ASME PVP-Vol.
488, Risk and Reliability and Evaluation of Components and Machinery
July 25-29, 2004, San Diego, California, US
PVP2004-3020
PLANT ASSET MANAGEME NT
RIMAP (RISK -BASED INSPECTION AND MAINTENANCE FOR EUROPEAN INDUSTRIES)
THE EUROPEAN APPROAC H
Robert Kauer
Aleksandar Jovanovic
TV Industrie Service (TV SD Group)
Westendstr. 199
80686 Munich, Bavaria, Germany
[Link]@[Link]
MPA Stuttgart
Pfaffenwaldring 32
70569 Stuttgart, Germany
jovanovic@[Link]
Sture Angelsen - Gjermund Vage
Det Norske Veritas
N-1322 Hvik, Norway
[Link]@[Link]
ABSTRACT
The paper presents an overview of the European project RIMAP
(Risk-Based Inspection and Maintenance for European Industries) as
well as a more detailed insight into its application for the power
industry (RIMAP Power Workbook). RIMAP is partly financed by
the European Commission for the "Growth Programme, Research
Project; Contract Number G1RD-CT-2001-03008.
INTRODUCTION
Globalization and increased competition are keywords that cha racterize the present development at a world wide market. A co mpanys ability to recognize innovative concepts will be decisive for
meeting the progressive demands at competitiveness.
Process-specific control and operation concepts in combination
with a sufficient maintenance strategy significantly influence the
economic efficiency of a plant in the same way as the quality of its
products. Present-day plant management requires an integral approach to enable decision making, considering the interaction between different systems as well as between different phases during a
life cycle with a focus on cost -effectiveness. Hence, it is strictly
necessary to actively drive the plants assets.
Adapted probabilistic reliability and risk assessment methods
combined with the information extracted from generic and plant
specific data as well as from structural reliability models yield to a
solid foundation for decision making in a wide range of usage for
asset management and maintenance optimization tasks. Special
emphasis is given to the risk assessment, which is the foundation for
making a decision. In this context the term "risk" is not limited to a
risk concerning safety but also can be related to a risk concerning
availability and ultimately money.
However, the current situation in Europe regarding inspection
and maintenance activities in process and power plants is varying
over a wide range. While in some European countries, like the UK,
risk based approaches are in use and accepted by the industry and the
authorities, in most of the other countries, e.g. Germany, the current
practice toward safety related issues is still more or less time-based
and prescriptive. This is due to the fact that in the European Union
(EU)-member countries only the requirements for the construction
and design of pressure vessel equipment is standardized (European
Pressure Equipment Directive (PED), while all the legislation for inservice inspection is still with the national authorities (ISI -codes).
The only requirement is that the national regulation must be adapted
to the basics of the PED. Therefore, the main classification of pressure equipment in the PED with its influence on the construction and
design requirements is adapted in several national ISI codes (e. g.
German BetrSichV). In these cases, the expenditure for ISI is linked
to the consequence classification in the PED. Whilst in the PED the
word risk is avoided (the requirements are only consequence related) in the ISI codes one can often find implicit expression for risk
if prescribed periods have to be extended or reduced. Here, it is often
stated that efforts have to be adapted to the extent (=consequences)
and the likelihood of what can happen, which is exactly the definition
for risk.
RIMAP Consortium:
Det Norske Veritas AS
Staatliche Materialprfanstalt Stuttgart
Electricity Supply Board
TV Industrie Service, TV SD Group
TNO Industrial Technology
VTT Industrial Systems
Hydro Agri Sluiskil B.V.
Mitsui Babcock Energy Ltd.
ExxonMobil Chemical Ltd.
Energie Baden-Wrtemberg AG
The Dow Chem. Comp. N.V.
Joint Research Centre of the EC
Bureau Veritas
Corus Ltd.
Siemens AG
Solvay S.Y.
July 25-29, 2004, San Diego, California, US
PVP2004-3020
RIMAP WP-relations
Update on RBMI
WP3: Risk
Assessment
Methods
WP4:
RIMAP
Application
Workbooks
State of practice
from inv. industries
WP5:
Validation and
comparison
RTD
WP2:
Generic
Method
Demo:
chemical,
power,
steel,...
Workshop on
utilisation of methods
Discuss revised
methods
User requirements
Exchange of experience,
Recommendations
Standardisation
TN
Point of
departure
Demo
WP1:
Current
Practice
Time
Fig. 1 Relationship between the RIMAP RTD WPs, the RIMAP Demo and the interaction with the RIMAP Thematic Network.
