iRiSintegrated
RISK MANAGEMENT SYSTEM
for Industrial plants

…integrates all relevant aspects of risks:

• RBI (Risk-based Inspection)
• RCM (Reliability Centered Maintenance)
• RCFA (Root Cause Failure Analysis)
• HSE/HSSE (Health, Safety, Environment / Security)

  

 

LEGEND (for answer categories) :

 (green) 
yes, confirmed 
 (yellow) 
no, not available 
 (blue) 
to be further explained to or discussed with the client
 please click the symbol of "paper clip" for detail explanations in the file attached

 

 
  GENERAL QUESTIONS
 

The RBI-iRiS is always cloud-based (i.e. internet/intranet-based). Technically, it is also possible to have it installed on one local machine, but R-tech has never had such a request so far.

The main server/cloud can be:

a.      Client’s server/cloud (one or more!)

b.     Steinbeis R-Tech server in Germany or in client’s country

c. Third party server, e.g. Amazon in the country of choice

That means, R-Tech meet any requirement related to possible installation of the system. The advantages of each of the particular solutions can be discussed with the client and the final solution specified acc. to the very needs of the client. The same applies to the use and users of the software, as well as for interaction among sites/plants. Our solution controls:

1.     Data sharing

2.     Users’ rights

3. Communication between the servers.

It should be noted, that one the most often configurations are these specified in cooperation with the client (e.g. full cloud solution with off-site database, local installation at client premises with remote access for maintenance, etc.

Please find attached of Steinbeis R-Tech software development road-map.

The specific technical solution development road-map can be modified and developed in cooperation with the client, taking into account his exact requirements through communication (online and offline)

An example of Maintain Design Conditions:

The section of "Design Information" is shown bellow, with the descriptions of all the data with should be entered.

Design Temperature [°C]

The design temperature of the equipment item should be recorded. Equipment designed for low temperature service may have a Minimum Design Metal Temperature and a maximum design temperature. 

Design Pressure [bar]

The design pressure of the equipment item should be recorded. If modifications to the equipment since its original fabrication have changed the design pressure, the current value should be indicated.

An example of Operation Conditions:

The section of "Operation Information" is shown bellow, with the descriptions of all the data with should be entered:

Operating Temperature [°C]

  • The normal operating temperature is used in consequence calculation and can be an important variable in several damage mechanisms. When a range of operating temperatures is employed as the result of a plant producing a variety of product grades, record of the most severe temperature is normally specified (highest for high temperature operations, lowest for low temperature processes).

  • Temperature extremes under upset conditions can have a profound effect on rate of damage for several damage mechanisms.

  • The highest and lowest temperature that could occur should be recorded.

  • For equipment which generates a large temperature change (heat exchangers, furnaces, etc.), the best practice is to input average temperature across equipment

Operating Pressure [bar]

  • The normal operating pressure entry is used in various consequence calculations and in determination of the the safety factor.

  • When a range of operating temperatures is employed as the result of a plant producing a variety of product grades,  record of the highest pressure should be recorded. Pressure extremes under upset conditions should be recorded if they are significantly different from normal operating pressure.

Our system has full capacity to set up custom KPIs in form of Normalized Score as image below

 

The solution can be installed in multiple instances on R-Tech servers or on servers of the client’s specification. This means that there can be multiple instances running in parallel (e.g. training and real production instances).

An example of an Saas-oriented agreement is shown below:

===================================================================================

Software as a Service Agreement (SaaS)

 

between

(“Client”)

Contact Client: xxxx

 

and

Steinbeis Advanced Risk Technologies GmbH, Willi-Bleicher-Straße 19, 70174 Stuttgart, GERMANY

Reg.: Stuttgart HRB 725454 (“Consultant”)

Contact Consultant:xxxx

1      Scope of the agreement and delivery

This SaaS Agreement covers:

a.      The purchase of the iRiS-Software as a service as described in details in Annex 2 (the „Software“)

b.      Customized modules meeting the Client’s needs (see Annex 1).

c.       Four one-week trainings for up to Client's administrators/trainers will be conducted following the testing of the Software at Client's premises (the “Training”).

2      Terms of delivery/schedule

The Software will be delivered as per tentative Time plan below. The total duration of the Agreement related to the customization and maintenance of the purchased Software covers the period of 18 months. Any changes and/or modifications will be discussed and mutually agreed in writing, based on the discussions during the project meetings.

 

3      Acceptance procedure for the software

Acceptance and receipt of the delivery shall be performed by the Project Managers of the Client and the Consultant, by signing the Records of performed delivery/service, within 15 days of the successful implementation of the Software at the Client premises, at the conclusion of the 6 month period foreseen by this offer. The acceptance procedure should use the standard Consultant forms. The liability of the consultant is limited to the re-work of all jointly recognized defects.

