TM V4 005 IRC Configuration

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Version 4.0.1.28 TM-V4-005 Revision #: 0 Date: 7/18/2007 of 29

Inspection Risk Codes (IRC) and RBI Configuration (TM-V4-005)

1.0 PurposeInspection Risk Codes (IRC) are numerical indicators used by Integrity, Inspection and Reliability Engineers tocategorize equipment based on API 580/581 and/or Corporate specific methodology. The greater the risk associatedwith a piece of equipment or circuit, the more frequent it will be subjected to Visual and NDE inspections.

In this section of the training manual, the user will learn how to:

• Locating Inspection Risk Code (IRC) Information• Configure your Inspection Risk Codes• Creating a New IRC, RBI Configuration• Configure your RBI Degradation Mechanisms• Configure your RBI Equations• Configure your RBI Matrix

2.0 Description

2.1 Locating Inspection Risk Code (IRC) Information

If the the Risk Based Inspection (RBI Module) is available, the summary of IRC information is located under theLookup Data menu; the user is then able to research the current Inspection Risk Codes existing within the VisionsDatabase.



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The default Risk Assessment Identification (RAID) appears, summarizing the Default IRCs that exists within Visions.Here the user may research this and any other RAIDs and corresponding IRCs that are ready for use when carrying

out anRBI Assessment.

(See Training Manual, TM-V4-014 – Risk Based Inspection Assessment).

Selecting a RAID will cause the Lookup data to automatically refresh and present the user with the associated IRCinformation.

RAID Drop down list, identifying which Risk Assessment the user wishes to research.

Inspection Risk Code Displays what value IRC has selected at the bottom of the Lookup table andsummarizes associated Number, Name, Short Name and Color.



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On Stream External Defines the External Inspection Interval, the Remaining Life Factor and provides adefinition of the IRC value.

On Stream Internal Defines the Internal Inspection Interval of the selected IRC, Remaining Life Factor anda description of the IRC characteristic.

2.2 Creating Inspection Risk Codes without the RBI Module

If the client has not purchased the Risk Based Inspection (RBI) Module, the user can still define IRCs to properlyschedule equipment inspections, TML inspections and PSV Service Reports.

Under the “Lookup Data” Menu, the user can create IRCs through with the Lookup Data | Inspection Codes command:

A pop-up screen will appear for the user to create, edit and delete IRCs to be applied to the equipment, TMLs andPSVs existing within Visions:



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The functionality of the above table is the same as the functionality of the table described in Section 2.1.The user is able to create as many IRC values as necessary to properly schedule equipment, TML and PSV scheduling.

2.3 Creating Inspection Risk Codes with RBI Configuration Module

To create, edit or copy IRCs, the user must go to the RBI Configuration command, located under the Configurationsmenu.



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Here the user will be presented with the RBI Configuration Log summarizing all currently created and completed RBIConfigurations. The Default RBI Configuration is located at the top of the list with the RAID being number 1 and titled,

“Default Configuration based on ASME standards”.

The default configuration comes with already existing IRCs and an extensive library of Degradation Modes andMechanisms that are based on API 571 standards. The user has the option to use the information presented in theDefault RAID as their RBI Assessment configuration or may clone and then edit the RAID information to better suit theequipment being assessed.

The RBI Configuration toolbar located at the top of the screen allows the user to create, edit, delete and clone RiskConfigurations.

Icon Command Function

Refresh Upon saving your recently edited RBI Configuration(s), refreshes the RBIConfiguration to present the user with previously blank fields.

Show / Hide Navigator Controls whether or not the left sidebar, called the Navigator, is displayed.

New Creates a new RBI configuration

Clone Clones an already existing RBI configuration for the purpose of editing andcreating another RBI Configuration for use on another plant, business unit,equipment type(s).

Delete Deletes the selected RBI configuration.

Open Opens the desired RBI configuration highlighted.



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Open in New Form Allows for multiple RBI configurations to be opened at one time.

The Risk Configuration window summarizes currently existing RAIDs according to the following characteristics:

Column Header Function

RAID Visions identifier for numerically ordering RAIDs.

Date Completed Identifies the date that RAID was first created.

Title Should identify the Configuration, what equipment types it will apply to.

Complete Active Checked if the all the necessary steps to create a RAID have been carried out.

Active Checked if the RAID is available to be applied to a Risk Assessment(s).

Author

Notes

Completed RAIDs will appear in Green text while RAID that are currently not completed will appear in Red text.

Note: A RAID that has been completed can be deactivated, however, equipment that has been assessed under theRAID will still conform to the IRCs defined under the RAID until a new RBI assessment has been carried out.

