RBI Components

About RBI Components

In Risk Based Inspection, you can divide equipment into components whose risk you want to analyze using an RBI 581 Risk Analysis. You can divide a piece of equipment into components based on shared degradation mechanisms. Each sub-part of the asset that shares the same degradation mechanisms will belong to the same RBI Component.

In GE Digital APM, the information related to an RBI component is stored in the following Criticality Calculator RBI Component records:

  • Criticality RBI Component - Cylindrical Shell
  • Criticality RBI Component - Exchanger Bundle
  • Criticality RBI Component - Exchanger Header
  • Criticality RBI Component - Exchanger Tube
  • Criticality RBI Component - Piping
  • Criticality RBI Component - Pump Compressor Casing
  • Criticality RBI Component - Tank Bottom
  • Criticality RBI Pipeline Segment (only if the Pipeline Management license is active)

Heat Exchanger

Consider a Heat Exchanger, which is a piece of equipment that contains the following components:

  • A Cylindrical Shell that makes up the Heat Exchanger Shell section.
  • A Cylindrical Shell that makes up the Heat Exchanger Channel section.
  • Any number of small tubes that make up the Heat Exchanger Bundle section.

Each of the components can contain items such as Nozzles, Flanges, or Piping.

In RBI, to analyze the ways in which the exchanger can fail, you must divide the components into logical groups that represent common failure characteristics. Each group of components is a separate component and is represented by a single RBI Component record. Keep in mind that some of these groups are involved in the overhead system, and others are involved in the cooling water system.

For example, you might group the equipment's components as follows:



  • Heat Exchanger Shell: Includes a cylindrical shell, an inlet nozzle, an outlet nozzle, and a head, often referred to as a shell cover. The Shell is part of the Cooling Water System (blue) because the purpose of the shell is to allow water to flow over the tubes and cool the process fluid running through the channel and bundle section of the exchanger.
  • Heat Exchanger Channel: Includes a cylindrical shell, an inlet nozzle an outlet nozzle and a flat head, often referred to as a dollar plate. The Channel is part of the OVHD System (yellow) because the purpose of the Channel is to funnel the process fluid in to the tubes and allow cooling of the process fluid running through the channel and bundle section of the exchanger.
  • Heat Exchanger Bundle: Includes tubes, baffles, and a tubesheet. The Bundle is part of the OVHD System (yellow) because the purpose of the bundle is to provide as much surface area as possible for the process fluid in to the tubes and allow cooling of the process fluid running through the bundle section of the exchanger.

If you create an RBI 581 Risk Analysis using this example, your database contains the following records:

  • Unit / Area (Functional Location record)
  • Overhead System (Corrosion Loop record)
  • Cooling Water System (Corrosion Loop record)
  • Heat Exchanger (Equipment record)
  • Heat Exchanger Shell (Criticality Calculator RBI Components record)
  • Heat Exchanger Channel (Criticality Calculator RBI Components record)
  • Heat Exchanger Bundle (Criticality Calculator RBI Components record)
Note: If you have already created Functional Location records to represent the OVHD System and Cooling Water System using the recommended asset hierarchy, you must create additional Corrosion Loop records to represent these same systems. The existing Functional Location records need not be linked to the Corrosion Loop records.

About Integration with Thickness Monitoring (TM)

If the Thickness Monitoring license is active, and TM Analyses exist for the Equipment records that you analyze using RBI, you can specify that TM Analysis values be used to calculate corrosion rate values that are used in RBI at:

  • The equipment level

    -or-

  • The TML Group level

TM Integration

Suppose that the asset that you are analyzing in TM and RBI represents a shell and tube heat exchanger. The shell and tube heat exchanger has two subcomponents, the shell side and the tube side, each with its own process flow. Since the corrosion environments of these subcomponents differ, you have created the following TML Groups (in the TM module):

  • TML Group - Shell Side
  • TML Group - Tube Side

When you first begin analysis on the shell and tube heat exchanger, you are not sure what the TM corrosion data will show, (i.e., whether TML Group - Shell Side or TML Group - Tube Side will have more aggressive corrosion). As a result, you may want to specify in RBI that TM Analysis values at the asset level be used to calculate RBI corrosion rate values.

As you analyze the shell and tube heat exchanger in TM, you notice that a subset of the TMLs on the shell side near the nozzle have very high corrosion rates. At this point, you create a third TML Group, TML Group - Shell Nozzle to represent this subcomponent, and you move the Thickness Measurement Locations associated with this subcomponent from TML Group - Shell Side to TML Group - Shell Nozzle. As a result, you may want to now specify in RBI that TM Analysis values at the TML Group level be used to calculate RBI corrosion rates. Specifically, you want to specify that the TML Corrosion Analysis value associated with TML Group - Shell Nozzle be used to calculate RBI corrosion rates.

