Risk-based Inspection
Experience of an Oil & Gas operator
TOTAL Energies, France
Tohoku Forum, November 9th of 2023
Ricardo Gonzalez

Contents• RBI, what it is• How it works and example• Benefits and reasons to adopt• Requirements and limitations• History of RBI in TotalEnergies• Deployment effort• Additional tools• Leading indicators• Calculation details• Digital RBI• Conclusions

2

In-service inspection
Inspection actions to identify degradation based on credible industry damage
and failure modes, to determine further actions to control the operationalrisk, predict equipment end of life and feed the fitness for service evaluation

And not…
Inspection actions to verify equipment’s conformity to design code anddetermine maintenance actions to recover its original condition and strength

Inspection approachevolution

3

Reactive

Calendarbase

Condition
base

Risk
base

Inspection approach evolution
Reactive

Calendar baseCondition baseRisk baseStrategy

Run tofailureLegal
requirement

Equipment
life

Risk management

Benefits

ReducedbudgetLeveledbudgetReliability
assurance

Optimized scope,
budget & reliability

Drawback

CostlyfailuresCostly failures& budgetFeed-backneededValidity ofprediction

API Codes: Vessels 510,

API 580 supported
by 581, 571 & 584

RAGAGEP(*)

None

Legal text(*) Recognized And Generally Accepted Good Engineering Practice4

Piping 570, AST 653,
Heaters/Boilers 573, PSV 576

RBI, a systematic proces that…
Begins with identification of facilities or equipment
Continues with a determination of risk, via probability and consequence of failure
And culminates in the creation of an inspection risk-based management plan based on
the credible damage mechanism(s) and the risk of failure
Inspection teams should utilize the RBI output to effectively and efficiently prioritize theexecution of their inspection programs
Risk Matrix
Corrosion
kinetics
Equipment
data

5

Inspection
Probability

Inspection
qualityNo
inspection
ConsequenceAimed to provide minimum elements for…
Developing, implementing, and maintaining inspection programs
Of pressure-containing equipment
To insure safe and reliable operation through risk-prioritized inspection
Through a framework that specifies the minimum requirements and expectations
needed for a quality application of the methodology

6Same case, different
strategies
Ractive
Visual internal inspection, CA
not affected
Next inspection eventually
upon equipment opening

Calendar
23,9 > 21,3 → OK
Corroded area repair by welding
Next inspection in 2023, internal

Condition baseRlife 13,6 yrs., ½ in 2025 (API 510)
Next inspection in 2023, internal

Risk-based
Generic frequency 3E-05, Management factor 0,4
Increased CR to 0,5 mm/yr. due to process change since 2015 yrs.
Highly effective inspection
Timeframe 9,2 yrs. To 2027, DF 8,2 POF = GFF x MF x DF =1,02E-04 (Level 3), COF = Major
Next inspection in 2027, non-intrusive by UT Scan
7

Benefits
Identification of damage mechanisms and failure modes
Identification of equipment with insufficient or inadequate inspection history
Safety, health, and environmental and/or economic consequences
Recommendation of inspection methods and techniques
Establishment of the extent of inspection
Optimum inspection interval
Development of cost-effective actions
Overall reduction in risk for the facilities
Other required mitigation

Integrity and reliability improvement at the same time8

RBI limitations• RBI does not compensate for mistakes due to lack of skills on inspection• The effectiveness of an inspection can be limited- Lack of coverage- NDT limitations- NDT procedures and technician skills

Richmond fire learnings- 6 injured & unit destroyed)- Corrosion by Sulphidation- No awareness of increasing
temperature and opportunity
crude processing- No program for low silicon CS- No history of spool change => nodedicated CML

9Typical oil Refinery

Exposed surface
Vessels9%

Bundles 35%
Piping1056%

Unbalanced inspection effort
Equipment Exposed Inspection
typesurface
EffortHC
Leaks

