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REPORT SUMMARY

Date:
Page

23/09/2016
of
1

In addition to this summary, this report includes the following forms:


Report Summary
Rating Criteria and Classifications
Analysis Plans Summary
Analysis Plan Details (One per Item)
Items Summary (All Items)
Equipment Types (All Project Items)
Component Types (All Project Items)
Area Risk Matrix at Plan Date (All Project Items)
Area Risk Matrix at Plan Date (Selected Items)
Financial Risk Matrix at Plan Date (All Project Items)
Financial Risk Matrix at Plan Date (Selected Items)
Area Risk Matrix at Plan Date Results Assuming Inspections Performed (All Project Items)
Area Risk Matrix at Plan Date Results Assuming Inspections Performed (Selected Items)
Financial Risk Matrix at Plan Date Results Assuming Inspections Performed (All Project Items)
Financial Risk Matrix at Plan Date Results Assuming Inspections Performed (Selected Items)
Consequence Summary
Damage Summary at RBI Date
Damage Summary at Plan Date
Recommended Inspections at Due Date
Probability at RBI Date
Risk Summary at RBI Date
Risk Summary at Plan Date
HexTubes Summary
PRDs Summary
Thinning Damage Factor
Risk Discovery Logic
Risk Discovery Summary (with Ratings)
Risk Discovery Details (One per Item)
PFD Standard
FMEA Standard
AIAG Form A
AIAG Form B
AIAG Form C
AIAG Form D
AIAG Form E
J1739 (2002)
J1739 (2009)
MIL-STD-1629A
VDA-86
VDA-96
VDA Action Tracking
Functions
Failures
Effects
Causes
Controls
Actions
Functional Failure Analysis
Failure Effect Categorization (One per Effect)
Maintenance Task Selection (One per Cause)
Tasks
Control Plan Standard
DVP&R Standard

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

16

REPORT SUMMARY

Severity Rating Scale


#
Description

Criteria 1

Criteria 2

Date:
Page

Occurrence Rating Scale


#
Description

Insignificant

Area <= 9.29 m^2

Financial <= $10,000

Remote

Minor

9.29 m^2 < Area <= 92.9 m^2

$10,000 < Financial <= $100,000

Very Low

Significant

92.9 m^2 < Area <= 279 m^2

$100,000 < Financial <= $1,000,000

Low

Serious

279 m^2 < Area <= 929 m^2

$1,000,000 < Financial <=


$10,000,000

Moderate

Major

929 m^2 < Area

$10,000,000 < Financial

High

Detection Rating Scale


#
Description
1

Almost certain

Very high

High

Moderately high

Medium

Low

Slight

Very slight

Remote

10

Almost impossible

Item #
1

1.1

1.1.1

Tag Number

Criteria 1
Criteria 2
Current controls almost always will
detect the failure. Reliable detection
controls are known and used in
similar processes.
Very high likelihood current controls
will detect the failure.
Good likelihood current controls will
detect the failure.
Moderately high likelihood current
controls will detect the failure.
Medium likelihood current controls
will detect the failure.
Low likelihood current controls will
detect the failure.
Slight likelihood current controls will
detect the failure.
Very slight likelihood current controls
will detect the failure.
Remote likelihood current controls
will detect the failure.
No known controls available to
detect the failure.
Alternate Part
Name
Part Number
Description
Number
QARUN CPF
QARUN
PETROLEUM
COMPANY
CENTRAL
PROCESSING
FACILITY
Crude Storage
Tank-A (55,000
bbls.)
TANKBOTTOM_1

Date Created: 23/09/2016

Tank-A Bottom

Creator: Qarun Integrity RBI team

Tank-A is one
from 3 main
tanks (A, B & C )
located at Qarun
Base CPF , with
a capacity of
55,000 bbls. (of
each ) of the
crude oil after it