Note: A RAID can only be deleted if it has not been completed. Deactivated RAIDs are unable to be deleted until allequipment conforming to the defined IRCs have been re-assessed.

2.3.1 Creating a New RBI Configuration

Unlike cloning the Default RAID or other created RAID configuration a new configuration will present the user with no

pre-existing IRC definitions, Degradation Modes and related Mechanisms or Risk Matrix and will allow the user to startfrom scratch.

Clicking on the “New” icon located on the Risk Configuration toolbar will open a new RAID window.



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Colored fields are mandatory. The RAID information in the red box is read-only and is always displayed.

2.3.2 Information

The Information tab summarizes the characteristics of the RAID and governing equations:



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It is broken into two (2) sections:

• RAID Information• Axis Definitions

2.3.2.1 RAID Information



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Field Function

Author Defaults to the username of the person who has created the RAID. Can be edited todisplay whatever is required.

Matrix Size Defines the Length and Height of the Risk Matrix.

Display Using IRC Number or IRC Name to be displayed on the Risk Matrix.

Completed Checked if the RAID is completed.

Active Checked if the RAID is available to be used in Risk Assessments.

Comments Any miscellaneous notes about the RAID.

2.3.1.2 Axis Definitions

Field Function

Equation X Displays the Equation for X-Value of the RAID as defined in the Equations Tab (SeeSection 2.3.5)

X Axis Label Identifies the definition of the X-Axis of the RAID.

X Axis Order Ascending or Descending in Value along the X-Axis.

Equation Y Displays the Equation for X-Value of the RAID as defined in the Equations Tab (SeeSection 2.3.5)

Y Axis Label Identifies the definition of the Y-Axis of the RAID.

Y Axis Order Ascending or Descending in Value along the Y-Axis.



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2.3.2 Inspection Risk Codes

Creating an IRC involves noting the:

• IRC Value• Restricted Interval (External) Frequency• Restricted Interval (Internal) Frequency

All created IRCs are summarized in the IRC summary located in the middle of the page:



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Field Function

IRC Number Identifies the Inspection Risk Code value.IRC Name Defines the Inspection Risk Code value.

Color Defines the corresponding Inspection Risk Code value.

IRC Short Name Defines the short name of the Inspection Risk Code.

Remaining Life (External) Percentage value (less than 100%) used to schedule the next inspection based on theremaining wall thickness of the equipment. (For more information on Remaining Life,See Training Manual, TM-V4-006, “TML Trending” ).

Remaining Life (Internal) Percentage value (less than 100%) used to schedule the next inspection based on theremaining wall thickness of the equipment. (For more information on Remaining Life,See Training Manual, TM-V4-006, “TML Trending” ).

The buttons used to Create, Edit and Delete IRCs are located at the top of the Inspection Risk Codes tab:

Command Function

New IRC Creates a new IRC.

Edit IRC Edits the selected IRC in the IRC Summary Table.

Delete IRC Deletes the selected IRC in the IRC Summary Table.

Clicking on “New IRC” results in a pop-up window appearing with the necessary IRC fields:



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The colored fields are Mandatory for the user to define before the RAID can be completed and the user can haveaccess to the OK commands. However, it is suggested that all fields be completed so that the user(s) that researchIRC values can gain a clear understanding on the classification and definitions of Risk associated with RBIassessments. The definition of the IRC is separated in the three (3) sections:

• IRC Number and Naming• On Stream (External) inspection frequency• Off Stream (Internal) inspection frequency

IRC Number and Naming – Definitions



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Field Function

IRC Number Not editable by the user, defines the IRC number.

IRC Color Defines the color to be associated with the IRC number.IRC Name Defines the name associated with the IRC number.

IRC Short Name Defines the short name to be associated with the IRC number.

On-stream (External) - Definitions

Field Function

Restricted Interval (External) Defines the maximum period measured in months that can occur between ExternalOn-Stream or Off-Stream inspections.

Remaining Life A percentage value (less than 100%) used to decrease the Restricted Interval whenthe wall thickness of a piece of equipment is known to be nearing its user-definedCritical Thickness.

Descriptions Text box used to define the characteristics of the equipment or circuit that would be

associated with this IRC value such as corrosion risks, inspection history, andassociated consequence of failure.

Off-stream (Internal) – Definitions



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Field Function

Restricted Interval (Internal) Defines the maximum period measured in months that can occur between Internalinspections.

Remaining Life A percentage value (less than 100%) used to decrease the Restricted Interval when

the wall thickness of a piece of equipment is known to be nearing its user-definedCritical Thickness.

Descriptions Text box used to define the characteristics of the equipment or circuit that would beassociated with this IRC value such as corrosion risks, inspection history, andassociated consequence of failure.