RBI and TM Integration Workflow

  1. When you create an RBI Component, specify whether corrosion rate should be considered at the asset level or at the component level. To do so, in the Source of Calculated Corrosion Rate field in the RBI Component, select Asset or Component.

  2. If the value in the Source of Calculated Corrosion Rate field is Asset, then:

    The following fields in the associated RBI 581 Thinning and Lining Evaluation are populated with corresponding values in the associated Asset Corrosion Analysis.

    • Short Term Avg Corr Rate
    • Long Term Avg Corr Rate
    • Controlling Corrosion Rate

    The following fields in the associated Criticality Int. Corr. Deg. Mech. Eval. are populated with values from the linked TML Group:

    • Controlling Corrosion Rate
    • Long Term Corrosion Rate
    • Short Term Corrosion Rate

  3. If the value in the Source of Calculated Corrosion Rate field is Component, then link the RBI Component to one or more TML Groups.

    The aforementioned fields are populated based on the most conservative value (i.e., the highest value) among the corresponding values in the Asset Corrosion Analyses linked to the TML Groups.

    The value in the Controlling Corrosion Rate field in the Asset Corrosion Analysis is in mils per year. This value is converted to inches per year, and then used to populate this field.

    For example, suppose the Component is linked to two TML Groups whose controlling corrosion rate values are 0.3 mils per year and 0.45 mils per year respectively. These values are stored in the Controlling Corrosion Rate field in the Asset Corrosion Analysis record that is linked to each TML Group.

    Since the most conservative value between the two TML Groups is 0.45 mils per year, it is converted to inches per year as 0.00045 inches per year. This value is used to populate the Controlling Corrosion Rate field in the associated RBI 581 Thinning and Lining Evaluation or Criticality Int. Corr. Deg. Mech. Eval.

About Using TM Analysis Values at the Thickness Monitoring Location (TML) Group Level

Note: The following information assumes that you are using the RBI module to complete this workflow. Alternatively, you can also use the Thickness Monitoring module to identify the TML Group records whose TML Corrosion Analysis values you want to use to calculate RBI corrosion rates.

When you specify that TM Analysis values at the TML Group level be used to calculate RBI corrosion rate values, the RBI corrosion rate values are determined based on the average of the Long Term Corrosion Rate and Short Term Corrosion Rate values in the TML Corrosion Analyses that are linked to one or more TML Groups that are linked to the Equipment that is being analyzed in TM and RBI. The TML Groups whose TML Corrosion Analysis values are used are determined by your selections on the Link to TML Groups dialog box.

Note: The following information assumes that you are using the RBI module to complete this workflow. Alternatively, you could use the Thickness Monitoring module to identify the TML Group records whose TML Corrosion Analysis values you want to use to calculate RBI corrosion rates.

When you specify that TM Analysis values at the TML Group level be used to calculate RBI corrosion rate values, RBI gets the Controlling Corrosion rate, the Short Term Corrosion Rate (STCR) and Long Term Corrosion Rate (LTCR) values from TM. The values for Long Term Average Corrosion Rate and Short Term Average Corrosion Rate are based on the average of the LTCR and STCR value in TML Corrosion Analysis. The TML Groups whose TML Corrosion Analysis values are used are determined by your selections on the Manage TML Groups window.

While you can specify that RBI Corrosion Rate values be determined by one or more TML Groups by linking the RBI Components to one or more TML Groups, a TML Group can be linked to only one RBI Component.

Note: TMLs for which the Long Term Corrosion Rate or Short Term Corrosion Rate have not been calculated will be excluded from the calculations that determine RBI corrosion rate values.

Calculating Short Term and Long Term Average Corrosion Rates

Suppose an Equipment is linked to three TML Groups whose Thickness Measurement Locations are each linked to five TML Corrosion Analyses with the following Long Term Corrosion Rate and Short Term Corrosion Rate values:

TML Group 1

TML Corrosion Analysis record Long Term Corrosion Rate Short Term Corrosion Rate
11.005 MILS/year 1.006 MILS/year
21.003 MILS/year 1.003 MILS/year
31.005 MILS/year 1.006 MILS/year
41 MILS/year 1.001 MILS/year
51.005 MILS/year None

TML Group 2

TML Corrosion Analysis record Long Term Corrosion Rate Short Term Corrosion Rate
11.004 MILS/year 1.004 MILS/year
21.008 MILS/year 1.008 MILS/year
31.005 MILS/year None
41 MILS/year 1.001 MILS/year
51.005 MILS/year 1.006 MILS/year

