Professional Documents
Culture Documents
Johann F. Oosthuizen
Anglo American
Anglo Field Services
South Africa
The Anglo American Conference on Condition Monitoring and Non-destructive Testing
18 & 19 November 2008
1 D1-1
Order of Presentation
• Current inspection approach
• Risk Based Inspection
– Overview
– Process
– Outcome
• RBI Application & Case study
• Other RBI Applications
• Benefits of RBI
2 D1-1
Risk Based Inspection
3 D1-1
Current plant equipment inspection
• In-service inspection:
– traditionally been driven by prescriptive industry
practices
– fixed locations, fixed frequency (calendar-based) and
fixed methods of inspection
– Two extremes of inspection
• Very little – replace when equipment fails.
• Too often and too thoroughly – becomes uneconomic.
– No encouragement to analyse:
• threats to structural integrity
• consequences of failure
• risks created by each item of equipment
• Do we inspect what needs to be
inspected?
4 D1-1
Risk Based Inspection
• Next generation of inspection
approaches and interval setting
• Adapts risk analysis to the
process of inspecting
equipment
• Addresses ways to manage risk
on an equipment level
• Focus on maintaining the
mechanical integrity of plant
items and minimising the risk of
failure due to deterioration
5 D1-1
RBI Process
• RBI is a combination of the following processes:
Risk Assessment
No unacceptable defects
Engineering
Assessment
Remediation /
Inspection Repair
Planning &
Pass
Scheduling
Fail
Inspection Evaluation of Defects Fitness for Service
Implementation Inspection findings Evaluation
6 D1-1
RBI Outcome
Reduction of safety and operational risk
Engineering
Assessment
&
Inspection
Planning &
Scheduling
7 D1-1
RBI Outcome
• A relative ranking by risk of all equipment
evaluated.
• A Written Scheme of Examination for the
equipment showing what, how and when it should
be inspected.
• Documentation demonstrating that the risk
assessment & inspection planning processes are
implemented effectively and appropriately.
8 D1-1
Application of RBI
10 D1-1
Case Study – Refrigeration
Plant
• Applied RBI methodology
Risk Assessment
Engineering
Assessment
Inspection
Planning &
Scheduling
11 D1-1
Case Study – Refrigeration
Plant
• Fitness-for-Service assessment results
12 D1-1
Case Study – Refrigeration
Plant
• Fitness-for-Service assessment results
Risk Assessment
No unacceptable defects
Engineering
Assessment
Remediation /
Inspection Repair
Planning &
Pass
Scheduling
Fail
Fail
13 D1-1
Case Study – Refrigeration
Plant
• All vessels with no remaining life:
– 27 vessels required attention
– Max allowable pressure calculated for present condition
– Verify if plant can operate at calculated pressure
• If operating below calculated pressure then vessel require
derating
• If operating above the vessel requires replacement
– Was possible to reduce pressure relief valve setting to
below MAWP in present condition
• 27 vessels on 12-month inspection interval
• 38 vessels on 24-month inspection interval
14 D1-1
Other Applications of RBI
• Haul trucks
– Chassis
– Spindles
– Truck body
• Shovels
– Ropes
– Winders
– Beams
– Bucket
15 D1-1
Other Applications of RBI
• Draglines
– Ropes
– Boom
– Winder
– Bucket
16 D1-1
Other Applications of RBI
• Electrical Motors
– Insulation and Bearings
• Vibration assessment and Partial Discharge Monitoring
• Gearboxes
– Gear sets and Bearings
• Vibration assessment and Lubrication monitoring
• Other Plant Equipment
17 D1-1
Benefits of RBI
19 D1-1
Your strategic partner in reducing risks
associated with safety and production critical
machines, systems and components
20 D1-1