4      Implementation of the Software

The Software will be made functional and tested at the Client’s premises. Responding the Client’s request the installation of the software will be cloud-based, at the cloud platform chosen by the Consultant (see the details below). The Consultants personnel will be deployed in South Africa as needed to discuss, align and implement the time plan or any measures/actions for Client-specific requirements. The kick-off meeting will be planned as telephone conference/video conference.

During the initial 6 month period, the Software will be deployed on the Consultants servers. This will ensure quick modification/implementation of any Client-specific requirements, as well as corrections and improvements. Following the 6 month period, the Software may be installed on Client or cloud-based servers, at Client request/preference.

5      Use of the Software

The number of Client users accessing the software is unlimited (Client employees as users, only). The Client may use the system to input data, analyze, load, display, print and reproduce views obtained from the Software and distribute them at his/her will. The ownership of the input data and the software results is exclusive to the Client. Please refer to item 9 for further information.

6      Duration of Agreement

The duration of the agreement is 18 months, staring on March 31, 2017, and not restricted geographically as long as the provisions of item 8, 9 and 10 are met and applied. The stipulations related to the ownership of IPR and the restrictions (item 10) apply without any limitation on time.

7      Client responsibility at delivery/implementation

During the time foreseen for this project, it is required to have one dedicated Client representative to support the Consultant’s implementation team to ensure the Client’s fulfillment of requirements for a successful implementation of the software (e.g. ensuring quality of data that has to be imported into the Software Database).

8      Maintenance of the Software

For the duration of this agreement, the Consultant will correct all defects and possible issues found and implement the improvements agreed by both parties. Possible prolongation is subject to subsequent agreements.

9      Further development and configuration of the Software

The Consultant agrees to:

a)      Customize its existing Software (iRiS) to meet the Client’s requirements. Ownership of IPR related to the base version of the Software remains with the Consultant

b)      Client’s access to further joint development/modification the Software. Ownership of IPR related to modifications of the base Software to Client requirements (the Client-module), and any further joint developments will be the subject of a separate Joint Venture Agreement, as stated below

c)      Allow an unlimited number of the Client’s employees to use the Software (also for, e.g. internal/external consulting; the use of the software by users not in the direct employ of the Client is explicitly forbidden).

A respective joint IPR (Intellectual Property Rights)/Joint Venture Agreement between the Client and the Consultant will be prepared to specify the foreground IPR (joint ownership) for any joint development in the software and will include the options such as a Memorandum of Understanding (MoU) or Joint Venture. Without the IPR agreement, the above mentioned items (b) and (c) are not allowed.

10    Restrictions

The Client shall not:

·        Disclose any relevant information (e.g. software documentation or training handouts) to third parties (e.g. other consultants of the Client, or similar)

·        give third parties access rights for the use of the software

·        contravene the general rules of software licensing

Any exceptions must be based on separate agreements, concluded in writing and signed by the Client and the Consultant.

11    Skill Development & Localization

The Consultant will engage a local South African student/trainee and an Client EIT and involve and train them in this proposed project. A SD&L report will be prepared by the Consultant to present involvement of the local trainee and the fulfillment of the SD&L activities.

12    General Terms and Conditions

For any issues not specified or covered by this Agreement, the Steinbeis/EU-VRi Terms and Conditions in Annex 1 apply.

 

By signing, both parties agree to implement this agreement in good faith.

 

The Client

 

 

 

Place, Date

 

Name

As witness:

 

 

 

 

 

Place, Date

 

Name

 

 

 

Place, Date

 

Name

 

The Consultant

 

 

 

Place, Date

 

Name

As witness:

 

 

 

 

 

Place, Date

 

Name

 

 

 

Place, Date

 

Name

 

Annex 1: Terms and Conditions

Annex 2: Software Specification

Annex 1        Standard Terms and Conditions

 

Terms and Conditions

of

Steinbeis Advanced Risk Technologies / EU-VRi

 

1. Applicability

(1)    These standard terms and conditions shall apply to all contracts between StC and its Clients in respect of services (Leistungen), in so far as not otherwise explicitly agreed upon in writing.

(2)     These standard terms and conditions shall only apply, if the Client is a merchant and the contract is made within his trade business, or if the Client is a legal person or a trust under Public Law in the meaning of § 310 para. (1) Sentence 1 BGB (German Civil Code).