TML Group 3

TML Corrosion Analysis record Long Term Corrosion Rate Short Term Corrosion Rate
11.002 MILS/year None
21.003 MILS/year 1.005 MILS/year
31.005 MILS/year 1.006 MILS/year
41 MILS/year 1.001 MILS/year
51.002 MILS/year 1.004 MILS/year

When you create an RBI Analysis for the RBI Component that corresponds to this piece of equipment, if you specified that TM Analysis values at the TML Group 1 level be used to determine RBI corrosion rate values:

  • The value in the Long Term Avg. Corr. Rate field in the Criticality Int. Corr. Deg. Mech. Eval that is created automatically would be calculated as follows:

    Long Term Avg. Corr. Rate = (1.005 + 1.003 + 1.005 + 1 + 1.005) / 5

    Long Term Avg. Corr. Rate = 1.0036

  • The value in the Short Term Avg. Corr. Rate field in the Criticality Int. Corr. Deg. Mech. Eval that is created automatically would be calculated as follows:

    Short Term Avg. Corr. Rate = (1.006 + 1.003 + 1.006 + 1.001) / 4

    Short Term Avg. Corr. Rate = 1.004

You can specify that TML Corrosion Analysis values from more than one TML Group be used to calculate RBI corrosion rates. If you specified that the TML Corrosion Analysis values associated with TML Group 1 and TML Group 3 be used to determine RBI corrosion rate values:

  • The value in the Long Term Avg. Corr. Rate field in the Criticality Int. Corr. Deg. Mech. Eval that is created automatically would be calculated as follows:

    Long Term Avg. Corr. Rate = (1.005 + 1.003 + 1.005 + 1 + 1.005 + 1.002 + 1.003 + 1.005 + 1 + 1.002) / 10

    Long Term Avg. Corr. Rate = 1.003

  • The value in the Short Term Avg. Corr. Rate field in the Criticality Int. Corr. Deg. Mech. Eval that is created automatically would be calculated as follows:

    Short Term Avg. Corr. Rate = (1.006 + 1.003 + 1.006 + 1.001 + 1.005 + 1.006 + 1.001 + 1.004) / 8

    Short Term Avg. Corr. Rate = 1.004

About Using TM Analysis Values at the Asset Level

When you specify that TM Analysis values at the asset level be used to calculate RBI corrosion rate values, the RBI corrosion rate values are determined based on the selected Corrosion Rate for all the TML Corrosion Analyses that are linked. By default, the Source of Calculated Corrosion Rate field in the RBI Component will be set to asset.

When an RBI Component is created and integrated with TM, the value in the Selected BM Corrosion Rate and Selected Cladding Corrosion Rate fields of the RBI 581 Thinning and Lining Evaluation for the selected asset can be:

  • Controlling Corrosion Rate
  • Calculated Rate
  • Estimated Rate
  • Long Term Avg
  • Short Term Avg
Note: TMLs for which the Controlling Corrosion Rate, Long Term Corrosion Rate, or Short Term Corrosion Rate have not been calculated will be excluded from the calculations that determine RBI corrosion rate values.

Controlling Corrosion Rate Details

When the Source of Controlling Corrosion Rate field is set to Component, and you have multiple TML Groups mapped to the same Component, then the Controlling Corrosion Rate for a TML is determined by evaluating the corrosion rates that have been calculated for the TML. The TML Controlling Corrosion Rate is set to the highest (i.e., most conservative) of these corrosion rates.

Calculated Rate

If you select this option, the values in the Base Material Calculated Corrosion Rate and Cladding Material Calculated Corrosion Rate fields are calculated. They are used to calculate the damage factor.

Estimated Corrosion Rate Details

The Estimated Corrosion Rate for a TML is the rate of corrosion assigned to the Internal Corrosion Rate of an RBI Component by a subject matter expert.

Long Term Corrosion Rate Details

Long Term Corrosion Rate is a calculation that indicates the rate of corrosion over the full length of time for which measurements have been recorded. The Long Term Corrosion Rate will be calculated for a given TML if the analysis settings for the related Equipment or TML Group specify that Long Term Corrosion Rate should be used.

Short Term Corrosion Rate Details

Short Term Corrosion Rate is the rate of corrosion as determined by the most recently recorded values. The Short Term Corrosion Rate will be calculated for a given Thickness Measurement Location record only if the Analysis Settings for the related Asset specify that Short Term Corrosion Rate should be used and there are two more Thickness Measurements for the Thickness Measurement Location record.

alculating Short Term and Long Term Average Corrosion Rates

Suppose an Equipment is linked to five TMLs for which five TML Corrosion Analyses exist with the following Long Term Corrosion Rate and Short Term Corrosion Rate values.