Due to the latter, risk-informed procedures are in principle suitable for getting acceptance in all EU-member countries and also in
those countries having a more or less prescriptive regulation, riskinformed procedures for planning in-service activities are already on
its way.
The main goal to be achieved is to find a European wide accepted
method for risk-based inspection and maintenance and to embed
available and existing methods, tools, standards, etc. To realize this
issue, the European project RIMAP (Risk-Based Inspection and
Maintenance Procedure for European Industry) was launched in
2001. In the following, the project will be described in general. After
that a special insight will be given to the application within the
power industry.
RIMAP (RISK-BASED INSPECTION AND MAINTENANCE
FOR EUROPEAN INDUSTRIES)
Project Overview
Risk Based Inspection and Maintenance Procedures for European
Industry (RIMAP) is a European project that shall develop a unified
approach for making risk based decisions within inspection and
maintenance. The focused industries are:
Power,
Petrochemical,
Chemical and
Steel.
The project is divided into three sub-projects:
RTD (Research and Technology Development)
DEMO (Demonstration for each industry sector)
TN (Thematic Network)
The RIMAP RTD/DEMO/TN projects started in 2001. The RTD/
DEMO projects will be completed in 2004, while the RIMAP TN
will be completed in 2005.
The RIMAP RTD project is divided in 5 main technical work
packages (WP), see Figure 1. Th e WP's are structured with a clearly
defined interrelation in order to achieve an efficient execution of the
project.
WP1: Current practice within the involved industries.
WP2: Development of a generic RBMI method, based on a
multi-criteria decision process.
WP3::Development of detailed risk assessment methods,
damage models for participating industry sectors, the use of
inspection data.
WP4: Development of RIMAP application workbooks for
each industry sector: guidelines for development of Risk
Based Inspection and Maintenance plans.
WP5: Validation of the RIMAP methodology.
The RIMAP DEMO project consists of 4 demonstration cases,
one for each industry sector, to prove the applicability, while the
RIMAP TN project accompanies the entire development by disseminating the information and results of the RTD and DEMO part to a
wider community of companies to review what has been developed
and to get an overall acceptance.
RIMAP Documentation Level - I
D2.2
Exec. Summary & Introduction to RIMAP
RIMAP Procedure
D2.1
RIMAP Framework
RIMAP Validation / Benchmarking
WP5
Overview Document (D3.1)
RIMAP Documentation Level - II
Damage
Mechanisms
RIMAP Tools
NDT
Efficiency
Human
factors
PoF
CoF
D3.1 and I3.x as Appendices to D3.1
RIMAP Documentation Level - III
RIMAP Application
Workbooks
Power
Petrochemical
Steel
Chemical
D4.x
Fig. 2 RIMAP document hierarchy
The main deliverables from the RIMAP RTD project will be (the
related documents can be depicted from Fig. 2):
A method describing an unified approach to maintenance and
inspection planning based on risk decision criteria and cost
optimization.
Guidelines for practical use, in the format of one "Workbook"
for each industry sector.
Spread knowledge between industry sectors.
The RIMAP method will be tested within 4 industry sectors in
the RIMAP Demonstration project and, as such, it will be a major
contribution to European standardization.
The project is currently completing WP4 and WP5 in addition to
having started the industry specific demonstration projects.
The RIMAP Framework
In order to put the idea of risk based maintenance and inspection
into action it is necessary to install proper procedures and tools
within an adequate framework to ensure the required quality, transparency, and documentation.
The general RIMAP framework consists of the RIMAP working
process (management related issues) and the RIMAP procedure
(technical related issues), which are briefly described in the following:
trates the work processes involved in implementing and managing
RIMAP at a plant or facility.
RIMAP defines the working processes and provides requirements
to the personnel that will execute the working processes. Implementation of RIMAP also requires an active management that focuses on
the following issues:
Management of change
Operating procedures
Safe work practices
Pre-start-up reviews
Emergency response and controls
Investigation of incidents
Training
Quality assurance
Resources
Management of work processes
Define
goals &
requirements
Organisation
Materials
Support
Establish
Insp . & Maint .