Criteria
Annual Failure Probability/
Frequency: <0.00001
Annual Failure Probability/
Frequency: 0.00001 to 0.0001
Annual Failure Probability/
Frequency: 0.0001 to 0.001
Annual Failure Probability/
Frequency: 0.001 to 0.01
Annual Failure Probability/
Frequency: >0.01

Classification Options
Abbreviation

16
Criteria 2
Probability of Failure <=0.1
0.1< Probability of Failure <=0.2
0.2< Probability of Failure <=0.3
0.3< Probability of Failure <=0.5
0.5< Probability of Failure

Description

Critical

KI

Key Intermediate

KLd

Key Leading

KLg

Key Lagging

Comments

23/09/2016
of
2

Significant

Qty per
System
1

Qty per
Assembly
1

Supplier

Similar To

URD

Reliability model

Inherit

Inherit

Petrojet

Based on RBI
analysis

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

RBI_DF_TANKBOTTO
M [WB2 (0.163,
7.68E+15)]

REPORT SUMMARY

Date:
Page

23/09/2016
of
3

16

was treated in
CPF

Equipment Type
Tank650
Component Type
TANKBOTTOM

Count
1
Count
1
RISK PRIORITY

PROBABILITY OF FAILURE CATEGORY

Low

Medium

Medium High

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

High

REPORT SUMMARY

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16

Medium High

High

CONSEQUENCE
RISK PRIORITY

PROBABILITY OF FAILURE CATEGORY

Low

Medium

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

REPORT SUMMARY

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16

Medium High

High

CONSEQUENCE
RISK PRIORITY

PROBABILITY OF FAILURE CATEGORY

Low

Medium

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

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16

Medium High

High

CONSEQUENCE
RISK PRIORITY

PROBABILITY OF FAILURE CATEGORY

Low

Medium

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

REPORT SUMMARY

Date:
Page

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16

TANKBOTTOM_1

Medium High

High

CONSEQUENCE
RISK PRIORITY

PROBABILITY OF FAILURE CATEGORY

Low

Medium

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

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16

Medium High

High

CONSEQUENCE
RISK PRIORITY

PROBABILITY OF FAILURE CATEGORY

Low

Medium

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

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16

Medium High

High

CONSEQUENCE
RISK PRIORITY

PROBABILITY OF FAILURE CATEGORY

Low

Medium

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

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16

Medium High

High

CONSEQUENCE
RISK PRIORITY

PROBABILITY OF FAILURE CATEGORY

Low

Medium

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

REPORT SUMMARY

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CONSEQUENCE
Component Name
TANKBOTTOM_1

Component Type
TANKBOTTOM

Equipment Name
Crude Storage Tank-A
(55,000 bbls.)

Component Description
Tank-A is one from 3 main
tanks (A, B & C ) located at
Qarun Base CPF , with a
capacity of 55,000 bbls. (of
each ) of the crude oil after
it was treated in CPF

Representative
Process Fluid

Storage Phase

C17-C25

Liquid

Fraction of
Toxics in
Process Fluid
(wt/wt)

Fract
ion
Tot
DF
of
DF DF
D
al
DF DF
Fo
Compo Represen Stor Toxic Opera Operati
DF
DF SCC- DF
For SC DF For
DF
F
Compon Equip
Invent DF DF DF
SCC SC
r
Compone
nent
tative
age s in ting
ng
SCCHIC/SO SCCSCC C- SCCExt- Ex
ent
ment
ory (RB Thinn Lini
- CSC
nt Name
Descri Process Phas Proc Press Temper
Cau
HICCarbo
- HS HIC/SO Corro tType
Name
Mass I
ing ng
Ami SS
Cption
Fluid
e
ess
ure
ature
stic
H2S
nate
CLS C- HIC-HF sion C
Dat
ne C
PT
Fluid
CC HF
UI
e)
A
(wt/
wt)
TANKBOTT TANKBO Crude Tank-A
C17-C25 Liqui
14.7 115 (F) 67982 6
6
OM_1
TTOM Storage is one
d
(psi)
31 (kg)
Tank-A from 3
(55,000 main
bbls.) tanks
(A, B &
C)
located
at
Qarun
Base
CPF ,
with a
capacit
y of
55,000
bbls. (of
each )
of the
crude
oil after
it was
treated
in CPF