2.3.3 Degradation Mechanisms



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Degradation Mechanisms identify the corrosion risks associated with a piece of equipment and / or circuit that is to beassessed during the RBI process. As there are infinite forms Degradation available for the user to use, the RiskConfiguration simplifies the process by grouping the Degradation Mechanisms into Degradation Modes.

In addition, the user has the opportunity to define the available NDE Techniques that will aid in identifying theseDegradation Mechanisms before they lead to an equipment failure.

Degradation Mode – Definitions

The Degradation Mode defines the parent form of degradation that all related Degradation Mechanisms will bedefined under. This allows the user to quickly and easily the associated forms of Degradation during RBI Assessments.

Field Function

Degradation Mode Identifies the type of degradation the Degradation Mechanism can be associatedunder.

Description Defines the Degradation Mode.



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2.3.4 Risk Factors

For API 580 and 581 Risk Assessments, the Risk Factor values are used to determine the Likelihood andConsequence of Failure. Within the Likelihood and Consequence of Failure, the user can create variables that willquantify these two Risk Factors. The defaults variables within the default RAID are defined as follows:

Likelihood of Failure

Variable Short Name Definition

Confidence inInspection Data

InspDataConf Confidence is based on the number and type of previous inspections, as wellas the ability of previous inspection information to instill confidence in thecondition of equipment (i.e., have previous inspections and/or methods beenadequate in detecting the presence of predicted failure modes?).

Probability ofOccurrence

ProbOccur Probability of failure occurrence is scored subjectively based on knowledge ofprocess chemistries, conditions and past experience / history of degradation



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within specific or similar equipment.

Predictability ofDamagedLocations

PredDamLoc Predictability of failure mode occurrence is scored subjectively by person(s)knowledgeable in corrosion mechanisms and specific processes and is afunction of how well one might predict where degradation may occur, whatlevel of confidence is there in previous inspection data, and how effectiveinspection techniques are in detecting deterioration.

Consequence of Failure

Variable Short Name Definition

Release Rate RelRate Considers the type of failure, pressures associated and commodity state (liquid,vapor, gas). Differentiate a catastrophic or burst type failure to that of aweeping failure such as a pit or crack. Consider only the rate of release based onthe size of opening and pressure.

Release Volume

RelVol Considers the release rate, potential volumes of product loss and the time it maytake to detect and stop or contain the release.

Toxicity /Harm

ToxHarm Considers the effect the release may have on personnel and/or the public.Considers the toxic nature of the product, pressure involved, failure type andtemperature of the product (i.e., while water may pose no toxicity threat,sufficient pressure and temperature may pose a significant threat).

Flammability Flam Considers the combustible nature of the product, which could greatly impact theoverall consequence of a failure event. Consider the ignition properties as wellas the flammable nature.

BusinessImpact

BizImp Considering the type and location of failure, assess the potential impact toproduction losses, repair and costs / durations, impacts to related operations orequipment, and company image in the eyes of regulators, insurers, the publicand external clients.

Environmental

Impact

EnvImp Considering the rate and nature of release, the damaging properties of the

product and ability of the product to contaminate the environment based on leaklocation.

To distinguish which axis the user is viewing or editing, the Risk Factors are separated by two (2) sub-tabs at the topof the Risk Factor screen:

Clicking on the desired axis name will bring up respective screen displaying the associated Risk Factors.



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2.3.4.1 Creating New Risk Factors

The necessary commands for creating and editing the user-defined Risk Factors are defined along the top of the RiskFactor tab:

Command Function

New Risk Factor Creates a new Risk Factor for the Selected Axis (Likelihood or Consequence of Failure)

Edit Edits the selected Risk Factor (Name, Short Name, Values).

Delete Deletes the selected Risk Factor

Clone

Move Up Moves the selected Risk Factor up through the table of existing Risk Factors.

Move Down Moves the selected Risk Factor down through the table of existing Risk Factors.

2.3.4.2 New Risk Factor

Click on “New Risk Factor” and a pop-up window will appear:



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A Risk Factor is defined by three (3) Sections,

• Factor Information• Factor Value Definition• Lookup Table (Optional)

Factor Information – Definitions

The Risk Factor information is used to identify the specific Risk Factor to be assigned to the X or Y Axis. The user cancreate as many Risk Factors as necessary to properly calculate the X and Y Risk Values.

Field FunctionShort Name Identifies the short name of the Risk Factor that will be used in the defining the Equation in

calculating the X or Y Axis Value.

Factor Name Identifies the Risk Factor

Definition Provides a detailed definition of what the Risk Factor is measuring.

Factor Value – Definitions



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Field Function

Factor Value Used to semi-quantitatively measure the degree of the Risk Factor. The user can use as manyFactor Values as deemed necessary; the Default Risk Configuration measures all Risk Factors ona scale of 1-10.

