Module 03 - Working Procedures & Software

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Working Procedures &Software

RBI Offshore Training Course

Module 3



Content of the module

This module covers:

• Inspection Management working proceduresand Guidance

• Description of the Synergi RBI Offshore

software• Work flow & use of Synergi RBI Offshore



Inspection Management Circle & Working Procedures

Acceptance Criteria

Information gathering

& screening

Detailed RBIPoF calculation

CoF Unignited

CoF ignited

Reporting

Inspection programme

Inspection planning

& execution

Data evaluation and Updating



RBI Team• RBI team must be multidiscipline

• The team should include the Client / operating

unit

• There should be the following disciplines

present:

– Consequence / Risk

– Materials / Corrosion

– Inspection

• The Client/Operating unit should contribute

detailed installation operations and maintenance

knowledge.



Synergi RBI Offshore

• Determine when to inspect, where to inspect

and how to inspect, or whether monitoring is abetter solution

• Assess how changes in process and materials

affect the installation risk and inspectionprogramme

• Aid to managing installation risk to be within

the Clients own acceptance criteria



Synergi RBI Offshore: Outputs

• Calculates quantitative values per tag for:

– Risk – PoF

– CoF for Safety, Economy

– Inspection date (≈

Time to risk limit)• Lists likely degradation mechanism

• Can output graphically (matrix) or numerically



Synergi RBI Offshore: Program features

• Project (data set) administration

• Gridview Spreadsheet-like editing• On-line help

• Development is continuing



Synergi RBI Offshore: Main Data &

background data• Main data are the corrosion circuit, tag and part, which

contains the tag-specific data with repair method &

process conditions• “Background data” are data used many tags, such as

materials & coatings type and properties, model

properties etc

• Because of the relationships, the background data

should be lset first, then circuit, tag and part last.



15

Asset Hierarchies in Synergi RBI Offshore

• Asset hierarchies designed to facilitate the analysis

process

RBI Study Node

Field

Installation

System

Tag

Inspection

Part

Inspection

Thickness Measurement Location

Area

Isolatable Section

Tag

Corrosion Circuit

Tag

Corrosion Circuit

Part



Synergi RBI Offshore: Design philosophy

• Probabilistic modelling

• Fallback system if data is missing, e.g.:Age: 1. Component, 2. System, 3. Installation

Temperature: 1. Actual, 2. Operating, 3. Design

• Calculation reports for documentation of

decisions made during calculations

• Option for manual override of corrosion rate

and PoF



Synergi RBI Offshore: Limitations

• Many PoF models have been simplified to

reduce data gathering and entry requirements,

but this can still be extensive.

• Remember GIGO: Garbage in, garbage out.

Careful data entry and verification pays.

• Uses a different PoF methodology to Synergi

RBI Onshore - direct calculation of PoF, no use

of generic data.

• Limited to physical processing of hydrocarbons

at low temperatures (< 150C)



Work flow

• Follows the Inspection Management Circle

• DNV (Offshore RBI) allows a multi-stage work

process :screening then possibly a semi-

quantitative and then fully quantitative RBI:

– Reduces number of tags to be assessed, reducing

data search & handling

– Involves & motivates the Client

– Transfers installation knowledge where documents

do not exist



© Det Norske Veritas AS. All rights reserved.

Sunday, 08 May 2011

21

Synergi RBI Flexible Workflow Example

Collect relevant

data

Level 1 RBI : Screening At System& Circuit level

Annual GVI . Corrective

maintenance

Inspectionplanning

Inspectionexecution

Assess findings & upadte

database withfindings

Need to Update RBI ?

Level II RBI : Semi - Q

Assessment per circuit Use of DNV RP - G 101

Create Circuits

Low risk

High risk

Medium risk

Low risk

Level III RBI: Detailed

Based on subdividing circuits intotags & subtags Use of ORBIT Offshore

High

risk

Inspectioninterval

acceptable ?

Yes

NoRisk analysis Risk Level

Other riskmitigating actions

Confirm data Unacceptable

risk

Medium risk

Acceptable risk

No

Yes

Risk analysis Risk Level

Risk analysis Risk Level



Acceptance Criteria determination

• Since inspection time is based on exceeding a

risk limit, we must define those limits

• Screening & detailed RBI need the acceptance

limits

• Specify quantitative limits for safety, economy& environment



Case Study: Veritas 1 Wellhead Installation

• Input:

– P&IDs in Training manual– RBI Study Input Data: Handout “Contract between Operator

AS and RBI Planners AS for Inspection Services on the Veritas

1 Wellhead Installation

Slide 23

Wing Valve ESD

Export Pumps

Condensate/Gas Gas

Condensate Booster Pumps

Water

Separator 20VA0001

MeteringPackage

E x p o r t R i s e r



Creating a Case study

• Open Synergi RBI Offshore

• File/ Save As “Veritas 1 Case Study.orbx”

under folder C:\trainingFiles

Slide 24



Name Field and Installation

• Rename to “Veritas Field” and “Veritas 1

Installation”