(3)     The standard terms and conditions of StC shall apply exclusively. Contrary or deviating terms of the other party shall only be binding if and to the extent that StC explicitly consents to their validity in writing. The standard terms and conditions of StC apply, even if StC fulfills the order of the Client without reservation in the knowledge of contrary or deviating terms of the Client. Deviating agreements apply only to a particular agreement and not to future agreements, unless otherwise explicitly agreed upon in writing.

(4)    The standard terms and conditions shall also apply to all future agreements between StC and its Clients for services (Leistungen).

2. Scope of orders

(1)    The services (Leistungen) of StC will be provided in any one case within the scope determined in the offer which remains open until the conclusion of the contract as services (Dienstleistungen) and/or project-services (Werkleistungen) in accordance with the applicable statutory requirements unless otherwise provided in these standard terms and conditions. StC provides services (Dienstleistungen) (consultation and support of the Client) at its own responsibility. The Client is, however, himself responsible for the results desired and achieved by him. In the case of project-services, StC is responsible for the results to be achieved as well as the management, control, and observation of the provision of the service.

(2)    StC and the Client are each authorized to apply in writing for modifications to the agreed upon scope of services. StC and/or the Client shall examine the possibility of implementing this modification after service of the application therefore. The result of this examination shall be communicated to the other party in writing without delay. StC is authorized to invoice its costs to the ordering party, in so far as the ordering party's application for modification requires a comprehensive and costly examination. The contractual adjustments necessary for such an examination and/or for a modification to the agreed upon scope of services shall be set forth in a supplementary agreement.

3. Fulfillment of orders

(1)    Orders shall be fulfilled observing the current state of science and technology.

(2)    Only StC is authorized to direct its employees.

(3)    StC is authorized to obtain the services of third parties for the fulfillment of orders. StC alone, however, remains directly obligated to the Client.

4. Duties of the Client

(1)    The Client shall provide StC in sufficient time before the fulfillment of the order, without charge, all information, materials, devices, documents and things, plans, etc., necessary for the fulfillment of the order, and shall do so, if necessary, at its own cost.

(2)    In so far as StC carries out its duties at the location of the Client, the Client shall provide the personnel of StC, or of the third parties mandated by StC access to all space, installations (hardware, software, networks, etc.) and other instrumentalities, during the usual business hours and within operational rules of access without cost, which is ordinarily necessary for StC to provide the service. If need be, the Client will obtain functional work stations (Arbeitsplätze), at no cost to StC, for the employees of StC or for third parties mandated by StC.

(3)    The Client will furthermore participate in anyway necessary in the fulfillment of the order.

(4)    If the Client does not or does not timely fulfill his obligations under paras. (1) - (3) and if this leads to delays and/or additional work, the agreed upon time frame and/or the agreed upon remuneration shall increase accordingly.

5. Remuneration and payment times

(1)    The services and project-services will be invoiced at the unit price or on a time-and-materials basis as set forth in the offer after completion and/or acceptance of the services (Leistungen), unless another form of invoice and payment is agreed upon in the offer. In the case of services (Dienstleistungen) and project-services on a time-and-materials basis, the accruing hours worked and travel time shall be invoiced at the applicable hourly rates and the used materials at the prices applicable at the time of the service (Leistung). Other costs, especially commuting, food, and lodging, will be additionally invoiced. Estimated prices for services (Dienstleistungen) and project-services on a time-and-materials basis contained in the offer are non-binding.

(2)    Value-added tax shall be invoiced separately at the applicable value-added tax rate.

(3)    Invoices are payable upon receipt and in full.  Unless otherwise agreed, the Client shall be in default of payment, if invoices are not paid within 30 days after the date of invoice.

(4)    In case of default, interest shall be payable at the rate of 8% above the base rate of the European Central Bank. The right to claim further damages shall not be excluded. 

(5)    Multiple Clients are jointly liable.

(6)    The Clients can only set off non-appealable or unchallenged counterclaims or counterclaims recognized by StC. 

6. Acceptance

(1)    Project-services shall be accepted within 15 days by the Client as soon as StC has demonstrated compliance with the agreed-upon description of services (Leistungsbeschreibung). Immaterial deviations do not authorize the ordering party to refuse acceptance. The obligation to cure defects within the scope of liability for warranties remains unaffected thereby.

(2)    Confirmation of compliance with the agreed upon description of services shall be prepared by both parties by the mutual execution of a protocol of acceptance.

(3)    Placing the result of the project (des Werkes) in operation and/or the productive use of the project or of parts of the project shall be deemed to be an acceptance.

7. Warranties in the case of project-services

(1)     StC warrants that project-services are performed free from defects of material or of title. In particular the project-services performed are in accordance with the agreed-upon description of services (Leistungsbeschreibung) and with the agreed-upon scope of services (Leistungsumfang).