Definition Corresponding definition to the degree of the Risk Value (e.g. 1 = Very Low, 10 = Very High).

Factor Lookup Table – Definitions (optional)

The Factor Lookup Table is designed to provide those responsible for executing the RBI Assessments with a user-defined set of values and scenarios to aid in the decision making process of the deciding the appropriate Risk Factor Value by comparing it to real-life values. For example, if the user was measuring the dollars lost due to a total plantshutdown, this table might be used:

Days Lost Dollars Lost1 $2.5 Million

2 $5.0 Million

3 $8.0 Million

4 $11.0 Million



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Another example would be the ranking of volume released measured against a varying hole size:

Hole Size Volume Lost

0.25” 10 Liters

0.50” 50 Liters

2.00” 175 Liters

4.00” 250 Liters

Field Function

Use Lookup Table Check if the user wishes to create a Factor Lookup Table.

Table Size Defines the size of the Factor Look up Table.

X Axis Label

Y Axis Label

2.3.5 Equations



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Equations are used to define the X and Y Axis values during the Risk Calculation Process. In addition, , the Min andMax values of the X and Y Axis will determined according to the Risk Factor Values defined in Section 2.2.4.1.

The Default Equations for the X (Likelihood) and Y (Consequence) Axis values are defined as follows:

Likelihood = (PredDamLoc+InspDataConf)/2+ProbOccur

Consequence = (RelRate+RelVol+ToxHarm+Flam)/4 + EnvImp + BizImp

The Equation Tab has three (3) function sections,

• Equation• Risk Factor• Calculator

Equation – Definitions

Field Function

Equation X /Equation Y

Identifies what Axis the Equation is being defined to.

Min XMin Y

Identifies the Minimum Value of the X and Y Axis respectively

Max XMax Y

Identifies the Maximum Value of the X and Y Axis respectively

Risk Factor – Definitions



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Derived from Section 2.3.4 and 2.3.4.1

Calculator – Definitions

This panel is to be used to develop the equations that, based on the Risk Factors and associated Risk Factor Values,will determine the Maximum and Minimum Values of the X and Y Axis. Only mathematically correct equations will beaccepted.

When the equations have been defined, the user clicks on “Accept X Axis Equation” or “Accept Y Axis Equation” to theright of the calculator to finalize the equations and enable progress.



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2.3.6 Risk Matrix

The Risk Matrix for a newly created RAID will appear blank as follows. However, if the user has cloned a Configuration

from another RAID, the Risk Matrix will take the appearance of the original. The user has the option to reconfigure thenew or cloned matrix.

New Configuration Cloned Configuration

Along the top of the Risk Matrix Tab are three commands:

Commands Function

Complete Configuration Disables any editing of the Risk Configuration.

Activate Configuration Allows the Risk Configuration to be assigned to equipment and/or circuit RBI Assessments.

Deactivate Configuration Prevents the Risk Configuration from being assigned to equipment and/or circuit RBI Assessments.



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To determine what IRC a given area of the Risk Matrix is to be associated with, click on the square in question:

A pop-up screen will appear summarizing all IRC values. Select the desired IRC and click on “OK”.

Along the X and Y Axis of the Risk Matrix, the user can define the intervals of the Risk Matrix grid by clicking on theincrease / decrease values. However, the Maximum and Minimum values are not editable.



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2.3.6.1 Completing your Risk ConfigurationOnce the Risk Matrix has been defined, the user need only to click on “Complete Configuration” to allow it to be usedin future RBI Assessments.



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If all the steps outlined in Sections 2.3 through to 2.2.6.1 are properly completed, then the user will be notified of theRisk Configuration with the pop-up message,

If the user attempts to complete the configuration before the Matrix has been properly edited, the following pop-uperror will appear,

2.4 Cloning a Risk Configuration

Cloning a Risk Configuration is useful for copying and editing a previously created RAID or the Default RiskConfiguration (RAID #1). For example, the user may wish to alter the Risk Factors, but may still want the definedDegradation Modes and Mechanisms. Another example would be to alter the ranges of the X and Y Values of the RiskMatrix while still keeping the previously entered information intact.

To clone a Risk Configuration, select the desired Risk Configuration to be cloned in the Risk Configuration Log andclick on the “Clone” button located along the toolbar,

Visions will automatically create a new RAID highlighted in red text located at the base of the Risk Configuration Log,



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The Author will default to the name of the user who has cloned the Risk Configuration; however that can be changedunder the Information tab.

The user will then follow the same steps as outlined in Sections 2.3.1 to Section 2.3.6.1 to properly configure andactivate the cloned Risk Configuration.

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