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Operating
Pressure

Operating
Temperature

Inventory Mass

14.7 (psi)

115 (F)

6798231 (kg)

DF
DF
Brit
DF ExtDF DF Brit- DF BritDF
- DF Probab
Ext- CUI
Brit- Temper
885
HT
Sig MF ility Of
CLS Fract Embrittle Embrittle
HA
ma AT Failure
CC CLS
ure
ment
ment
Pha
CC
se

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

0.00419
3

REPORT SUMMARY

Date:
Page

Fract
ion
Tot
DF
of
DF DF
D
al
DF DF
Fo
Compo Represen Stor Toxic Opera Operati
DF
DF SCC- DF
For SC DF For
DF
F
Compon Equip
Invent DF DF DF
SCC SC
r
Compone
nent
tative
age s in ting
ng
SCCHIC/SO SCCSCC C- SCCExt- Ex
ent
ment
ory (Pl Thinn Lini
- CSC
nt Name
Descri Process Phas Proc Press Temper
Cau
HICCarbo
- HS HIC/SO Corro tType
Name
Mass an ing ng
Ami SS
Cption
Fluid
e
ess
ure
ature
stic
H2S
nate
CLS C- HIC-HF sion C
Dat
ne C
PT
Fluid
CC HF
UI
e)
A
(wt/
wt)
TANKBOTT TANKBO Crude Tank-A
C17-C25 Liqui
14.7 115 (F) 67982 6
6
OM_1
TTOM Storage is one
d
(psi)
31 (kg)
Tank-A from 3
(55,000 main
bbls.) tanks
(A, B &
C)
located
at
Qarun
Base
CPF ,
with a
capacit
y of
55,000
bbls. (of
each )
of the
crude
oil after
it was
treated
in CPF

Num
Fin
ber
anc
of
Com ial
Equi
Insp
Com
pon Ris Tar
Comp
pme
ecti
pone
ent k get
onent
nt
ons
nt
Desc
Dat
Name
Na
Nee
Type
ripti (Pl e
me
ded
on an
for
Dat
Thin
e)
ning

Date Created: 23/09/2016

Effec
tiven
ess
of
the
Inspe
ction
s
Need
ed
for
Thin
ning

Num
ber
of
Insp
ecti
ons
Nee
ded
for
Lini
ng

Effec
Effec
Effec Num tiven
Num tiven Num tiven ber ess Num
ber ess ber ess
of
of
ber
of
of
of
of Insp the
of
Insp the Insp the ecti Inspe Insp
ecti Inspe ecti Inspe ons ction ectio
ons ction ons ction Nee
s
ns
Nee
s
Nee
s
ded Need Nee
ded Need ded Need for
ed ded
for
ed
for
ed SCC- for
for
SCC- for SCC- for Sulfi SCC- SCCCaus SCC- Ami SCC- de Sulfi HIC/
tic Caus ne Amin Stre de SOHI
Crac tic Crac
e
ss Stres Cking Crac king Crac Crac
s
H2S
king
king king Crac
king

Creator: Qarun Integrity RBI team

Effec Num
tiven ber
ess
of
of Insp
the ecti
Inspe ons
ction Nee
s
ded
Need for
ed SCCfor Carb
SCC- onat
HIC/S e
OHIC Crac
-H2S king

Effec
tiven
Effec
Effec
Effec
ess Num tiven
Num
Num tiven Num tiven
of
ber ess
ber
ber ess ber ess
the
of
of
of
of
of
of
of
Inspe Insp the
Insp
Insp the Insp the
ction ecti Inspe
ectio
ecti Inspe ecti Inspe
s
ons ction
ns
ons ction ons ction
Need Nee
s
Nee
Nee
s
Nee
s
ed ded Need
ded
ded Need ded Need
for
for
ed
for
for
ed
for
ed
SCC- SCC- for
SCCSCC- for SCC- for
Carb PTA SCCHIC/
CLS SCC- HSC- SCConat Crac PTA
SOHI
CC CLSC HF HSCe
king Crac
C-HF
C
HF
Crac
king
king

