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1、 GUIDE FOR SURVEYS USING RISK-BASED INSPECTION FOR THE OFFSHORE INDUSTRY DECEMBER 2003 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 Copyright 2003 American Bureau of Shipping ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA Copyright American Bur
2、eau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:37:42 MDTNo reproduction or networking permitted without license from IHS -,-,- This Page Intentionally Left Blank Copyright American Bureau of Shipping Provided by IHS under license wi
3、th ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:37:42 MDTNo reproduction or networking permitted without license from IHS -,-,- ABS GUIDE FOR SURVEYS USING RISK-BASED INSPECTION FOR THE OFFSHORE INDUSTRY . 2003 3 Foreword This Guide contains the technical requirements and criteria
4、 employed by ABS to consider alternate Survey arrangements using Risk-Based Inspection (RBI) approaches for offshore installations. It is applicable to static pressure retaining equipment, and structures for offshore floating and fixed-base platforms. ABS supports the implementation and use of RBI t
5、echnologies as a means for optimizing inspection resources, while maintaining or perhaps lowering levels of risk. ABS recognizes the benefits that RBI can bring to an asset and makes provision within its rules for classification of assets, accordingly, thus allowing RBI to be utilized as an alternat
6、ive for the Owner to maintain ABS classification for the asset. This Guide has been written for worldwide application and, as such, installation specific data, analyses and plans are generally required to demonstrate the adequacy of the RBI plan. It is not the intention of this Guide to impose requi
7、rements or practices in addition to those that have previously proven satisfactory in similar situations. This ABS Guide does not inhibit the use of any technological approach that can be shown to produce an acceptable service performance during the life of the structure with the risks understood an
8、d appropriately controlled. The application of this Guide does not cover any statutory survey requirements that may apply to the installation being considered (e.g., MODU code, SOLAS, MARPOL, coastal state regulations, etc.). Although ABS is authorized to perform statutory surveys on behalf of some
9、authorities, ABS is not in a position to alter or waive them. The cognizant administration or regulatory body is the final determining body for statutory or regulatory requirements under their jurisdiction. The Owner shall ensure that in developing the RBI plan, due consideration is given to Coastal
10、 and Flag State requirements. Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:37:42 MDTNo reproduction or networking permitted without license from IHS -,-,- This Page Intentionally Left Blank Copyright American
11、 Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:37:42 MDTNo reproduction or networking permitted without license from IHS -,-,- ABS GUIDE FOR SURVEYS USING RISK-BASED INSPECTION FOR THE OFFSHORE INDUSTRY . 2003 v GUIDE FOR SURVEY
12、 BASED ON RISK-BASED INSPECTION FOR THE OFFSHORE INDUSTRY CONTENTS SECTION 1 Introduction1 1 General 1 3 Purpose2 5 Scope.2 7 Definitions 3 SECTION 2 Fundamentals of RBI.5 1 Definition of RBI.5 3 Risk Assessment and Inspection.5 5 The RBI Process7 7 RBI Benefits.7 9 RBI Limitations.8 FIGURE 1 Risk M
13、atrix .6 SECTION 3 RBI Program Development9 1 Main Steps in the Development of an RBI Program9 3 RBI Team Setup 11 5 Component Grouping and Baselining12 5.1 Asset Hierarchy.12 5.3 Breakdown into Inspectable Units.12 5.5 Baselining and Fitness for Service (FFS) Assessment .13 7 Risk-Based Prioritizat
14、ion14 7.1 The Risk Assessment Methodology16 7.3 Assessment of Likelihood of Failure18 7.5 Assessment of Consequence of Failure18 7.7 Potential for Escalation .20 9 Inspection Plan Development20 9.1 Degradation Mechanisms and Inspection Methods.21 9.3 Scope of Inspection (Sample Population Size, Loca
15、tion and Extent of Inspection) 24 9.5 Frequency of Inspection26 9.7 Compiling the Inspection Plan.26 Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:37:42 MDTNo reproduction or networking permitted without licen
16、se from IHS -,-,- vi ABS GUIDE FOR SURVEYS USING RISK-BASED INSPECTION FOR THE OFFSHORE INDUSTRY . 2003 11 Inspection Execution27 11.1 Controlling the Inspection Execution .27 13 Analysis of Inspection Results.28 13.1 Anomalies28 13.3 Trending of Results .29 15 RBI Program Updating.29 15.1 Operation
17、al Events30 15.3 Improved Inspection and Integrity Knowledge.30 15.5 Unanticipated failures31 TABLE 1 Basic Elements for an RBI Risk Prioritization15 TABLE 2 Advantages and Disadvantages of Qualitative and Quantitative Risk Analysis Approaches.18 TABLE 3 Degradation Mechanisms, Causes and Inspection
