API 580 Propared by K.P.Nkutty Date : 28-02-08, 1 41-The expected outcome from the application of RBI process should be 2.The linkage of probablity of allure with appropriate inspection or other risk mitigation actives to manage risk. D The linkage of consequence of fallure with appropriate inspection or other risk milgaton activites to manage rik {Che linkage of cost of fllure with appropiate inspection or other risk mitigation activities to w rage rsk ine inkago of isk wih appropiate inspection or other sls mitgation actives to manage risk Zthe Ral process is capable of generating. 2 Aranking by fk of al deterioration mechanisms evaluated ranking by isk of al equpment evaluated CA Gatatod desertion of he maintenance plan to be employed fr each equipment tem. GA deta descrpton ofthe Inspection plan tobe employed foreach equlpmant lem tas ge pba (eka Tikey elements ofa RBI program are all ofthe following except. 2 Metagenent systems for martanng documertaton personal quafieaton data requrements and snahis updates ErDocumerted method for probabil of flue determination G1 eDecumerted method for consequence of fafure determination eaumaied nathoogy fr naraing Yk vou apecte an ober gate ees, 2 benefits after Implementaion a ‘2 Anoveral reduction In ke fo the faces and equipment assessed An acoeptanefunerstancing ofthe curent sk -. Slaerienton of equipment tat oes not requ ingpeston or some other form of mitgation. 1 Bitot te above teNone ofthe above. ERB will compensate for. 2 inaccurate or missing information B nacre design o faulty equipment instalation. Operating ouside te desgn envelope _-v-e Noteffecvely executing te plans Fate above. hore be tove RP 680 le specialytargted fr. 2 ycrocarbon indus |. | Bebemleal Process Industry a) Stel nave, Power Plant Dose 3.ckd 4a8s Proseursed equipment and associated componentsvinternals covered by this document aro albu. a Pressure Vessels Al pressure containing components _q'\ b Process pang — Pipe and piping component ‘Storage anke Atmosphere and pressurised catng Equipments Excapt pumps and compressor casings. Non pressurlaed equipment not covered by ths document RP 580 are all but. 5 alnatument and contol systems 1” Beletral systems Goes ese re valves.8:The primary audtence for RP 580 is. ~-alnspecton personne ~b.Engg personnel. ‘eMateias personne {4 Operatone personnel 16 teks abee acadakb {Oia proesure vessel subject to deterioration from corrosion under Insulation develope a teak, the possible consequences ae. 1 Form a vapour coud tnt coud ste causing nur and equipment éamage iE Rauase ara love chemical tat coud cause heath probems. {Resut na pil and cause envionmental deterioration. gov ore a unite dow and have an adverse economic impact. 5° have minal safely healt envronmental or economic pact Hof the above fam 80 rik Lowest lk level ag. Bilghest rk eve at nstant risk level. None ofthe above. 42RBI concepts can be applied . a dualtatiey bQuantatvaly. ¢ Sem! cuanttatvey. lof te above Quantitative risk analysis logic models generally consists of. 2 Event tees and probabity wees. | broly trees and fault res. 4-1" Consequence trees and event ees ites and faut bees “14. QRA Ie gonorally comprised ofthe following tasks except. ‘Ghrevenve and predictive falure assessment. fo." Syun and Hazards enbteaton {robaliy assessment and consequence analysis Ret results $EAQRA deals with. Drove «Disk associated with equpment deterioration. 6:3 Risk associated with equipment parts deterioration, ‘None of te above. eAlofthe above ‘he accuracy of any typeof RBI assessment depends on .. 2 Sound metnodoogy. Otay data. £ Knowlesgeabe personnel G4 Gntcttne above. ‘7-The sutablty and current condition of the equipment within the current operating ‘envelope wil determine. Consequence of alu. 65° Brrobabiy of fare. Coto faire eAlot te above None ofthe above «Jest primary product ofan RBI effort should be. fan nspecton han foreach equipment evaluated An mepecton pan for each Un evalsteg An inspecton plan forthe Pant evaluated roprosonts «1None ofthe above. 