23/09/2016
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16

DF
DF
Brit
DF ExtDF DF Brit- DF BritDF
- DF Probab
Ext- CUI
Brit- Temper
885
HT
Sig MF ility Of
CLS Fract Embrittle Embrittle
HA
ma AT Failure
CC CLS
ure
ment
ment
Pha
CC
se

Effec
Num
Effec
tiven
ber
Effec
tiven
ess
of
Num tiven
ess
of
Insp
ber ess
of
the
ecti
of
of
the
Inspe
ons
Insp the
Inspe
ction
Nee
ecti Inspe
ction
s
ded
ons ction
s
Need
for
Nee
s
Need
ed
Exte
ded Need
ed
for
rnal
for
ed
for
Exter
Corr
CUI- for
SCCnal
osio
Ferri CUIHIC/S
Corro
ntic Ferri
OHIC
sionFerri
tic
-HF
Ferri
tic
tic

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

0.00428
1

Num
ber
of
Insp
ecti
ons
Nee
ded
for
Exte
rnal
CLS
CCAust
eniti
c

Effec
tiven
ess
of
the
Inspe
ction
s
Need
ed
for
Exter
nal
CLSC
CAust
eniti
c

Num
ber
of
Insp
ecti
ons
Nee
ded
for
Exte
rnal
CUI
CLS
CCAust
eniti
c

Effec
tiven
ess
of
the
Inspe
ction
s
Need
ed
for
Exter
nal
CUI
CLSC
CAust
eniti
c

Num
ber
of
Insp
ecti
ons
Nee
ded
for
HTH
A

Effect
ivene
ss of
the
Inspe
ction
s
Need
ed
for
HTHA

REPORT SUMMARY

TANKB TANK Crud


OTTO BOTT e
M_1
OM Stor
age
Tank
-A
(55,
000
bbls.
)

Component
Name
TANKBOTTOM_1

TankA is
one
from
3
main
tank
s (A,
B&
C)
locat
ed at
Qaru
n
Base
CPF
,
with
a
capa
city
of
55,0
00
bbls.
(of
each
) of
the
crud
e oil
after
it
was
treat
ed in
CPF

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16

Me 01/0
diu 1/20
m 19
Hig
h

Component
Type

Equipment
Name

TANKBOTTOM Crude Storage


Tank-A (55,000
bbls.)

Component Name

Date:
Page

Component Type

Date Created: 23/09/2016

Component
Description
Tank-A is one
from 3 main tanks
(A, B & C )
located at Qarun
Base CPF , with
a capacity of
55,000 bbls. (of
each ) of the
crude oil after it
was treated in
CPF
Equipment Name

Financial
Risk
(RBI
Date)
Medium
High

TOTAL
TOTAL
Component Financial
Consequen Consequen
ce Area
ce ($)

Component
Description

Creator: Qarun Integrity RBI team

16035420

Area
Based
Risk

Financial Probabilit
Based
y Of
Risk ($)
Failure

0 (m^2)

67235.366 0.004193
31

Financial Risk
(RBI Date)

TOTAL
TOTAL
Component
Financial
Consequence Consequence
Area
($)

GFFT

Total DF
(RBI
Date)

0.000722

Area Based
Risk

RBI Date

21/09/201
6

Financial
Based Risk
($)

Total DF
(Plan
Date)

Total DF
(Plan
Date
w/Insp)

Probability Of
Failure

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

Target
Date

Total DF
(Target
Date)

01/01/201
9

GFFT

Total DF (RBI
Date)

REPORT SUMMARY

TANKBOTTOM_1

Component Name

TANKBOTTOM

Component Type

TANKBOTTOM_1

TANKBOTTOM

Crude Storage Tank-A


(55,000 bbls.)