Programme
Plan
Tasks &
Activities
Execute
Work
orders
Active
manage ment
Resource
needs
Perfor m
Corrective
Actions
Prepare
Improvement
Tasks
Evaluate
Technical
condition
Results
Costs
Technical
condition
Repor t
Failures
& Status
Reliability
SHE level
Fig. 3 RIMAP Work process
RIMAP Work Process. To implement and manage a system
for risk based inspection and maintenance management sets requirements to a plants (maintenance) management system. Fig. 3 illu s-
As risk based inspection and maintenance planning is a multidisciplinary task, it requires a team, where all necessary competencies
are represented and expertise are available (e. g. EN 45004). Another important issue is the recurrent evaluation at a certain interval
to assess all the modifications and new data available to make sure
the entire process runs into a continuous loop.
RIMAP Procedure. In Fig. 4, the generic RIMAP procedure
is shown. It is industry independent and applicable to different
equipment types (static, safety systems, etc.).
The steps in the procedure are the same for different industrial
sectors (chemical, petrochemical and power) and for different equipment types even if the techniques (e. g. tools for assessing probability
or consequence of failure) may vary from one application to another.
Plant hierarchy: The plant hierarchy is a prerequisite for an efficient risk assessment and maintenance and inspection planning, since
the plant is divided into manageable sections.
Failure mode: Assigning functions and sub functions to the physical items at the plant simplifies the identification of failure modes. The
failure modes are then used to identify failure causes, root causes, and
damage mechanisms.
Scenario development: RIMAP uses risk, the combination of
probability and consequence of failure, to prioritize inspection and
maintenance activities. The assessment of the probability and consequence of failure are combined in the bow-tie model, see Fig. 5. A
scenario is damage mechanisms leading to a potential event with a
consequence (safety, health, environment, or business).
Failure or main event (e.g. adverse event,
problem, issue, functional problem, operational
disturbance or similar) the probability and
consequences of which are analyzed in order to
define risk related to it.
CoF
Cause tree:
PoF analysis
covering e.g.
failure modes,
causes etc.
Consequence tree
CoF analysis e.g. by
means of an event tree
Event
PoF
Fig. 5 The Bow-tie-model
Fig. 4 RIMAP procedure
So, within the generic RIMAP procedure it is possible to meet
the requirements of other already existing risk related programs like
EN 1050 for machinery or IEC 61 508 for electrical safety systems.
As shown in Fig. 4 above, the core of the procedure the multilevel
risk analyses includes a seamless transition from screening to detailed analysis. Here, it is obvious that for a certain level of risk a
sufficient depth of the analysis is required.
The RIMAP description of Risk, PoF, CoF
The RIMAP project provides guidelines on how to perform risk
based inspection and maintenance planning for all types of equipment: active components, static components, and safety critical
equipment. The steps required to perform maintenance and inspection planning are similar for each type of equipment. The steps in the
analysis are similar for all equipment classes:
Probability of failure (PoF): A number of methods for determining the probability of failure is discussed (expert judgement, rate models,
statistical, physical models, etc.) The industry specific workbooks contain industry specific models.
Consequence of failure (CoF): Consequences of failure are d ivided into four categories. Safety instant consequences on humans
within or outside the plants area. Health consequences long term
effects on humans within or outside the plants area. Environmental
consequences and business consequences of failure. Methods are provided for making this type of assessment.
Risk assessment: Risk is the combinations of the probability of
failure and consequence of failure. The level of risk is compared to the
company acceptance criteria regarding safety and environmental risk.
For financial and cost consequences, a cost-benefit assessment is proposed. The cost is related to the mitigation cost. The benefit is the reduced risk versus the mitigation.
Mitigating activities and risk reduction: Based on the risk assessment (safety, health, environment, business) mitigating activities are
proposed for the high-risk items. Mitigation activities can be maintenance/inspection, redesign, operational constrains depending on the
actual case.
Methods for PoF assessment. RIMAP does not recommend particular methods for PoF assessment although the industry
specific workbooks describe some methods for PoF assessment.
RIMAP recommends that the level of detailing is adapted to the case
and the risks involved. This means that in some cases expert judgement by domain experts can be considered as good as more advanced
calculations. The project stresses the need for good information to
base the assessment on.
The PoF assessment enters into the analysis in different ways for the
static equipment, safety critical components and rotating equipment:
Static equipment: For trendable degradation mechanisms, the
acceptable risk is combined with the consequence of failure
to determine a PoF limit. The PoF limit is combined with the
damage rate to obtain a maximum time to inspection.