3 Sa.Examplos whore inspections may be suficient to manage risks to accoptable levels are atqupment nearing retroment ulate mechanisms such as facture and fatigue 0 Consequence dominated risks. lone of fe above vine the inspoction programme is optimised based on an understanding of the risk the __sontroduction bone that may be eased ae al ofthe following oxcopt +. 9Seftectve.unnecessay or Inappoprste inspection actlles may be eirinated. B inspection of ow risk Rem may be elminated or reed. ‘.Oniine non evasive Inspection methods may de subetiuked for nvasive methods that requre ‘equipment shutdown Blame ona ppacons maybe usted tor mow fete Remetspecions, "inventories are reduced to Decrease the Probably offalure. ger in the Consequence of fale. WY Bincrease the Probably of fare. ‘oecreace the Consequence of fale. 22nd of life inopecton RBI strategies may be devolopod in association with using the methods described in SAPIRP 576 4.0 BAPIRP 579 CAPIRPST2 GAPIRESTT 28.Screening tthe Facility evel may be done by asset or product vale. 2 s bho problemas at sch ect ester PSM facies d.Age of facilities. OA of te above For process units screening priorities may be based onthe folowing except 2 Relate risk economic mpactana relay of process uns. 4 BRelatve COF of process unis 73" BRelatve POF of process uns :Tumaround schedule. 28Consequence analysls san ald in establishing @peatve risk ranking of equipment tems. ik BAbsolde fak ranking of equipment tems Unmitgated sk ranking of equipment tems. {4 Resa isk ranking of equipment toms. _/ isto cansquncn fects of os of containment canbe general considered be in he sionang catcyorice sat for 2 Say and neath impact. ‘Environmental impact Production lossen jntenance and fe-constructon cost, (e)hventor losses ‘Unts of measures of consequences that can be used in a RBI assessment ae 4, aSafety and cost \)” bAffected area. nvronmental Damage. ulation density cost "The least developed consequence measures among those curently used for RBI is a Safety consequence measures. Cost onsequence measures Aifected area consequence measures. ronmentl consequence eases s we but.4 20-The volume of lu released i typeally derived from a combination of he following except 2 Votre of aval for rlease Ease nage 14 ETTemperature of the fui. Tok te Detecion and lao te. St Flammacioeverte can cause damage by ~ a'thama raion plat over pressure Thermal conduction. ‘Tne convection agase Saneoe acts 32.The RBI programme typically focuses on 455 agtrone ita fom aw ire! omasone Strand meat envonmertal as pose and elsyed enaronmerta ak. GiNone ofthe ab Salts crvronmontal cost may be clelatedas the sum of acleanup come Fines. Hs. Ofer costs Ealot be above Probably of Failure information is based on all exce ‘Engineering based, ee aa b.inspection based. paceeaer persion base Mararance tated $3e.Consequonce information ie tradtonally stngneerng base Rinpecoonoased, D2 Gopesionbesea NU ENbitonace sed Seatssumplione or eatimates of inpit values are often used alien consenuenceofalure cata are not avaiable. V2.5 Bivronposay ote ota re not aval en Sonsequence ander pcbabiy fare data are not aval hone otto sbove ‘72a is considered unacceptable and tere for requiring risk migstion various ‘mlagatoneatogoros that should be considered are Sosenmssionng oe birspection/Condition monitoring. \—— & Corsuence and Prosaptymitgaton ‘@all the above. Sante Risk pot or Matrix the highest risk ranking equipments are found atthe atsntotom ei Bretton. yt Lenton pe 2e,npocton serves to oe direst mitre cteraraton mecha. ‘@)centify monitor and measure