Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
ABSTRACT given to the risk assessment, which is the foundation for making a
The paper presents an overview of the European project RIMAP decision. In this context the term "risk" is not limited to a risk con-
(Risk-Based Inspection and Maintenance for European Industries) as cerning safety but also can be related to a risk concerning availability
well as a more detailed insight into its application for the power in- and ultimately money.
dustry (RIMAP Power Workbook). RIMAP is partly financed by the However, the current situation in Europe regarding inspection and
European Commission for the "Growth Programme, Research Pro- maintenance activities in process and power plants is varying over a
ject; Contract Number G1RD-CT-2001-03008. 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
INTRODUCTION practice toward safety related issues is still more or less time-based
Globalization and increased competition are keywords that char- and prescriptive. This is due to the fact that in the European Union
acterize the present development at a world wide market. A com- (EU)-member countries only the requirements for the construction and
panys ability to recognize innovative concepts will be decisive for design of pressure vessel equipment is standardized (European Pres-
meeting the progressive demands at competitiveness. sure Equipment Directive (PED), while all the legislation for in-
Process-specific control and operation concepts in combination service inspection is still with the national authorities (ISI-codes). The
with a sufficient maintenance strategy significantly influence the only requirement is that the national regulation must be adapted to the
economic efficiency of a plant in the same way as the quality of its basics of the PED. Therefore, the main classification of pressure
products. Present-day plant management requires an integral approach equipment in the PED with its influence on the construction and de-
to enable decision making, considering the interaction between differ- sign requirements is adapted in several national ISI codes (e. g. Ger-
ent systems as well as between different phases during a life cycle man BetrSichV). In these cases, the expenditure for ISI is linked to
with a focus on cost-effectiveness. Hence, it is strictly necessary to the consequence classification in the PED. Whilst in the PED the
actively drive the plants assets. word risk is avoided (the requirements are only consequence re-
Adapted probabilistic reliability and risk assessment methods lated) in the ISI codes one can often find implicit expression for risk if
combined with the information extracted from generic and plant spe- prescribed periods have to be extended or reduced. Here, it is often
cific data as well as from structural reliability models yield to a solid stated that efforts have to be adapted to the extent (=consequences)
foundation for decision making in a wide range of usage for asset and the likelihood of what can happen, which is exactly the definition
management and maintenance optimization tasks. Special emphasis is for risk.
RIMAP Consortium:
Det Norske Veritas AS TNO Industrial Technology ExxonMobil Chemical Ltd. Bureau Veritas
Staatliche Materialprfanstalt Stuttgart VTT Industrial Systems Energie Baden-Wrtemberg AG Corus Ltd.
Electricity Supply Board Hydro Agri Sluiskil B.V. The Dow Chem. Comp. N.V. Siemens AG
TV Industrie Service, TV SD Group Mitsui Babcock Energy Ltd. Joint Research Centre of the EC Solvay S.Y.
ASME PVP-Vol. 488, Risk and Reliability and Evaluation of Components and Machinery
July 25-29, 2004, San Diego, California, US
PVP2004-3020
RIMAP WP-relations
Update on RBMI
RTD
Point of
Current departure Generic Assessment RIMAP Validation and
Practice Method Methods Application comparison
Workbooks
Demo:
Demo
chemical,
power,
steel,...
TN
from inv. industries utilisation of methods methods Recommendations
Standardisation
User requirements
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 suit- RTD (Research and Technology Development)
able for getting acceptance in all EU-member countries and also in DEMO (Demonstration for each industry sector)
those countries having a more or less prescriptive regulation, risk- TN (Thematic Network)
informed procedures for planning in-service activities are already on
its way. The RIMAP RTD/DEMO/TN projects started in 2001. The RTD/
The main goal to be achieved is to find a European wide accepted DEMO projects will be completed in 2004, while the RIMAP TN will
method for risk-based inspection and maintenance and to embed be completed in 2005.
available and existing methods, tools, standards, etc. To realize this The RIMAP RTD project is divided in 5 main technical work
issue, the European project RIMAP (Risk-Based Inspection and Main- packages (WP), see Figure 1. The WP's are structured with a clearly
tenance Procedure for European Industry) was launched in 2001. In defined interrelation in order to achieve an efficient execution of the
the following, the project will be described in general. After that a project.
special insight will be given to the application within the power indus- WP1: Current practice within the involved industries.
try. WP2: Development of a generic RBMI method, based on a
multi-criteria decision process.
WP3::Development of detailed risk assessment methods, dam-
RIMAP (RISK-BASED INSPECTION AND MAINTENANCE age models for participating industry sectors, the use of in-
FOR EUROPEAN INDUSTRIES) spection data.
WP4: Development of RIMAP application workbooks for
Project Overview each industry sector: guidelines for development of Risk
Risk Based Inspection and Maintenance Procedures for European Based Inspection and Maintenance plans.
Industry (RIMAP) is a European project that shall develop a unified
WP5: Validation of the RIMAP methodology.
approach for making risk based decisions within inspection and main-
tenance. The focused industries are:
The RIMAP DEMO project consists of 4 demonstration cases, one
Power, for each industry sector, to prove the applicability, while the RIMAP
Petrochemical, TN project accompanies the entire development by disseminating the
Chemical and information and results of the RTD and DEMO part to a wider com-
Steel. munity of companies to review what has been developed and to get an
overall acceptance.