Tank-A is one from 3


main tanks (A, B & C )
located at Qarun Base
CPF , with a capacity of
55,000 bbls. (of each ) of
the crude oil after it was
treated in CPF
Component
Description

Equipment Name
Crude Storage Tank-A
(55,000 bbls.)

Tank-A is one from 3


main tanks (A, B & C )
located at Qarun Base
CPF , with a capacity of
55,000 bbls. (of each ) of
the crude oil after it was
treated in CPF

Medium High

Financial Risk
(Plan Date)
Medium High

Financi
Compone
TOTAL
Financi
Financi
Probabili
al Risk Probabili
Compone Compone Equipme
nt
Financial
al
al
ty Of
ty Of
nt Name nt Type nt Name Descripti Consequen
Based
Based
Failure
(RBI
Failure
on
ce ($)
Risk ($)
Risk ($)
Date)

PRD Name

Component Description

Area - Based Risk

Date of
Last
Last Corrosi
Compon
Number Inspectio
Equipm
Thinni
Wall
Inspecti
on
Component Compone
ent
of
n
ent
ng
Thickne
on
Rate of
Name
nt Type
Descripti
Inspecti Effectiven
Name
Type
ss
Thickne Base
on
ons
ess
Inspecti
ss
Metal
on
TANKBOTTO TANKBOTT Crude
Tank-A is Localiz 01/01/19
0
10 (mm)
0.1
M_1
OM
Storage one from
ed
95
(mm/yr)
Tank-A
3 main
Thinnin
(55,000 tanks (A,
g
bbls.)
B&C)
located at
Qarun
Base CPF
, with a
capacity
of 55,000
bbls. (of
each ) of
the
crude oil
after it
was
treated in
CPF
Risk Discovery Ratings
Category

Date Created: 23/09/2016

Factor

Creator: Qarun Integrity RBI team

Option

Date:
Page
16035420

TOTAL
TOTAL
Component
Financial
Consequence Consequence
Area
($)
16035420

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16

0 (m^2)

67235.36631

0.004193

0.000722

Area Based
Risk

Financial
Based Risk
($)

Probability Of
Failure

GFFT

Total DF (Plan
Date)

0 (m^2)

68642.51792

0.004281

0.000722

Financial
Financi
Financi
Financi
Risk
Financi
Recommend
Optimal
al Risk Probabili
al Risk
Probabili
al
Perform Perform
al
ed
Replaceme
ty Of
ty Of
Based
(Plan
Inspectio Replaceme
Based
Inspection
nt
(Plan
Failure
(Target
Failure
Risk Date with
n
nt
Risk ($)
for HexTube
Frequency
Date)
Date)
($)
Inspectio
n)
Financial - Based Risk
($)

Target Date for PRD

Assigned Components

Furnish
Minimu
ed
Corrosi
Welded
Corrosi Claddi
Injection/M Dead
Settleme Type of
m Wall
Thickne
on
Construct
Thinning
on
ng
ix-Point
Leg
Maintena
nt
Online
Thickn
ss at Rate of
ion
Mechani
Allowan Prese
Adjustmen Adjustm
nce
Adjustm Monitori
ess Per
Last Claddin
Adjustme
sm
ce
nt
t
ent
ent
ng
Code
Inspecti
g
nt
on
1 (mm) 3 (mm)
No
None
Other
Corrosion
Mechanis
m

Category

Factor

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

Option

REPORT SUMMARY

Failure

Area Consequence

Internal Corrosion

0.1 - None
1 - Low
2 - Medium
3 - High
5 - Severe
Stress Cracking
0.1 - None
2 - Low
4 - Medium
7 - High
10 - Severe
External Corrosion
0.1 - None
1 - Low
2 - Medium
3 - High
5 - Severe
Brittleness Cracking
0.1 - None
2 - Low
4 - Medium
7 - High
10 - Severe
Mechanical Fatigue
0.1 - None
1 - Low
2 - Medium
3 - High
5 - Severe
Flammability Damage to Equipment 0.1 - None
1 - Low
3 - medium
5 - High
8 - Severe
Flammability Injury to
0.1 - None
Personnel/Surroundings
3 - Low
5 - Medium
8 - High
12 - Severe
Toxic Health Issues to
0.1 - None
Personnel/Surroundings
3 - Low
5 - Medium
8 - High
12 - Severe