deterioration mechanisms. carers above faster event arvenfallures sGreumotanoes conte predied 2 ferstanoes can noe preceeBS Ceumstances canbe predicted provided inp datas given None ofthe above {The lovel of fek reduction achieved by inpection depends up on have ofl of te detrration mechanism, i Time tral beeen onet of Getoration and flue 2 Dotucton capasify of napectontecnque Scope and tequency of apecton icbine above te effectaanaas of past Ingpectons ls apart of determination of “he pst sk : Sine presentrisn, / 2% cutters Gate above ‘Key parameters that can afect future risk are. ‘Frequency of napecton and coverage. rook and txtrnues, Procedures andpracioes. js. ‘itmral or ocora inepeton Siler the above ‘Th risk mitation activites fall int all except a Recice magnitude ot consequence yt SRecue probaly of are Gecuce he survival offalure ofthe fact and people othe consequence ittgato tne primary source of consequence. {Samples of mitgation of probably of falure ar all except a Chonge of etary ((etetion of protective linings and coatings. jj.) Removal of dadlens. dlinecton pat design charges. eReauce temperature a ioabove auvespnere pressure boing point reduce ize of cloud below anosphere posse boling pantie reduas ze of loud, To below voto, pescue bong oro recues sz coud. 147 Soabove absolut pressure boing pont toveduee az of coud {ritmay be decrabe fo conduct an RBI assessment stor significant changes in 2 Prost condone. EDastoralon mechansetatestevertes, —/5.3:/ ESI promises Ghldhte above {eu.c.cle usualy responsible for implementing th recommended inspection plan derived ftom the RBI study Eivateals and corrosion spacial jou 5 Process specialist ‘Opeaton and Maintenance Personnel pecson or equipment specials. ade Sa. is responsibe for preparing a report onthe RBI study and datrbutng ito ‘SPproprate personel whom are sithor responsible for decielone on managing he risks or ‘eoporetblfor implementing actone to mfigts the aks. 2 lstorals and corosion spect B Process specisst Le Operabon and Maintenance Personnel, ©" dirapocton ot equipment specast ‘Seam acer $.o provides recommendation on methods of mitigating POF such as changes in imetalurgy addition of nition, addition of costingiinings otesara and corosion specs feat ‘Process specials Operation and Minerance Personnel ‘iropecton or equpment pect eam tender Simo shoul evaluat recommend methods of iekmiigaon through changes in process Conditions. Sistas and coroson specialist [5.2 rocass specs. Operator and Meintnance Personne! “trepecton or eauipment spect Team tonder $a. reeponsibe for implementing recommendations that pertain to process or equipment modification and monitoring. SMaterls ard caroion spelt cess epoca lors errand anenance Peer! opecton or eupment spect tManagoment Sane ie responsible for providing sponsorship and resources forthe RBI study. aeamender : biProcess specialist. jeut Operation and Maintenance Personal Simmpocton ov equipment specaist, Proact Scranton ns Seen oe — $foeeenrnam mente ste pment ot pict = iat Po SEES een amen arian a sires en: ==. a = oma58,Galvanic corrosion affects Sea water services. boaling water services. boiler feed water services, dake {Ammonia bioulphide corrocion ie a highly localised metal lass dua a erosion corrosion in ‘Stainless stee Nickel steels. Admiralty brass. Bronze 61.Ammonia bisulphide corrosion affects 2 Thermal or catalytic racking in hydrotreating systems. DB ydrocracking coking catalytic cracking systems. ‘Amine teating sour water eluent and gas separation systems, GaAllof the above 62,Carbonie acid corrosion asa chemical process. bisa electrochemical process. cig a blo-chemical process. ‘None of the above. 63,Carbonie acid corrosion affects: ‘aRelinery steam condensate system, ‘bHydrogen plant ‘Vapor recovery section of catalytic cracking unt. GA ofthe above. 