The project is divided into three sub-projects:
Exec. Summary & Introduction to RIMAP
RIMAP Documentation Level - I D2.2
D2.1 RIMAP Procedure
RIMAP Framework RIMAP Validation / Benchmarking
WP5
D4.x
The main deliverables from the RIMAP RTD project will be (the RIMAP defines the working processes and provides requirements
related documents can be depicted from Fig. 2): to the personnel that will execute the working processes. Implementa-
tion of RIMAP also requires an active management that focuses on
A method describing an unified approach to maintenance and the following issues:
inspection planning based on risk decision criteria and cost
optimization. Management of change
Guidelines for practical use, in the format of one "Workbook" Operating procedures
for each industry sector. Safe work practices
Spread knowledge between industry sectors. Pre-start-up reviews
Emergency response and controls
The RIMAP method will be tested within 4 industry sectors in the Investigation of incidents
RIMAP Demonstration project and, as such, it will be a major contri- Training
bution to European standardization. Quality assurance
The project is currently completing WP4 and WP5 in addition to
having started the industry specific demonstration projects.
Resources Management of work processes Results
Define Establish Plan Execute
goals & Insp. & Maint. Tasks & Work
requirements Programme Activities orders
The RIMAP Framework Organisation Costs
RIMAP Work Process. To implement and manage a system As risk based inspection and maintenance planning is a multidis-
for risk based inspection and maintenance management sets require- ciplinary task, it requires a team, where all necessary competencies
ments to a plants (maintenance) management system. Fig. 3 illus- are represented and expertise are available (e. g. EN 45004). Another
trates the work processes involved in implementing and managing important issue is the recurrent evaluation at a certain interval to
RIMAP at a plant or facility.
assess all the modifications and new data available to make sure the Failure mode: Assigning functions and sub functions to the
entire process runs into a continuous loop. 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.
RIMAP Procedure. In Fig. 4, the generic RIMAP procedure is Scenario development: RIMAP uses risk, the combination of
shown. It is industry independent and applicable to different equip- probability and consequence of failure, to prioritize inspection and
ment types (static, safety systems, etc.). maintenance activities. The assessment of the probability and conse-
The steps in the procedure are the same for different industrial quence of failure are combined in the bow-tie model, see Fig. 5. A
sectors (chemical, petrochemical and power) and for different equip- scenario is damage mechanisms leading to a potential event with a
ment types even if the techniques (e. g. tools for assessing probability consequence (safety, health, environment, or business).
or consequence of failure) may vary from one application to another.
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.
Consequence tree
CoF analysis e.g. by
CoF means of an event tree
Cause tree:
Event
PoF analysis PoF
covering e.g.
failure modes,
causes etc.
RIMAP recommends use of the expected scenario in analyses. Fuel supply and waste disposal system
This is dependent on the degradation mechanism expressed in the Boilers for conventional steam generation
scenario definition. It is essential that the choice of approach is made Steam systems (piping)
before the analysis starts and that the same method is used consis- Steam turbines
tently throughout the analysis. If a consistent scenario is not used, the Gas turbines
choice of risks mitigated will be affected, which may lead to a sub-
(electric) generators
optimal maintenance and inspection plan.
electric distribution
POD
1 POD = PonD = p1
100%
p1
Possible adverse
event #1:
acr
Failure due to
brittle fracture a
caused by an OR
undetected Very high
Possible critical size crack
damage (acr) High
mechanisms: p1
Medium p1
Low ;
- corrosion
Very low
cracking
-
(I.B)
material
OR PoF = p1 + p2 p1 p2
embrittle- p
ment (I.C) a=25mm acr
- cracking
(II.D)
p2
- Embrittle- Possible adverse p2
ment event #2
fracture
(II.E) Failure due to a
brittle fracture
caused by
uncertainty in OR
dimensioning of a Very high
crack identified
as a 25mm crack High
p2
Medium p2
Low ;
Very low
Fig. 6 Definition of PoF for the case of a structural failure and its main root cause
0.01 ACKNOWLEDGEMENT
TYP
Screening ANA Risk Based Inspection and Maintenance Procedures for European
For these Industry (RIMAP) is a project partly financed by the European Com-
components 6 Intermedia 1.
no further mission for the "Growth Programme, Research Project RIMAP Risk
0.001 analysis after
screening Detailed Based Inspection and Maintenance Procedures for European Indus-
needed 6
try"; Contract Number G1RD-CT-2001-03008.
PoF
2.
The authors would like to acknowledge the financial support by
0.0001
10 the European Commission.
8 3. A special acknowledgement is given to the support for the Demo
application provided by J. Barei, P. Buck (EnBW), P. Auerkari
2 (VTT), D. Balos, M. Perunicic (MPA-Stuttgart), and F. Hee (TV
Screening Intermediate Detailed
0.00001 SD).
100 1000 10000 100000 1000000 10000000
Consequences (Euro)
NOMENCLATURE
EU European Union
CoF Consequence of failure
D Deliverable
ISI In-service inspection
NDT Non-destructive testing
PED European Pressure Equipment Directive 97/23
PoD Probability of detection
PoF Probability of failure
RIMAP Risk Based Inspection and Maintenance for
European Industries
RTD Research and Technical Development
TN Thematic Network
WP Work package