Slide 25



Synergi RBI Offshore - Installation

• Used to define general installation details for

CoF calculations• Lists installation name, production volumes &

values, set risk acceptance limits, give

equipment costings (per tonne)



Exercise: Installation Data

• Fill Installation Dialogue:

– PLL limit: 0.0001– Economic limit: 10000 USD

– Sand present: No

– CO2 present = Yes– Unselect option: Include consequence fatalities in

economic risk

– Production affected (CostPerday)= (Throughput

(bbl/day)* OilPrice($/bbl) ->

$/day=5000*100=500,000 USD/day=150,000,000

USD/year

Slide 27



Installation

• Double-click on Veritas 1Platform and to enter

data

Slide 28



CoF Input

Slide 29



Installation Inspection Targets

Slide 30



Installation Parameters

• Correct: Oil Throughput 5,000 bbl/day

Slide 31



Data gathering & Screening - 1

• Request all necessary data up front; specify what

stage of the project it is needed by.

• Preferably get tag data electronically, as it saves

a lot of work & errors are less likely to be your

fault.

• Include Operating unit in the screening - they

must agree the result and often are the main

source of relevant information. Involvement alsogenerates acceptance of the RBI & goodwill.




• The purpose of screening:

– Reduces data to be assessed later– Increases our knowledge of the installation

– Gets the Client firmly on the RBI side

• The outputs of screening:– Systems with high PoF and CoF go to detailed RBI




Information required for screening is

• PoF:

– Materials,

– product service code & chemical description of content,

– temperatures, pressures,

– coatings, insulation types, current condition, likely changes in

these with time.• CoF:

– How the installation works, inter-relation between systems,

installation layout,

– revenue streams, costs of inspection,– detection and shutdown systems,

– blast & firewalls.




• Screening process

– Assess PoF and CoF against conservative acceptancelimits

– High PoF and high CoF: Detailed RBI

– Low PoF and high CoF: Preventative maintenance

– High PoF and low CoF: Corrective maintenance

– Low PoF & low CoF: Minimal surveillance

• Revise the screening periodically, as conditionschange and so may the assessment.



36

Screening Matrix

A Detailed RBI

B InsignificantPoF

C

I n s i g n

i f i c a n t C o F

D

PoF

1

10-2

10-3

10-4

10-5

Low ― Consequence― High

High PoF

Low PoF

Low CoF High CoF

Minimum

Surveillance

CorrectiveMaintenance

Preventive

Maintenance

Detailed RBI

Assessment



Screening matrix & reasons for revision

Likelihood of failuremay increase because

of material and

process

changes

A B C D E

Consequence of Failure

L i k e l i h o o d

o f F a i l u r e



Detailed RBI: Synergi RBI Offshore - System

• Used to describe the process and utility systems

on the installation, and records whether MIChas been identified there.

E i S i A f S



Exercise: Screening Assessment for System

20: Separation and stabilisation

• Insert System 20 – Separation and Stabilisation (in

Systems folder), Right-click System Screening &fill data

Slide 39

E i S i A t f S t



Exercise: Screening Assessment for System

20: Separation and stabilisation

• System boundaries: Wing valve, oil, gas and

water outlet isolation valves• Input material, product service, temperatures &

pressures

• Assess PoF and CoF• Click on Run to see the screening results

Slide 40



System Screening

Slide 41



Detailed RBI - 1

• Assesses individual tags and parts of tags

• Results in a quantified risk level and time toinspection per tag or part

• Input PoF and CoF data

• Ensure close contact and co-operation withOperating Unit

• Can report any way the inspection planner

wants• It is time and information-intensive



Detailed RBI - 2

• Work systematically & document all

assumptions

• Enter all the tags otherwise people might think

you forgot some;

– also they might be screened back in in the future.– Mark those screened out in the comment field.

• Assign process conditions and consequences to

tags



Detailed RBI - 3

• Electronic tag data must specify dimensions,

service, materials, coating, insulation,

temperatures, pressures, P&ID no. as aminimum.

• Reference to drawings is used to assign tags to

ESD Isolatable sections, areas.

• Process conditions assigned according to PFDs

and process simulations

• Repair strategy & production losses assigned

according to client strategy



Detailed RBI: Handling Piping

• Piping tags may have elbows, straights, tees &

reducers. These separate components are not

usually treated separately for RBI, but may have

different wall thicknesses and diameters.

• Pipe often quoted as a “schedule”.