18、 Methods .23 TABLE 4 Inspection Types, Techniques and Factors Affecting Confidence.24 FIGURE 1 Main Steps in the RBI Program Development.10 FIGURE 2 Levels of RBI Analysis .17 SECTION 4 RBI Program Approval and Classification Activities33 1 General 33 3 Program Requirements33 3.1 Approach.33 3.3 Imp
19、lementation for Existing Units33 3.5 Site Specific Information34 3.7 Survey Status34 3.9 Inspection Scope and Frequency34 3.11 Computerized System.34 3.13 Implementation Survey34 3.15 Cancellation of Program35 3.17 Coastal and Flag States Requirements.35 3.19 Damage, Failures and Repairs35 5 Submiss
20、ion Requirements.35 5.1 Program Description Submittal35 5.3 Program Results Submittal36 7 In Service Maintenance and Updating of RBI Plan .36 7.1 Annual Confirmation Survey of RBI Program36 7.3 Review of Plan Updates37 9 Special Conditions.37 9.1 ABS Surveyor Attendance.37 9.3 Usage of Eddy Current
21、and ACFM techniques37 Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:37:42 MDTNo reproduction or networking permitted without license from IHS -,-,- ABS GUIDE FOR SURVEYS USING RISK-BASED INSPECTION FOR THE OFF
22、SHORE INDUSTRY . 2003 vii APPENDIX 1 References39 1 Risk Assessment Techniques39 2 Risk-Based Inspection.39 APPENDIX 2 Risk Assessment for Process Systems.41 1 Assessing Process Accident Scenarios.41 3 Consequence Assessment for Process Systems42 5 Likelihood Assessment for Process Systems45 FIGURE
23、1 Example Event Tree for a Small Gas Release41 FIGURE 2 Example Event Tree for a Large Gas Release42 FIGURE 3 Results of a Process Leak of Flammable or Toxic Fluid .43 FIGURE 4 Modeling of Explosion Overpressure Area on an FPSO .44 APPENDIX 3 Reliability Analysis Approach for Marine Structures .47 1
24、 General 47 3 Documentation.47 5 Main Components of a Structural Reliability Analysis.47 7 Typical Failure Modes48 9 Limit states.48 11 Limit State Functions .49 13 Uncertainties and Probabilistic Models49 15 Degradation Mechanisms50 17 Reliability analysis50 19 Acceptance Criteria (Target Reliabili
25、ty).51 21 Influence of Inspection.51 APPENDIX 4 Contribution of Inspection Plan Elements.53 TABLE 1 Summary of Contribution of Inspection Plan Elements in an RBI Program .54 Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/
26、07/2008 19:37:42 MDTNo reproduction or networking permitted without license from IHS -,-,- This Page Intentionally Left Blank Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:37:42 MDTNo reproduction or networkin
27、g permitted without license from IHS -,-,- ABS GUIDE FOR SURVEYS USING RISK-BASED INSPECTION FOR THE OFFSHORE INDUSTRY . 2003 1 S E C T I O N 1 Introduction 1 General The inspection of process equipment and offshore structural components play a significant role in preventing failures. Inspection and
28、 testing programs are established to detect and evaluate deterioration due to in-service operation. The methods, frequency and acceptance criteria used in inspections can affect the likelihood of component failure. The inspection frequencies for pressure equipment and structures in the marine and of
29、fshore industry have traditionally been driven by prescriptive industry practices, usually at time-based or calendar- based intervals. This inspection practice, founded mainly on general industry experience for each type of component, has thus far provided an adequate level of reliability. However s
30、uch a practice does not explicitly consider the likelihood of failure of a component under its operation and loading conditions, nor the consequences of a failure. Current inspection practices make it difficult to recognize if the same or improved service reliability can be achieved by varying inspe
31、ction methods, locations or frequencies. Also, current practices do not easily identify if an inspection activity is excessive and provides no measure of increased assurance for the integrity of the component. Certain sectors of industry have recognized that significant benefits may be gained from m
32、ore informed inspection methods and have begun evolving into inspection program philosophies that combines factors such as satisfactory operating experience, low deterioration rates, minimal consequences of failure and condition-based inspection interval setting. Most operators have reached their cu
33、rrent practice by an evolutionary process based upon experience, regulatory and classification society compliance. However, very few operators have developed their existing programs on the basis of a systematic process that seeks to achieve a balance between risk and the level of inspection effort.