(2)     In case of defects of the project-services, StC shall be liable as follows:

a)        At the discretion of StC, StC shall cure the defects or perform new project-services. 

b)        In the case of failure to cure within a reasonable time, the Client may at his own choice reduce the payment or, insofar as the value or usability of the project should be substantially reduced, demand rescission of the contract, provided that claims for further damages remain unaffected hereof.

c)        In the case of defects of material or of title, the Client shall notify StC immediately hereof in writing.

(3)    The limitation period for warranty claims shall be twelve months. In case the legal provisions in § 438 para. (1) No. 2, § 479 para. (1) or § 634a para. (1) No. 2 BGB (German Civil Code) provide for longer limitation periods, these shall prevail.

(4)    Statements in documentation, prospectuses, project descriptions, etc. do not constitute warranties or guarantees.  Warranties or guarantees require the explicit written confirmation of StC in any case.

(5)    Apparent errors such as typographical errors, calculation errors, defects of form, etc., which are contained in a report, expert opinion, or other professional utterance of employees of StC may be corrected by StC at any time.

8. Liability

(1)     The limitations on liability of para. (1) do not apply, where a liability is mandatory under legal provisions, e.g. under the German Product Liability Act (Produkt­haftungs­gesetz), in case of intentional or negligent actions, in case of damages to life, body or health of persons and in the case of breach of material contractual obligations.  In the case of breach of essential contractual obligations, the liability for damages shall be limited to the contract-typical and foreseeable amount and shall be subject to the limitation period applicable for warranties under it. 7. para. (3) above, unless in the case of intentional or grossly negligent actions or in the case of damages to life, body or health of persons.  The aforementioned regulations shall not imply a change of the burden of proof at the expense of the Client.

(2)     StC shall be liable in the case of project-services for the damages of the Client caused by delay, if a firmly agreed-upon time for the complete fulfillment of performance is exceeded for reasons of StC.  The damages amount to be paid shall be limited, on the merits, to the proved damages of the Client and, in amount, to 0.5% for every accomplished week of delay, totaling however not more than 5% of the total payment for that part of the service not timely completed. The Client shall be obliged, upon the request of StC, to declare within a reasonable time, whether he rescinds the contract because of the delay of the project-services and/or claims damages instead of performance or requests continued performance of the services.

(4)    In so far as the liability of StC is limited, this shall also apply to the employees of StC and to any third parties mandated by it.

(5)    The Client shall notify StC in writing of any damages for which StC may be responsible, and give StC the opportunity to examine the damages and their cause.

9.     Confidentiality

(1)    The parties shall not make economic, technical and other information and knowledge, either made available by the respective other party in the preparation and execution of orders or otherwise having come into the knowledge of the parties, available to third parties

(2)    The obligation in accordance with para. (1) does not apply to information and knowledge, which

-    was known to StC before the issuance of the mandate,

-    StC legally received from third parties,

-    was generally known upon the issuance of the mandate,

-    became known subsequently without a breach of the obligation in accordance with para. (1)

(3)    The obligation under para. (1) applies to both parties after the expiration of the mandate for another two years.

10. Data Protection

The parties shall process or use personal data of the respective other party only for contractually agreed upon purposes under the observation of statutory requirements.

11. Inventions

(1)    Inventions, which are jointly made by the employees of StC and the Client during the execution of a mandate as well as protected privileges issued therefore stand at the joint disposal of the parties. Prior inventions brought in, and/or made solely by any one party will remain in the ownership of the respective party.

(2)    Inventions which are made during the fulfillment of an order by employees of StC as well as protected privileges issued therefore belong to StC. Inventions which are made during the execution of a mandate by the employees of the Client as well as protected privileges issued therefore belong to the Client.

(3)    The grant of licenses to inventions in the sense of paras. (1) and (2) and to the protected privileges issued therefore requires a special written agreement.

12. Work product

(1)    The transfer of ownership (Eigentum) and use rights in work product of any kind achieved within the framework of the scope of services (Leistungsumfang) agreed upon in the offer and notified to the Client, as, for example, documentation, reports, planning documents, evaluations, drawings, program materials, etc., requires a special written agreement.

(2)    StC carries no responsibility if technical documentation provided to it by the Client or within the Client's mandate breaches existing copyrights, industrial property rights, or other rights of third parties. The Client is alone liable if rights of third parties are violated by the fulfillment of its mandate. The Client shall indemnify StC against all claims of third parties for any such violation upon demand. The value of this liability is capped at the value of this contract. Item no. 8 herein remains unaffected.