64,Sulphuric acid corroston affects, ‘Sulphuric acd akyiaton unis b.Demineralzed water units. ceWNater treatment plans. dag {65.Hydrofluorie acid corrosion affects ‘aHydrofuorc alkylation units. ».Demineraized water units. Water treatment pants dag 66,Phosphoric acid corrosion affects atycrofuare alkylation units b,Demineralzed water units. ccWater veatment plants. ‘None of the above. 67,Phenol corrosion affects aydrofuorie alkylation uns. Heavy ol and dewaxing pants Water treatment plants. ‘None ofthe above. 68... 1s used as a biologleal corrosion inhibitor in water treatment plants. .Carbotc acid .Carponic ate. ‘¢Phosphorie acd Hydrochloric ai. {68.Amines are used in gas treatment to remove dissolved ‘4802 and COZ S02 and Hes ‘cH2S and CO2 {dNone of the above T0.The key variables in Amine corrosion are_a.Amine type and concentration. ‘Material of construction. Velocty temperature, acd gas loading, GA ofthe above. ‘Atmospheric corrosion is observed in rotective coating. Low temperature processes High temperature processes ‘¢Medium temperature processes None ofthe above 2culis ‘.Localised corosion General corrosion {¢General uniform cortosion ‘.General to highy localised corrosion 7a.in High temperature sulphide corrosion without H2 ‘a FeS is formed, B.Oceurs when minimum temperature is 450 deg F ‘where Sis present in quantiies greater than 0.2% Gallo te above. feNone ofthe above. {74 High temperature sulphide corrosion without H2 occurs in aGoker bFCC Hyero processing uni. Gal ofthe above. teNone ofthe above. ‘75: High temperature sulphide corrosion with H2 ‘aFeS is formed. Occurs when minimum temperature is 450 deg F ere Sis present in quanties greater than 0.2% Gall ofthe above. teNone ofthe above. 176. Naphthenie acid corrosion occurs in a Fumaces and transfer lines Bmigdle section of vacuum column in a crude unit ccalmasphericcstilation uns. dallof the above. ‘eNone ofthe above, 177, Oxidation occurs in ‘a Fumace tubes and tube hangers b atmospheric cstilation unt. Transfer ines {None ofthe above. '80.Chloride cracking behaviour Is alntergrannuiar Planar cc Transgrannular ‘dNone of he above. BH.Chloride eracking can Initiate in ‘2 Austenitic stainless ste! B.caroon stea! High alloy steel. ‘None o the above. ‘where carbon steels have boon used withouti ‘82.Chloride cracking Is common in all but a.ctmospherie column overheads of crude units ‘downwind of cooling water spray. equipment exposed to atmosphere. Gireactoreffuent condensating streams. fequipment with poor insulaton and water proofing '83.Chloride cracking can initiate from ‘the ID of the austenitic staniess steel equipment ihe OD ofthe austenite stainless steel equipment ithe ID and OD of the austenite stainless steel ezuipment Gop ofthe austenite stainless stee! equipment ‘84.Gaustie cracking can initiate from athe ID of the austenitic stainless steel equipmert ‘ithe OD of carbon steel equipment. tithe ID and OD of the carbon steel equipment. ‘dane ID of carbon steel equipment. {5.Caustic eracking behaviour is alintergrannuiar bPlanar :Transgrannular Sintergrannular and transgrannular ‘None ofthe above. '86.Caustic eracking is common in all but ‘atmospheric column overheads of crude units. bmereaptan treatment unis. sour water Yeatment unis crude unt feed preheat desalting festeam systems and caustic sevice, 87-Polythionie eracking Is common in 2 Desuphiriaer furnaces and hydro proces Boorude unt feed prenest desaltng austenite staniess steel catalytic cracking unit reactor and fue gas systems, ‘age above. 