TML Corrosion Analysis record Long Term Corrosion Rate Short Term Corrosion Rate
11.001 MILS/year 1.003 MILS/year
21.003 MILS/year 1.003 MILS/year
31.001 MILS/year 1.001 MILS/year
41 MILS/year 1.001 MILS/year
51.001 MILS/year None

When you create an RBI 581 Risk Analysis for the RBI Component that corresponds to this piece of equipment, if you specified that TM Analysis values at the equipment level be used to determine RBI corrosion rate values:

  • The value in the Long Term Avg. Corr. Rate field in the RBI 581 Thinning and Lining Evaluation is calculated as follows:

    Long Term Avg. Corr. Rate = (1.001 + 1.003 + 1.001 + 1 + 1.001) / 5

    Long Term Avg. Corr. Rate = 1.0012

  • The value in the Short Term Avg. Corr. Rate field in the RBI 581 Thinning and Lining Evaluation is calculated as follows:

    Short Term Avg. Corr. Rate = (1.003 + 1.003 + 1.001 + 1.001) / 4

    Short Term Avg. Corr. Rate = 1.002

Access an RBI Component

Procedure

  1. Access the Asset Summary workspace for the asset that contains the RBI Component that you want to access.

    -or-

    Access the Corrosion Loop that contains the RBI Component that you want to access.

  2. Below the graph, select the link corresponding to the component that you want to access.

    -or-

    In the left pane, select the component that you want to access.

    The workspace for the selected component appears, displaying the Component Overview section.



  3. Select the Component Details tab.

    The Component Details section appears, displaying the datasheet of the Component.



    Note: If needed, modify values in the available fields, and then select to save your changes.

Create an RBI Component

About This Task

This topic describes how to create a new RBI Component and link it to an Asset or a Corrosion Loop. You can also link an existing RBI Component to an Asset or a Corrosion Loop.

Procedure

  1. Access the Asset Summary workspace of the asset in which you want to create an RBI Component.

    -or-

    Access the Corrosion Loop in which you want to create an RBI Component.

  2. In the left pane, select , and then select Create New Component.

    The Create New RBI Component window appears.



  3. Enter values in the following fields:
    • Asset: This field is automatically populated with the asset for which you are creating an RBI Component.
    • Component Family: Select the component family for the Component that you want to create.
    • Component Type: Select the component type for the RBI Component that you want to create.
  4. Select Create.

    A new RBI Component is created, and is automatically linked to the selected Asset and the Corrosion Loop. The Component Details section appears, displaying the component datasheet.



  5. Enter values in the available fields.
  6. In the RBI-581 section of the datasheet, enter values in the available fields.
  7. In the upper-right corner of the datasheet, select .

    The changes made to the RBI Component are saved.

Results

What To Do Next

Access the Inventory Group of a Component

About This Task

You can also access all the inventory groups in a process unit.

Procedure

  1. Access the Component that is linked to the inventory group.
  2. In the upper-right corner of the page, select , and then select Inventory Group.

    The RBI 581 Inventory Groups workspace appears on a new page, displaying the following information:

    • If the component is linked to an inventory group, then the Inventory Group Configuration datasheet for the inventory group associated with the component appears.



      Tip: If you want to access a list of components linked to the inventory group, select the Linked Components tab.

    • If the component is not linked to an inventory group, then the Process Units with Inventory Groups graphs appears. A list of process units appear in the left section in the workspace.



      Tip: If you are a member of the RBI Admin Security Group, you can create an Inventory Group Configuration record in the RBI 581 Inventory Groups workspace.

Apply an RBI Component

About This Task

When you apply an RBI Component, you make a copy of the original record. The applied RBI Component is not automatically linked to the original RBI Component's Corrosion Loop. Instead, the applied RBI Component can be linked to the same or a different asset and then to a Corrosion Loop.

Procedure

  1. Access the RBI Component that you want to apply.
  2. In the upper-right corner of the page, select .

    The Hierarchy Finder window appears.



  3. Navigate through the Hierarchy Finder to select the asset to which you want to apply the RBI Component.
  4. Select OK.

    The RBI Component is applied to the selected asset.

What To Do Next

Delete an RBI Component

Before You Begin

Procedure

  1. Access the Asset Summary workspace of the asset that is linked to the RBI Component that you want to delete.

    -or-

    Access the Corrosion Loop that is linked to the RBI Component that you want to delete.

  2. Next to the Component what you want to delete, select the check box next, and then select .

    A message appears, asking you to confirm that you want to delete the selected RBI Component.

  3. Select Yes.

    The RBI Component is deleted, and all links to existing related entities are removed.