13. Termination

(1)    Contracts can be terminated at any time on 30 days' notice to the end of a calendar month.

(2)    The termination of contracts for good cause is possible at any time.

(3)    In those cases of termination under paras. (1) and (2) the Client shall pay the remuneration minus that part of the remuneration for the agreed-upon scope of services, which was saved by the termination. StC has an additional claim to payment for the services and costs which accrue in connection with the termination, also in respect of third parties.

(4)    If the termination occurs for reasons to be attributed to StC, then StC has a claim to payment for the services (Leistungsumfang) brought up to that time only in so far as they can be used by the Client.

(5)    Termination requires the written form in any case.

14. Issuance of documents and things,
retention right

(1)    The Client may demand the return by StC of the documents and things issued to it after expiration of a mandate. StC may refuse this return, until all of its claims under the agreement have been satisfied, in so far as such retention of particular documents and things in light of the facts and circumstances, especially in terms of the relative immateriality of the amounts owed, does not violate public policy.

(2)    StC can produce and retain duplicates or copies of documents which it returns to the ordering party.

15. General provisions

(1)    Agreements are concluded in written form. Side agreements are only effective if they have been confirmed in writing by StC.

(2)    The transfer of rights and duties under the agreements by the Client to third parties, excepting direct divisions and/or subsidiaries of the Client, requires the prior written consent of StC.

(3)    Jurisdictional venue is Stuttgart.


 

Annex 2: Software Specification

ClientRBI Software

 

Risk-Based Inspection (RBI), Remaining life assessment, inspection planning materials data management …

The Software’s purpose is to support engineers dealing with life management of primarily equipment under pressure in power plants. It should support the users in all steps of their work: data and documentation management, engineering analysis, decision-making and preparation of reports.

The Software is based on the Client RBI procedure, while referring to recognized methodologies (USA, EU), widely used nowadays by the leading industrial companies, and the use of the state-of-the-art methods and software tools (all intra/extranet based). The solution helps users to understand the basic problems and concepts, and to apply these efficiently in the shortest possible time and, in most of the cases without having to replace their existing system.

Software structure

The Software incorporates the Client RBI procedure and references the state-of-the-art US and EU standards in the field of RBI, including prEN 16991 (formerly CEN CWA15740 RIMAP) and API 580/581. It is comprised of different modules, depending on the field of use. These include:

·        Client RBI Procedure (Level 1, Level 2 and Level 3.1)

o   Baseline risk assessment tools, based on the Client RBI procedure, with database storing plant (component) and inspection data, RBI analyses, user management

o   Level 3.1 risk modelling based on Client RBI procedure

·        RBI Dashboard

o   Assessment overviews

o   Report templates

o   Pre/post-outage risk (performance) review

·        API 581 Modules

o   Qualitative unit/system-based approach (QLTA)

o   Component-based qualitative (Level 1) assessment

o   Component-based semi-quantitative (Level 2) and Financial Risk (Level 3) assessment

Software Requirements

Client-specific requirements resulting from the Gap Analysis, Pilot Phase 14 stations involved in the Rollout Phase can be implemented into the Software. They will be specified and agreed upon separately. A detailed time plan defining the development and implementation of additional and Client-specific modules will be developed contingent upon agreement between Client and R-Tech.

In addition, the Software is compatible with prEN 16991, the new EN standard (“ex-RIMAP”) and The Client procedure for Risk Based Inspection.

RBI Functionality

RBI Analysis Levels

The solution covers all levels, from screening analysis, over more detailed semi-quantitative and quantitative analysis, to the full-scale quantitative RBI analysis of equipment items.

Equipment Types for Analysis

All types of equipment items as covered by the Client RBI Process and guidelines.

Consequence of Failure Evaluation

The consequence of failure is determined for each equipment and damage mechanism and includes the following relevant components: safety consequence, business consequence and environmental consequence.

Consequence of failure is expressed as consequence category and/or as a numerical value (potential loss of life, safety area, damage area, business interruption time, cost etc.)

Damage Mechanisms

Degradation rates are either evaluated by the Software or set by the user. The available power industry-specific degradation mechanisms covered by the Client RBI Damage Mechanism guidelines, including:

·        Cracking-type mechanisms, such as

o   Corrosion Fatigue (CF)

o   Stress Corrosion Cracking (SCC)

o   Thermal Fatigue (TF)

·        Aging-type mechanisms, such as:

o   Creep (C)

o   Temper Embrittlement (TE)

o   Short-Term Overheating (STO)

·        Wall-loss type damage mechanisms, such as:

o   External Corrosion (EC)

o   Oxidation (OX)

o   Pitting Corrosion (CP)

·       

Defined and systematized according to e.g. the prEN 16991, the new EN standard (ex-CWA 15740:2008/2011 RIMAP) (Table 1).