88, Polythionic acid ls formed by a conversion of FeS in the presence of a Hand S bre ands cH2and 02 3S and 02 £8, Polythionic acid affects aferite SS in sensitised condition b austenite SS in the unsensitsed condition. ‘duplex SS in the unsensitised condition. {austenite SS in the sensitised condition, '3,Amines are used in gas treatment to remove C02 and SO2 (CHS and SO2 SH28 and CO2 eH2 and CO2 '90.Ammonia cracking occurs in ‘carbon stee! Admiralty brass eCuzn alloys Sal the above. ‘91 Ammonia cracking behaviour Is atfansgrannularin CS, Dintergrannular in Cu-zn alloys its0 c:intergrannuiar in CS. {None ofthe above. ‘92,HIGISOHIC occurs in acs LAS css aad above '83,HICISOHIC cracks aro primarly intergranular. Dtranegrannular planar, S.c0-axia, S2.HICISOHIG occurs in a.stress relieved equipments. bron-stress relieved equipments. Garess relieved and non-stress relieved equipments ‘neat veated above ac3, S4)HICISOHIC eracks are initiated by acisintegration of H2 gas. formation of H2 gas. ‘dlsintagration of molecular H2 gas out of ste! ‘formation of molecular H2 gas in incusions ofthe steel. 96,Sulphide stress cracking occurs in acs. BLAS ess aad above 96,Sulphide stress cracking occurs in astress relieved equipments. bnon-stess relieved equipments Cstess relieved and non-stess relieved equipments heat treated above ac3 {97-Sulphide stress cracks are primarly alintergrannuiar. bransgrannular planer. .c0-ayal 98.Hydrogen blistering occurs acs. BLAS ess aad above ‘98.Hydrogen blistering is primarly a Intergrannular. btransgrannular. ceplanar .00-axal 4100. Hydrogen blistering occurs in a.stress relieved equipments. bnon-stiess relieved equipments. €sress relieved and non-stess relieved equiprents heat teated above ac3, ‘01 Hydrogen cyanide cracking Is primarly ‘ainiergrannular ‘btransgrannular. planar." bac 4102. Hydrogen cyanide cracking occurs a by the destablzation of Fo203 protective scale. bby the destabization of FeS protecve scale. ©. by the destabilzation of Fe304 protective scale. 4.by the destablzation of MnS protective scale. 4OSHTHA attack occurs in acs. BLAS High nickel chromium alloys. S.aBb above {0S.HTHA attack is charecterised the formation of fissures along the grain boundaries due to aH bcHs Has. coz 4104. HTHA attack results in aintergrannular fissure cracking bdecarburstion ‘etvansgrannular cracking dash 408.Grain growth oceurs in C8 at S50F. Daausteniic Ss at 1150F. ‘CHigh nickel chromium alloys at 1650F. LAS at T100F 406.Grain growth results in ‘ole tube faures. bb Fumace tube fallures. exchanger tubes failures, ‘.coke tubes failures, 407.Graphitisation rosults In ‘FCC reactor fallures. » .Catatic cracking unt furs. = Desulphurisation unt falures coker unit fallures. 4108.Graphitisation begins at aa25F b725F 825F .925F 4109.Graphitisation occurs in stools ‘awhen normal pearlte decomposes in to weak ferte and graphite nodules, Bahn normal ferite decomposes in to weak pearite and graphite nodules. {cwhen normal pearite decomposes into weak toostte and graphite nodules, Giwhen normal roostite decomposes into weak pearite and graphite nodules, ‘40.Sigma phase embrittlement occurs when ‘a carbon ste! is held inthe range 1000F-1600F for extended te periods SS is hela in the range SOOF-1000F for extended time periods. {carbon stee! i held in the range S00F-1500F for extended time periods GSS is held in the range 1000F-T500F for extonded time periods. ‘111.8igma phase ombrittioment results In ‘.Boler tube failures. .Cast Furnace tube failures. ‘exchanger tubes ‘alures. ‘coke tubes failures.2 *12.885F ombritfement occurs after ‘a.aging offerte containing SS at 650F ~ 1000F and produces a loss of anbient temperature ‘ucity. aging of pearite containing SS at B50F ~ 1000F ané produces aloss of ambient temperature uct, ‘aging of austenite containing SS at 650F — 1000F and produces a loss of ambient temperature oct, ‘.aging of ferrte containing CS at BSOF ~ 1000F and produces a loss of ambient temperature ductiity 1113. 