34、In a facility with substantial production revenues, the cost of downtime can be significant. An effective inspection program is centered on knowing when, where and how to inspect. This enables the operator to not only control the integrity of the assets, but to control it with a focus on the economi
35、c value, while maintaining an acceptable service performance. Further, having a documentation trail for the inspection process allows for a focused and confident inspection plan updating should the operator undergo changes in operations, equipment, structures, personnel, contractors, company organiz
36、ation, etc. Risk-Based Inspection (RBI), which focuses on the optimization of inspection programs for pressure retaining equipment and structures, is the subject of this Guide. RBI begins with the recognition that the essential goal of inspection is to prevent incidents that impair the safety and re
37、liability of operating facilities. As a risk-based approach, RBI provides an excellent means to evaluate the consequences and likelihood of component failure from specific degradation mechanisms and develop inspection approaches that will effectively reduce the associated risk of failure. RBI is a p
38、rocess that assures inspection resources are focused on the areas of greater concern, and provides a methodology for determining the optimum combination of inspection methods and frequencies. As a result of this there is a continuous improvement aspect to the RBI process that allows for recalculatio
39、n of risk and subsequent refocusing of the inspections activities. Copyright American Bureau of Shipping Provided by IHS under license with ABS Licensee=Boeing Co/5910770001 Not for Resale, 08/07/2008 19:37:42 MDTNo reproduction or networking permitted without license from IHS -,-,- Section 1 Introd
40、uction 2 ABS GUIDE FOR SURVEYS USING RISK-BASED INSPECTION FOR THE OFFSHORE INDUSTRY . 2003 The recent trend towards RBI practices is being driven by factors such as: The increasing awareness and use of risk analysis in all aspects of the assets operations The location of facilities in remote locati
41、ons requiring highly effective inspection programs with limited resources Asset service life longer than designed and increased reuse of equipment in different services Increased emphasis on the justification of inspection frequency and practices required of the asset operators by financial venture
42、partners. The development and implementation of an RBI program requires the participation and coordination of groups within the operating organization, including process and hardware engineering, maintenance and operations personnel. The whole organization should commit and contribute to the RBI pro
43、gram. Inspections in themselves do not affect the actual failure likelihood of the components being inspected. The inspection process provides a means of gaining confidence in the service reliability of the component being inspected. When an inspection reveals an excessive deterioration, actions are
44、 initiated, such as the repair or replacement of the affected component or a change to the operating conditions. By identifying potential problems in a timely manner, RBI increases the chances that mitigating actions will be taken, thereby reducing the frequency of failures. Risk cannot be reduced t
45、o zero. There is always a “residual risk” associated with inspection. This is caused by factors such as operational errors, extreme weather, external events, process upsets, limitations of inspection methods and unrevealed deterioration mechanisms. 3 Purpose The purpose of this document is to provid
46、e guidance to ABS Clients on the application of RBI programs to maintain class for an offshore installation. This Guide describes the fundamentals of RBI, the essential steps in the development of an RBI program and the management systems necessary for maintaining documentation, data requirements an
47、d analysis updates. It also describes the interaction between executing the RBI programs and how ABS will audit the plan and execute surveys for maintenance of class within the context of such a program. Specifically, it identifies the minimum elements that ABS requires to be considered in the devel
48、opment and implementation of an RBI program so that it can be considered in lieu of the conventional maintenance of class surveys. This Guide is intended to clarify the elements involved in the development and implementation of an RBI program, but it does not intend to be a detailed technical reference of RBI methodologies, nor does it intend to single out or endorse any one specific RBI methodology. Appendix 1 lists some of the most commonly used RBI methodologies. 5 Scope This Guid