Example of pipe tag with tapping



Detailed RBI: Handling Vessels - 1

• Vessels should be defined as Tags

• Divide them up into their components with the

correct label, dimensions & materials as Parts.– It is conservative to assume the same schedule

for the nozzle as the attached pipe

• Assign each part the appropriate product servicecode



Detailed RBI: Handling Vessels - 2

• Synergi RBI Offshore is designed for items

with fluid on the inside and atmosphere on the

outside, so heat exchanger tubes are not easily

handled

• Synergi RBI Offshore uses pipe stressequations from ASME/ANSI B31.3 to calculate

stress



Detailed RBI: Handling Vessels - schematic

PT

PL

PW

Gas

Oil

Water

PG

Closed drains

Two phase

Water

Gas

Oil

Different

codes

Most

conservative

code

Oil



Detailed RBI: Synergi RBI Offshore - Area

• Used to describe each area/module for risk

calculation

• Lists size, no. of equipment & personnel, factors

affecting likelihood of ignition & spread,

mitigating factors• Use the layout drawings or line list to determine

areas & Isolatable sections



Exercise: Insert Area

• Right-click on Areas and insert Consequence

Area. Right-click and rename it to Lower Deck

Slide 53



Exercise: Edit Area Lower Deck

• Double-click on Area and fill data

Slide 54



Exercise: Area

• Pressure Wall Design Pressure = 1 bar

• Equipment design pressure= 0.3 bar• Maximum Explosion Pressure = 0.5 bar

• Assume that

– half of people in Lower Deck – half of people in Upper Deck

• Input rest of the data, estimating as necessary

from available data (volume, area, ventilationrate etc)

Slide 55



Area Data

Slide 56



Detailed RBI: Synergi RBI Offshore - Isolatable section

• Used to specify all the parameters needed to

calculate the simplified RBI-QRA per Isolatable

section for ignited CoF.

• List by Isolatable section the temp, pressure,

volume, area, fluid contents, potential for spread

to areas, equipment & risers

• Is used for detailed analysis



Exercise: Insert Isolatable Section

• Draw simple PFD/ Define isolat. section bounds

• Right-click on Isolatable sections, Insert

Isolatable section and rename to Separation

Slide 59



Exercise: Define Separator Isolatable section

• HOLDING POINT

Slide 60




Slide 61




• Calculate RBI QRA = Yes (use Synergi RBI

QRA model rather than external QRA)

• Assign Isolatable section to Lower Deck

• Lower Explosion Limit = 0.01

• Riser Fluid = Oil• Flash Fraction Oil = 0.2

• Kappa Gas = 1.3

• Mass burning rate = 0.05 kg/m2/s

• Molecular weight = 98 (condensate)

Slide 62

I l bl S i D



Isolatable Section Data

Slide 63

I l t bl S ti D t



Isolatable Section Data

Slide 64

E i I t C i Ci it



Exercise: Insert Corrosion Circuit

• Right-click on Corrosion Circuits folder and

insert Corrosion circuit. Rename to separator

corrosion circuit

Slide 66

E i Fill C i Ci it D t



Exercise: Fill Corrosion Circuit Data

• Double-click on separator corrosion circuit and

fill data under General

Slide 67

Separator Corrosion Circuit data



Separator Corrosion Circuit data

• Optional exercise: Screening of corrosion circuit

Slide 68

Detailed RBI: Synergi RBI Offshore Tag



Detailed RBI: Synergi RBI Offshore - Tag

• Can be a vessel, a pipe or a generic tag

• Tags can comprise a number of parts, such as the

individual components of a pressure vessel as shown.

Exercise: Insert Separator Tag



Exercise: Insert Separator Tag

• Right-click on Separation & Stabilisation

system and insert Vessel-Horizontal Vessel

Slide 70

Exercise: Fill Separator Data




• Right-click on Horizontal Vessel and choose Rename to

change to Separator 20VA0001

• Double-click on Separator 20VA0001and fill

20VA0001 data under General and Design tab• Assign isolatable section and corrosion circuit

Slide 71





Slide 72

Separator Tag Data



Separator Tag Data

• Separator Tag Design Data are inherited from

System. Edit if required

Slide 73

Detailed RBI: Synergi RBI Offshore - Part



Detailed RBI: Synergi RBI Offshore - Part

• The lowest level of detail in Synergi RBI

Offshore. Used to assign all physical, process

and consequence data to individual parts.

• Makes the links between the background tables

and the results tables.

• Most fields require the background tables to be

completed first, so work on Parts last.

Exercise: Insert Part



Exercise: Insert Part

• Right-click on Separator 20VA001 and Insert

Part Shell. Rename to Part-Shell-Oil Side

Slide 76

Exercise- Fill Part Data



Exercise Fill Part Data

• Double click on Shell – Part – Oil side and fill

part data as necessary

Slide 77

Exercise- Fill Part Data



Exercise Fill Part Data

Slide 78

Exercise- Fill Part Data- Design



Exercise Fill Part Data Design

• Material can now be specified precisely

Slide 79

Exercise- Fill Part Data - Detailed



a a a a

• CoF Method can now be quantitative

Slide 80

Exercise- Fill Part Data - Detailed



• Must specify repair categories and Production

loss profile

Slide 81

Detailed RBI: Synergi RBI Offshore -

ProdLossProfile



• Used to define the production loss profile resulting from

leak in pressure boundary for economic CoF calculations

• Production Loss profiles are defined in Repository editor

Full production

Time0

100

Detailed RBI: Synergi RBI Offshore –

Repair & Repair Diameter



• Used in Unignited consequence calculations

• Defines the repair strategies for each part type for

economic CoF calculations

• Repair times are defined in the Repository editor



Safeguarding life, property

and the environment

www.dnv.com

102

Module 03 - Working Procedures & Software

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