Risk Ranking

Risk values are allocated to each item analyzed for each possible damage mechanism and consequence of failure. Risk is expressed as a numerical value and also displayed in a risk matrix as a combination of a probability category and a consequence category.

Inspection Planning

·        Inspection planning is performed in accordance to South African Regulation, allowing the possibility of extension of the prescribed (36 month) internal inspection and static pressure testing interval.

·        Cost-benefit analysis for proposed inspections (i.e. risk-based NPV – Gain-Loss).

·        Optimizing inspections with respect to component criticality.

 

RBI Reporting

·        Standard reports available: risk reports, component summaries, inspection plan reports, etc.

·        The user is able to generate custom reports.

Data for RBI Analysis

Asset Data Structures

·        Station/Plant (e.g. Kendal, Matla, Lethabo, …)

·        Unit (e.g. U3, U4, U6, …)

·        Area (e.g. Boiler, Turbine, Gen Elec, …)

·        System (e.g. Auxiliary Steam System, HP Bypass System, …)

·        Equipment/Component (e.g. piping, pressure vessels, …)

·        The issue of Client unique component IDs and naming conventions (e.g. system, subsystem, equipment type for SANS categorization,…) has to be resolved jointly with Client.

Data Input and Verification

·        Data may be input either directly or by means of electronic transfer

·        Entry Form (with verification)

·        Spreadsheet Entry Form with verification

·        Capability to import data from external software (pre-specified formats)

Table 1: Damage mechanisms defined and systematized according to prEN 16991, the new EN standard (ex-CWA 15740:2008/2011 RIMAP)

Event, problem, issues

ID and type of damage or disturbances / deviations, functional problems

Subtypes / specifics / further details / examples

 

Common terms**

Client Guideline Terminology

MATERIAL DAMAGE RELATED PROBLEMS

I. Corrosion/erosion/environment related damage, leading to:

 

I.A Volumetric loss of material on surface (e.g. thinning)

I.A1 General corrosion, oxidation, erosion, wear, extended thinning

EC, E, FAC

CPE, E, EC, FAC, FAE, FLAC, GC, CP, IC, UIC/UFC, SOE, OX

I.A2 Localized (pitting, crevice or galvanic) corrosion

IC

CVC

I.B Cracking (on surface, mainly)

I.B1 Stress corrosion (chloride, caustic, etc.), cracking

SCC

SCC

I.B2 Hydrogen induced damage (incl. blistering and HT hydrogen attack)

 

HD

I.B3 Corrosion fatigue

CF

CF

I.C Material weakening and/or embrittlement

I.C1 Thermal degradation (spheroidization, graphitization, etc. incl. incipient melting)

 

G,

I.C2 Carburization, decarburization, dealloying

 

 

I.C3 Embrittlement (incl. hardening, strain aging, temper embrittlement, liquid metal embrittlement, etc.)

EMB

TE, SPE, SAE, HE

II. Mechanical or thermo-mechanical loads related, leading to:

 

II.A Wear

II.A1 Sliding wear

W

FRE

II.A2 Cavitational wear

E

CV

II.B Strain / dimensional changes / instability / collapse

II.B1 Overloading, creep

C

C, SF, SAC

II.B2 Handling damage

PC

 

II.C Microvoid formation

II.C1 Creep

C

C

II.C2 Creep-fatigue

 

CRF

II.D Micro-cracking, cracking

II.D1 Fatigue (HCF, LCF), thermal fatigue, (corrosion fatigue)

F, VF, TF, CF, TMF

MF, TF

II.D2 Thermal shock, creep, creep-fatigue

LTCCG

LTCT, SOH

II.E Fracture

II.E1 Overloading

 

 

II.E2 Brittle fracture

BF

 

III. Other structural damage mechanisms

G, GC, SRF, WD, CB, DMW

DMW, SRF, FOD

DISTURBANCES / DEVIATIONS / PROBLEMS (not related to structural materials)

IV. Fouling / deposits (without fluid flow disturbances)

 

V Fluid flow disturbances

V.A High / low fluid flow (HFF/LFF)

V.B No fluid flow (NFF)

V.C Other fluid flow problems (OFFP)

VI. Vibration (VIB)

VII. Improper dimensioning, improper clearances

VIII. Man made disturbance (deliberate and unintentional)

IX. Fires, explosions and similar

X. Damage and/or loss of function due to other causes

X.A External leakage (EXL*)

X.B Improper start or stop - failed to start/stop (FTS*)

X.C Failed while running (FWR*)

X.D Overheated (OHE*)

X.E Other (OTH*)

* acronyms broadly corresponding to those used in OREDA [33].