Businessinterruption

Vessels

9%

83%

7%

14%

Bundles

35%

1%

7%

50%

Piping

56%

16%

78%

32%

 83% on 9% of exposed surface that produces 10% of problems
 16% on components leading to 78% of leaks
 1% on reliability bad actors
11History of RBI in TotalEnergies
1990-93

Company became sponsor of RBI from the API

1995-99

First qualitative RBI Guide for vessel and piping

2000-03

Company develop their own RBI software with an expert body

2004

French inspection guide allows using RBI to optimize inspection periodicities

2007

Important increase of maintenance cost due to inspection request

2008-10First quantitative RBI guide for Refining, based on regulations flexibility

2011-12

Cultural change need identified. Communication, Audits and the concept of acceptable risk installed
Improvement of Integrity operating windows and Fitness-for-service also launched

Criticality based model

Data
12

Damageexploration

REX + Reg.+Technical Judgement+ Consequence +RB.eyeInspection
PlanHistory after concept change
2011-12

Cultural change need identified. Communication, Audits and the concept of acceptable risk installed
Improvement of Integrity operating windows and Fitness-for-service also launched2013-17

Deployment RBI and inspection effectiveness training and coaching and the implementation of turnaround scope
reviews

2018-19

Refining & Chemicals deploy a New RBI software

2020
2021-23

Concept of Dynamic RBI starts to be largely used for turnaround postponement assessment due to COVID
RBI software completed in Refining and Chemicals and RBI concept and new software started in Exploration andproduction facilities

Risk-based

Data

13

Damageexploration

Risk
Assessment
POF & COF

Risk
ranking

Inspection
Plan

Other
mitigation

Framework of an RBI-like inspection team
• 9 big domains, 54 workflows and 222 tasks

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RBI Review

Field inspection

CUI Plan

Turnaround
preparation

Damage review

MOC

FFS

New

REX

Main tasks & workload of a typicalrefinery• Method inspector, main actor to keep RBI up-to-date• In-house Unit inspector and assistant mostly dedicated to plan & inspect• External Unit inspector helps on planning and Turnaround preparation

Turnaround
preparation

Main workload estimation (MH/yr. medium size refinery)

RBI Review
39%

15

17%

11%

External

3500

2300

3400

CUI Plan
10%
MOC

2,5%

FFS

Damagereview

In house
Unit
inspector

18%

Field
inspection

Method inspector

Assistant Inspector

2100

New
REX

Other (Process, Corrosion, FFS, etc.)

1800

Corrosion update (IOW issue)

13%

RBI update

13%

Special RBI (Non-model, etc.)

13%

Field inspection

93%

Assessment following issues

4%

Inspection planning

25%

QA review

17%

Turnaround preparation

11%

Inspection planning

44%

Inspection facility request

11%

Corrosion loop update

11%Additional methods and tools• Some components not well managed by the RBI models and software's• Also, some damage mechanism are not modelized, and require a special approach• Creep damage can be managed through FFS dedicated tool instead of RBI• RBI for exchanger bundles can be supported by statistical analysis and tools• Statistical evaluation of corrosion rate should be supported by special tools• Management of risk beyond RBI can be supported by multidisciplinary Layer of Protection
Analysis (LOPA)• Risk-based cost/benefit assessment tools helps on financial decision making

16

Leading indicators• Early result showed important reduction of inspection workload, mainly during Turnarounds• Inspector cultural change progressively
followed of the approach acceptance from
Authorities• Integrity index showed improvement while
reliability index remined stable

Reliability index

Integrity index

17Probability of failure calculation• The probability of failure in API RBI is determined by three parameters:- Generic failure frequency- Damage factor- Management system factor

POF(t) = gff . Df . FMS

Based on industry data Due to fabrication flaws
 Non service-related damage
 Prior to operating exposure

18

Generic failure frequency

Damage factor calculation• The damage factor is the amount of damage as afunction of time and the effectiveness ofinspection
POF(t) = gff . Df . FMS