805F embritlement results In ‘cracking of FCC ractor during shutdowns. boracking of cast and wrought steels during shutdowns. ceracking of FCC reactor during start-ups. racking of east and wrought steels during start-ups. 114.Temper embrittiement occurs when ‘carbon steel hel for long periods of time in the range TOOF-1050F for extended time periods. LAS is hed for lang periods of ime in te range 7OOF-1050F for extended time periods. ‘carbon steel hel for long periods of time in the range 1 100F-1500F for extended time periods. {LAS Is held for long periods of tme in the range 1100F-1500F for extended time periods. ‘18.Temper embrittement occurs ‘adring shutdown and startup conditions, bat ambient temperature. cat elevated temperature. ‘dnone of the above. ‘16.Example of quid metal embrittioment is. astainess steel and mercury combination copper based aloy and zinc combination. zine based alloys. and copper combination. ditainiess steel and zine combination. 117-Carburisation occurs on a furnace walls heving coke deposits iD of umacs tubes having coke deposts 2.00 of furnace tubes having coke deposits ‘none of the above. '18.Carburisation results in a.an increase in the hardenabilty of ferric steel ban increase in the hardenabliy of some stainless steel an increase in the hardenabity of LAS, dab '19.Decarburisation occurs on AID of CS furnace tubes having coke deposits, b.OD of CS furnace tubes having coke deposits cD of CS furnace tubes. .OD of CS furnace tubes. ‘20.Metal dusting is ‘2.4 highy localised carburisation and subsequent wastage of stels exposod to mixtures of H2,CH,CO,CO2 and hydrocarbons inthe temperature range of S00F-1500F. a high localised decarburisation and subsequent wastage of stels exposed to mixtures of H2.CH4,CO,CO2 and hydrocarbons inthe temperature range of S0OF-1500F. oxidation of steel and leads fo te formation of Fe203, ‘None of the above 421 Selective leaching occurs in ‘.acmialty tubes uted in cooling water system boopper tubes in cooling water system cage None of the above,R *122.Mechanical fatigue 2.16 a falure of a component by cracking after the continued application of eycle stress which exceeds the materials endurance limit. bisa fire of a component by cracking after the continued application of cylc stress within the materials endurance imi. (ie a falure of a component by cracking after the continued application of cycle stress wich fexcends the materials elastic lit. Giga faire of a component by cracking aftr the continued application of cyte stress with the matetals elastic limit 4123.Cavitation occurs in apump impellers. elbows. ‘cpump casing. ago 4126.Corrosion fatigue occurs in ‘steam drum headers, boiler tubes cag 425.Britle fracture occurs ‘during. equipment pressursation in the absence of precautonary measures, bung star-up and shutdown, at elevated temperatures, None ofthe above. 4126-Firo is associated with ‘Thermal shock ‘Srhermal fatigue eThermal ses. ‘none of the above, 127.Creep occurs, ‘above normal YS. below normal YS, ‘ebelow endurance limit. dlabove endurance limit. ‘128.Stress ruptre occurs ‘a.above normal YS. below normal YS. exbelow endurance init above endurance limit 4129-Fallure in fire tubes is as a result of ‘Creep. bsvess rupture Decarburisation Gal ofthe above. 1130.Thermal shock ‘.oceurs wien large and non-uniform thermal stresses develp over a relatively long time ina piece ‘f equpment due to differential expansion or contraction bloceurs when large and non-uniform thermal stresses develop over a relatively shot time in apiece ‘of equipment due to differental expansion or contrection Cloceurs when large and unform thermal stresses develop over a relatively long time ina piece of equipment due fo differential expansion or contraction Goceurs when large and uniform thermal stresses develop ovr a relatively short time in a piece of equipment due to diferental expansion or contraction,