** Damage mechanisms labelling as commonly used in practical RBI – analysis (here a power plant example), EC – External Corrosion, E – Erosion, FAC – Flow Accelerated Corrosion, IC – Internal Corrosion, SCC – Stress Corrosion Cracking, CF – Corrosion Fatigue, EMB – Embrittlement, W – Wear/Fretting, C – Creep, PC – Plastic Collapse, F – Fatigue, VF – Vibration related Fatigue, TF – Thermal Fatigue, TMF – Thermo/mechanical Fatigue, LTCCG – Low Temperature Creep Crack Growth, BF – Brittle Fracture, G – Graphitisation, GC – Graphitic Corrosion, SRF – Stress Relief Cracking, OH – Overheating, WD – Welding Defect, CB – Casting Defect, DMW – Dissimilar Metal Weld Failure

RBI Data Output

The data output will include the following:

·        Item analyzed

·        Possible damage mechanisms

·        Probabilities of failure for each component and the respective damage mechanisms

·        Consequence of failure for each component

·        Risk ranking (discrete and matrix)

·        High-level inspection and test plan, including proposed inspection/test dates and techniques

·        Value/Cost of Risk

·        Results of risk assessment and inspection/test plans available to external software

RBI Data Customization

·        Probability category definition

·        Consequence category definition

·        Generic failure frequency data

·        Inspection priority definition

·        Inspection costs

·        Using the actual degradation rates for each equipment

Inspection Data Management

Asset Data, Resources and Document Management

·        Configuring asset data hierarchies such as functional hierarchy, geographical hierarchy, inventory group and equipment class grouping

·        Specifying equipment design and operating data using standard datasheet templates

·        Adding/editing/deleting equipment basic attributes such as equipment type/priority class/specification description/asset ID/department and engineering drawing

·        Recording component and parts list and relevant technical data

·        Allowing searches for specific component by “keyword” and sort by component ID/component type

·        Company organization hierarchy, including Software users/resources & permissions

·        Attaching and viewing documents such as Image files, Visio/AutoCAD drawings, PDF files, Excel files at the various levels of the asset hierarchy.

Inspection Scheduling

·        Provision of high-level inspection work scopes

·        Generation of automatic work-list and next inspection date based on schedule

·        Provision of Shutdown list for inspection work

Inspection management Reports

·        Overall component risk reports

·        Individual Component-level reports (2-pager)

·        Risk-ranked lists

Data Security- Access Mode

·        Site Administrator Access Mode

·        Standard User Access Mode

·        Viewer only Access Mode

User Interface Requirements

·        Users shall access the Software through the web or optionally through the operator’s intranet

·        Ability to operate in a networked environment. The database shall be accessible through a client server or web access

·        Import input data from R-Tech template file types, e.g. XLS (MS Excel), XML, etc.

·        Export of results for use/viewing in other software, e.g. MS Excel, MS Word, Adobe PDF, etc.

·        The Software allows multiple concurrent users on network


 

Software Look and Feel

 

Component based Level 1 – screening

 


The Level 1 screening analysis is performed quickly on a large number of components, in order to screen out components with low levels of risk.

Assessment of each component is carried out considering the most likely damage / failure mechanism and the worst case failure scenario. Level 1 assessment represents a conservative high level qualitative estimate.


 

Level 2 assessment - multiple DMs:

 


Utilizing a similar methodology to the Level 1 assessment, the Level 2 procedure contains more specific criteria and an expanded scoring system.

Not all of criteria available in the Level 2 analysis may be applicable to all potential damage mechanisms, but the selected criteria cover the majority of the main damage influencing conditions.

A significant difference from the Level 1 analysis is the fact that all feasible damage mechanisms that could affect the component(s) are considered, instead of just one dominant DM.




 

Level 3.1: Risk Modelling – Bowtie

 

Risk and mitigation factor / action modelling based on the Client RBI process and guidelines, for components with multiple damage mechanisms and consequence scenarios.

Short-term high risk components are subjected to detailed consideration by the appropriate SME team. The evaluation process considers the various factors which can influence the PoF and CoF score, and their effectiveness.


 

RBI Dashboard

 


The RBI Dashboard expands on the capabilities of the RBI Software and enables the quick and successful implementation of the Client RBI Process and Workflow.

A quick and precise overview is possible, thanks to logical structuring of plants, units, areas, analyses and components in a tree structure.

Individual components can be searched for among a vast database, thanks to advanced filtering options.

