensi thd kegagalan alat ?
Probability mitigation: Apakah tindakan yg diambil dapat
mengurangi PoF, misal perubahan aspek metallurgy atau
equipment redesign?
Technical Module
Subfactor (TMSF) atau
DAMAGE FACTOR (DF)
(Faktor Kerusakan yang
dipengaruhi oleh Inspection
Program)
10
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11
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Caustic Cracking
Amine Cracking
SSC/HIC/SOHIC
Carbonate Cracking
Polythionic Acid Cracking (PTA)
Chloride Stress Corrosion Cracking
(ClSCC)
g. Hydrogen Stress Cracking (HSC-HF,
HIC/SOHIC-HF)
7. Equipment Lining
8. External damage
a. External Corrosion of Carbon and Low
Alloy Steels
b. Corrosion Under Insulation (CUI) for
Carbon and Low Alloy Steels
c. External SCC of Austenitic Stainless Steels
d. External CUI SCC for Austenitic Stainless
Steels
12
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TMSF Thinning
Objective
Equipment Cover
Equipment Orientation
Inspection Method
13
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14
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TM
UT
PT
LRGW
VE
ECI
PEC
RT
TERIMA KASIH
15