Safety critical equipment: For safety critical equipment the
risk assessment is used to determine a requirement on availability. This limit is then used to determine maintenance
strategies that meet the requirements, mostly related to testing to find hidden failures.
Rotating Equipment: The PoF assessment, given a certain
maintenance program, is combined with the CoF assessment
to obtain a risk for the given maintenance program. The level
of maintenance is then chosen such that 1. SHE requirements
and legislation is satisfied and 2. maintenance program is
cost optimal within the boundaries that 1. define.
THE RIMAP APPLICATION WORKBOOK FOR POWER
PLANTS
The current RIMAP Application Workbook for Power plants includes two main parts on the methodology application and appendices on supporting information.
Part I
Detailed description on how to set up and perform risk analysis.
This section outlines the standard format, preparatory analysis, data
collection and validation, multilevel risk analysis and decision making, assessment of inspection techniques, implementation of plans,
and evaluation of the overall process.
In the damage mechanism section, the essential systematic a spects of damage mechanisms, applicable to power plant related
components, are covered, including where and how to look for damage, as well as analysis and prediction methods of damage development.
On plant hierarchy, a recommendation for a standard hierarchy is
given (see Table 1) with examples for possible damage related issues. See Table 2, where recommendations are given on a component
level using the number and quality of the stars to quantify the
applicability of a certain deterioration mechanism.
Water systems (G, L)
Feedwater/boiler water systems (G, L)
Feedwater treatment
Feedwater treatment (GA, GB, GC)
Condensate treatment
Condensate polishing (LD)
Boiler water transport
Feedwater pumps (LAC)
Condensate pumps (LCB)
Feedwater piping (LAB)
Feedwater tank, deaerator (LAA)
Feedwater heaters (LAD)
HP feedwater heaters
LP feedwater heaters
For both static equipment and safety critical equipment more frequent inspection or maintenance may be proposed if this is more cost
effective.
CoF assessment. A set of requirements to CoF assessments
have been formulated. Complying with the requirements implies that
the RIMAP procedure has been followed. Methods for assessing the
safety, health, environmental, and business consequences of failure
have also been given. The consequence assessment applies to all
equipment types (static, rotating, instrumented protection functions)
and to all industry sectors represented in the project. The methods
are easily extended to other industry sectors.
The consequence assessment is based on a certain scenario. RIMAP distinguishes between two types of scenario:
Worst case scenario: Combine a given root cause/damage
mechanism with the most serious/severe consequence that the
given root cause/damage mechanism may lead to, e.g. loss of
all fluid within the segmentation area, ignition, etc.
Expected scenario. Combine the root cause/damage mechanism with the expected or typical consequence that the given
root cause/damage mechanism will lead to.
RIMAP recommends use of the expected scenario in analyses.
This is dependent on the degradation mechanism expressed in the
scenario definition. It is essential that the choice of approach is made
before the analysis starts and that the same method is used consistently throughout the analysis. If a consistent scenario is not used, the
choice of risks mitigated will be affected, which may lead to a suboptimal maintenance and inspection plan.
Table 1 Extract: Recommendation for the plant hierarchy
The risk analysis section outlines applicable procedures, and PoF/ CoF evaluating methods. The section on risk consideration deals
with reduction and mitigation of risk with links to maintenance and
inspection techniques.
Part II
System / Subsystem / Component data on item by item basis.
The system and component related considerations are listed and
default information is given item per item.
The main systems and components that are currently covered to
varying extent include:
Fuel supply and waste disposal system
Boilers for conventional steam generation
Steam systems (piping)
Steam turbines
Gas turbines
(electric) generators
electric distribution
Under these headings, different subsystems and components are
considered from the point of view of general features and operating
conditions, typical damage mechanisms and failure modes, basic
default PoF and CoF data (with references), description of typical
preventive and corrective actions, and suggested rating scales on PoF
and CoF factors for specific problems on a given component type.
Table 2 Extract: Plant hierarchy vs. typical problems
DEMO APPLICATION
The full scale application of the RIMAP Power Workbook took
place at a South German coal fired 760MWe power plant, in operation since 1987. The demo has the following main objectives:
to demonstrate the applicability and usefulness of the RIMAP
methodology on several practical cases.
to demonstrate several economic advantages
to demonstrate the benefits of standardization
to give input and feedback to further development of the
methodology and standards for power related issues.
The assessment presented focuses on parts of the boiler, the main
steam piping, and the hot reheat piping (overall 64 components).