Df thinInternal
corrosion

Df elin

Lining damage

Df extd

External
corrosionDf sccStresscorrosioncracking

Df hthaHightemperature H2
AttackDf brit

Brittle fracture

Df mfatMechanicalfatigue

Df-total = min [ Df thin,Df elin ] + Df extd + Df scc + Df htha + Df brit + Df mfat
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Fluid inventory calculation

Generic frequency• Select hole sizes, Determine fluid properties,
calculates release rate and estimate fluid inventory
Fluid properties
Liquid release rate
Vapor release rate

Estimateinventory

20

PinholeSmall rupture

Corrosion hole

Large rupture

StartType of release estimation• Determine release type and assess detection and isolation systems
Release typeInstantaneous

Detection
21

Continuous

Isolation

Flammable consequence

VCE• Calculate flammability and estimate probabilities of
events (example of continuous release)
80%

1

30%
Late ignition

Example

2

70%
75%

20%

Gas

Flash fire

Early ignition

Above AITJet fire25%

No Ignition

Safe
dispersion

Ignition

Pool fire

LiquidNo Ignition

Safe
dispersion

VCE: Vapor cloud explosion, AIT: Auto ignition temperature
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Other consequences• Calculation of toxic consequence- Common chemical industry toxic materials & representative fluid- Determination of toxic release and probabilities- Toxic COF for HF, H2S, Ammonia and Chlorine• Non-Flammable Non-Toxic consequences- Steam, acid caustic leaks• Environmental consequence- Based on remediation & clean-up cost

• Financial consequence- Cost of equipment (and surroundings) repair and replacement- Business interruption
IDLH: Immediately dangerous to life or health, AEGL3-10: Acute exposure guideline Level (10 ‘), ERPG-3: Emergency response planification guideline

23

Inspection entering the digital era

Conventional Equipment
data
RBI

Enhanced
RBI

Data &
History

History

Corrosion
Model

Corrosion
kinetics

Statisticalanalysis ofInspect.
resultPOF, COF& Risk analysis

Inspection

Process
parameters
prediction

FFS orRisksimulation

POF: Probability of failure COF: Consequence of failure, FFS: Fitness-for-service
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Example• Following corrosion issue in 2020, a Fin-fan’s conventional RBI asked inspection mid 2021
• Process improvements led to mitigate corrosion, but RBI at fixed corrosion rate could not
managed this improvement• Enhanced RBI applied andupdated once a month

UT ScanActual pH• Outlet line used as inspection
monitoring location once amonth• Turnaround moved to
September 2023 instead of2021

1st update

2nd update

RBI

2nd
1st

3rd

Target risk

3rd update
25Piping

Equipment

Extrapolate
to?

Field insp. / NDT

1

Calendar

Visual

None

None

2

1

2

Condition

TML & RLife

Visual + spot UT

None

2

2

3

RBI

Fixed CR

RBI + corrosion
model

None

1

1

1

4

Enhanced
RBI

Dynamic RBI

Risk & FFS
simulation

Connected
equipment

½

1

1

½

5

Smart
integrity

Machine learning
applied to process &inspection history

Damage & risk
simulation

All Refinery

1

½

1

6

Digitalintegrity

Machine learning update applied toprocess data and fixed field captors

All Refinery

26?

Data scientist

Approach

Approaches & context

Engineer

Step

Inspector

Digital transformation of Inspection

Summary and conclusions• Understanding the risk-based decision-making process is a key of success• Integrity improvement should be highlighted first• Cultural change rather coming from training and coaching• Deployment & update effort must be optimized and audited, don’t create monsters!
• Scope review from knowledgeable central office help to assure world class performance• Integrity operating windows essential for the credibility of conventional RBI internal corrosion
management• Additional tools required to support change management• Management of risk beyond RBI essential for integrity assurance• Digital RBI must follow and should be managed with care due to implications on skills, manpower
and regulations
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Backup28

Context of 10 European Refineries
27000 Piping circuits
9000 Heat exchangers
8000 Drums