Financial Consequence

Date:
Page

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15

Component Repair

Surrounding Equipment Repair

Business Interruption

Environmental Damage/Cleanup

16
0.1 - None
1 - Low
2 - Medium
3 - High
5 - Severe
0.1 - None
2 - Low
4 - Medium
6 - High
8 - Severe
0.1 - None
2 - Low
4 - Medium
7 - High
10 - Severe
0.1 - None
2 - Low
4 - Medium
7 - High
10 - Severe

Flammab
Intern Stres Extern Brittlen
Surroun
Mark
ility
Flammability
Toxic Health
Business Environment
al
s
al
ess
Mechan
Compon
ding
item
Damage
Injury to
Issues to
Interrup
al
Overal
Corros Cracki Corros Crackin
ical
ent
Equipme
for
to
Personnel/Surrou Personnel/Surrou
tion
Damage/Cle
Ite
Tag Part
l
ion
ng
ion
g
Fatigue
AREA
FINANCIAL Repair
nt
Na
Descrip Comme more
FAILU
Equipme
ndings
ndings
anup
m
Num Num
Discov
CONSEQU
CONSEQU
Repair
me
tion
nts
detail
RE
nt
#
ber
ber
ery
ENCE
ENCE
ed
Rating
analy
(0.1 (0.1 - (0.1 - (0.1 - (0.1 - (0.1 - 5)
(0.1 - 5)
sis
(0.1 - 12)
(0.1 - 12)
10)
(0.1 - 10)
5)
10)
5)
10)
(0.1 - 8)
(0.1 - 8)
Completion Status in %
Potential Failure Causes with Associated
RPN
Preventive Actions
Detection Actions
R/D
Remarks/Status
Failures and Failure Effects
20
40
60
80
100
1.1.1 - TANKBOTTOM_1
Function ID
Function #
Function
Last Updated By
Last Updated
Name

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

REPORT SUMMARY

Date:
Page

23/09/2016
of
16

16

Failure ID
Failure #
Failure Mode
Prob of Loss
Last Updated By
Last Updated
Name
Function
Effect ID
Effect #
Effect
Local Effect
Next Level Effect
COFi
COFr
Last Updated By
Last Updated
Name
Function
Failure Mode
Cause ID
Cause #
Damage Mechanism
Detection Method
POFi
POFr
Last Updated By
Last Updated
Name
Function
Failure Mode
Effect
Control ID
Control #
Control
Control Type
Last Updated By
Last Updated
Name
Function
Failure Mode
Effect
Damage Mechanism
Actual
Last
Action Action Actio
Action
Person
Planned
Action Planned Review Actual Review
Review
Last
Functio Failure
Damage
Completion
Updated
Name
Effect
ID
#
n
Category Responsible Completion Date
Taken
Cost
er
Cost
Date
Comments
Updated
n
Mode
Mechanism
Date
By
Reference
Proposed
Assigned
Last Updated
Damage
Task ID Task Description
Type
Status
Condition Comments
Zone
Access
Last Updated Name
Document
Interval
interval
By
Mechanism
Characteristics
Part/Process
Number

Process
Name/Operation
Description

Machine,
Device, Jig,
Tools for Mfg

No.

Product

Methods
Process

Special
Char.
Class

Specification/Tolerance

Evaluation/Measurement
Technique

Reaction Plan
Sample
Size

Sample
Frequency

TANKBOTTOM_1
TANKBOTTOM_1

Date Created: 23/09/2016

Creator: Qarun Integrity RBI team

Generated by ReliaSoft's RBI Software http://www.ReliaSoft.com

Control Method

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