Risk analysis was done on three levels: screening, intermediate analysis and detailed analysis.
On the level of screening, only the general statistical data and the
results of on-line monitoring were taken into account. For this purpose, the existing measurement systems (measuring pressure, temperature and temperature difference at the calculation points) and the
existing fatigue monitoring system were used. For the purpose of risk
analysis, the algorithm was extended for the probabilistic analysis
(Monte Carlo simulation).
On the level of intermediate analysis, inspection results (replica)
were introduced and probabilistic assessment of replica findings was
done.
For the detailed level, the analysis was extended by means of
probabilistic high-temperature fracture mechanics and the fatiguecreep crack growth analysis. In addition to the analysis of recorded
data, the detailed analysis also included what-if analysis for different assumed load cases and it was accompanied by the corresponding
non-destructive testing on a model (establishing of the minimum
detectable nozzle corner crack for the most critical component.
The principle is shown in Fig. 6. For detected cracks the real dimensions of which can reach critical crack size, i.e. can be larger
than the measured ones (here one 25 mm crack only) are to be assessed. As well as undetected cracks, among which a crack of a
critical size may appear.
The results of the work clearly show the benefits of the proposed
method for concentration on critical items: Out of the 64 monitored
POD
components taken for screening analysis (see Fig. 7), 6 were selected
for intermediate analysis and only 1 for the detailed assessment.
In addition overall level of risk was managed all the time and the
costs and benefits of risk based approach were made visible, transparent and measurable. Characteristic results are shown in Fig. 8.
1 POD = PonD = p1
100%
p1
Possible adverse
event #1:
Possible
damage
mechanisms:
a cr
Failure due to
brittle fracture
caused by an
undetected
critical size crack
(a cr )
corrosion
cracking
(I.B)
material
embrittlement (I.C)
cracking
(II.D)
Embrittle- Possible adverse
ment
event #2
fracture
(II.E)
Failure due to
brittle fracture
caused by
uncertainty in
dimensioning of a
crack identified
as a 25mm crack
a
OR
Very high
p1
High
Medium
Low
Very low
p1
OR
PoF = p1 + p2 p1 p2
p
a=25mm
a cr
p2
p2
a
OR
Very high
p2
High
Medium
Low
Very low
p2
Fig. 6 Definition of PoF for the case of a structural failure and its main root cause
Fig. 7 Determination of critical components (screening analysis)
NOMENCLATURE
0.01
Screening
PoF
0.001
For these
components
no further
analysis after
screening
needed
Intermedia
te
TYPICAL
ANALYSIS PRICES
1.
Detailed
6
2.
10
0.0001
3.
Screening
Intermediate
Detailed
EU
CoF
D
ISI
NDT
PED
PoD
PoF
RIMAP
0.00001
100
1000
10000
100000
Consequences (Euro)
1000000
10000000
Fig. 8 Overall results (screening, intermediate, detailed)
CONCLUSION
European practices for risk-based decision making are under development to create a guideline and applicable tools for practical use.
The current project RIMAP, involving more than 40 companies
promises to deliver a consolidated European risk-based practice.
The application from power plants presented here and the other
industries covered, will demonstrate the applicability and principle
acceptance of the procedures and tools and lead to an acceptance of
the methodology throughout Europe.
Detailed information can be gathered on the projects websites,
(see References).
RTD
TN
WP
European Union
Consequence of failure
Deliverable
In-service inspection
Non-destructive testing
European Pressure Equipment Directive 97/23
Probability of detection
Probability of failure
Risk Based Inspection and Maintenance for
European Industries
Research and Technical Development
Thematic Network
Work package
ACKNOWLEDGEMENT
Risk Based Inspection and Maintenance Procedures for European
Industry (RIMAP) is a project partly financed by the European Commission for the "Growth Programme, Research Project RIMAP Risk
Based Inspection and Maintenance Procedures for European Industry"; Contract Number G1RD-CT-2001-03008.
The authors would like to acknowledge the financial support by
the European Commission.
A special acknowledgement is given to the support for the Demo
application provided by J. Barei, P. Buck (EnBW), P. Auerkari
(VTT), D. Balos, M. Perunicic (MPA-Stuttgart), and F. Hee (TV
SD).
REFERENCES
More information and references to special aspects are given at
RIMAP RTD or RIMAP Demo project:
[Link]
RIMAP TN:
[Link]