500 Heaters
1000 Towers
2500 Air coolers

2929

Economics

Estimation for 10 Sites and typical 6 years cycle

Global saving% with RBI

3027000 Piping circuits-50%

9000 Heat exchangers

42%

8000 Drums

50%

500 Heaters

20%1000 Towers

50%

2500 Air coolers

42%

Global26%

RBI basic requirements
 Integrity assurance strategy based on risk management Stick to risk-based upon decision-making approaches
 Implementation of solid monitoring of process variables
related to degradation
 Assure effective management of change

31Integrity operating windows
Structured analysis- Review parameters, kinetics and the damage mechanism- Review current plan (inspection date)- Assess if RBI can be jeopardized, if yes, trigger deep
assessment

Failure occurs quickly

Safe, reliable,
profitable- Record the analysis

Examples oof IOW violations• Change in the fluid’s Sulphur content• Stop of corrosion inhibitor injection

TARGET• Change in the pH or fluid chemical composition• Cathodic protection not working/not under control

Safe to operate indefinitely
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Failure occurs with sustained operation

RBI performance in 201133

Inspection framework
Equipment data
Conditions
 Physical & process data Consequence IOW, MOC
 REX

Not acceptable risk
 Detailed risk analysis
 Formal risk acceptanceLife assessment
 Inspection and process review
 Fitness-for-service

Risk-based decision
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Risk assessment
Risk assessment
 Circuitization
 Damage review
 Degradation kinetics
 Probability of failure Review of parameters Mitigation options

Inspection
 Date & effectiveness Facilities
 Applied NDT Extended if severe damage
 Evaluation & result

EffectivenessInspection manager main responsibilities• Inform Site management of non-acceptable risks• Set-up inspection policy• Assure inspection plan
• Inspection activity tracking and reporting• Ensure training and skills of Inspection personnel• Manage inspection activities- Role and responsibilities of Inspection team- Track inspection schedule recommendations- Use of FFS- Manage and optimize Inspection associated costs- Maximize on-stream non-intrusive inspections- Assure resources- Implement best-practices- Deploy new NDT technology
35

Inspection team duties• Implement inspection methods• Outline inspection plans• Assess inspection results and write inspection reports• Ensure monitoring of corrosion/degradation issues• Ensure application of fitness-for-service• Manage database and equipment history records• Provide information for inspection budget preparation, cost tracking, annual review andinspection Contracts• Provide advice and supervision on quality assurance activities

36

RBI deployment in downstream• Deployment RBI means a big Company effort and a « users » cultural change• Based on experience, a cycle of > 6 years must be considered• A combined effort of Development, communication, training and audit need to be put in place37

Example of upstream• 5 weeks deployment for CPF and 23 for a FPSO
• Core team of 4 Inspectors that can be outsourced• 3 Engineers (Site or Outsourced)• 10 assistants and clerks that can provide the Site (to adapt based on complexity)
Item

38

Onshore(CPF)

Offshore(FPSO)

Equipment

362

1599

Part

378

1766

Main units

1

7Inspection task

756

3532

Position

Team

CPF

FPSO

Weeks

Duration

Weeks

Duration

Method inspector

2

7

4

40

20

Unit inspector

2

10

5

49

24

Assistant inspector

4

25

6

139

23

Corrosion Eng.

1

1

1

6

6

Process Eng.

1

2

4

14

27

Valoriz. Eng.

1

1

2

10

10

Maintenance Eng.

1

1

2

10

10

Clerk

4

4

5

98

24

Inspection entering the digital era• RBI, the best platform for integrity and business-related decision making• It still heavily rely on expert judgment• Corrosion rate determination leads to frequent pit falls• Strongly improvement through IOW, but not easy to integrate into RBI• Process control not under use to drive risk determination

Questions to answer
 Is RBI & integrity operating windows enough?
 Continue to rely on expert judgment case by case?
 What are the alternatives?
 How degradation works?
 What if using prediction models based on process control and use Inspection as acalibration factor?
39