 


The RBI Dashboard can quickly display the required pertinent information to highlight results and progress, or relevant indicators, such as:

· number of assessed components vs number required to be assessed,

· number of components located in the respective risk categories.

Custom overview breadth is supported – From a single plant area in a single unit, to the entire fleet if required.


 


The RBI Dashboard serves as an extension of the Client RBI Process/Guideline, and enables the review and comparison of pre- and post- outage RBI results. Key information can be quickly filtered, calculated and displayed, such as:

Number of DMs pre- and post-outage

Comparison of pre- and post- outage PoF, CoF, Risk (Sum and Average)

Assessment of all components, or only inspected within x past years.





 

 

API 581 Technical Modules

 

The iRiS RBI software suite consists of the following modules:

1. API 581 qualitative analysis (unit/system-based) system for a system/unit-based approach (screening)

2. API 581 qualitative (component-based) – Level 1, semi-quantitative – Level 2 and Level 3 analysis modules

 


API 581 qualitative analysis system for unit-based approach (screening) – QLTA:

R-Tech’s QLTA is based on the Workbook for Qualitative Risk Analysis given in Appendix A of the API581 Base Resource Document

QLT is used to determine the Likelihood and Consequence Category for a given system / unit, and is subdivided into the following sections:

Part A: Likelihood Category
Part B: Damage Consequence Category
Part C: Health Consequence Category

The final consequence is determined as the highest category derived from Part B or C. For multiple fluids, the exercise should be repeated, to derive separate risks for each hazardous material. The material with highest risk should be considered first during the component-based Qualitative assessment.

 

API 581 component-based qualitative (Level 1 and semi-quantitative (Level 2 and Level 3) analysis modules

iRiS RBI performs all the tasks necessary to determine the risk rank of the equipment and optimize the inspection plan, according to API581, based on the qualitative approach (level 1) or semi-quantitative (Level 2 and Level 3) approach.





 

 

Yes access to Techstreet, Knovel (targeted licensees for RBI-related literature), ISO and CEN Standards, selected API, ASME and other standards, access to Publisher's databases (Springer, Elsevier) and, also, full-scale access to university resources through Steinbeis university (see the figure below).

   In addition Steinbeis R-Tech has its proprietary Knowledge Base ("Safetypedia") containing 

  • over 100,000 book
  • about 800 journals and reports
  • almost 20,000 standards
  • over 1,000 other documents

 ... see below:

Our system complies fully with following standards by the certification of TüV Austria (please see the image below)

  • European standard EN 16991:2018 on Risk Based Inspection Framework

  • US standard API 580/581 by American Petrolium Institute (API)

  • German standard VGB S-506:2019 - Condition Monitoring and Inspection of Components of Steam Boiler Plants, Pressure Vessel Installations and Water-or Steam-Pipes in Thermal Power Plants, 3rd edition 2019

  • CEN CWA 15740:2008 (2011) Risk Based Inspection and Maintenance Procedures for European Industry (RIMAP), now being accepted as prEN 16991:2016 (“Risk Based Inspection Framework”)

 Practically, following are examples of types of data linking to asset:

  • Customized input data sheets: User requiring that the data are collected/acquired “off-line”, e.g. by means of dedicated forms or sheets which are then checked and imported into the system. Especially important for large number of components (e.g. cases of 10,000+ components).

  • Customized input for inspection data (e.g. NDT – non-destructive testing)


Our software is audited and received the positive feedback from TüV Austria Certification Organization

 


Please visit: www.risk-technologies.com and www.steinbeis.de for general organization of Steinbeis Risk-Technologies Group: STeinbeis Advanced Risk Technologies GmbH (R-Tech) is in charge of commercialization of the RBI tools, R-Tech Institute (part of the Steinbeis University) is in charge of RBI-related education and  the international branches (e.g. the one in South Africa) support implementation on site.

The software has the ability to import data from an Excel template forms. Also during installation we can migrate your existing data from your database to the iRiS database within the limits of compatibility.

You can use iRiS software in most current browsers, for example:


Our Hot-line (Help-desk) support is from Monday to Friday, 9 am to 5 pm excluding Bank Holidays (normal working hours).

The client can have access to a help-desk via direct e-mail or telephone for user level support. Direct e-mail and telephone support (i.e. related to how to use the functions of the application) is provided.

The official language of communication is English. Technical Support – in cases of technical and other issues not related to the use of the software, questions will be addressed to technical support.

The services offered cover trouble-shooting in case of incidents and will be provided in the presented order: A request for the technical support will be initialized by the client by filing in the form provided on a web portal.

After the client submits the trouble report, it will be sent to support@risk-technologies.com. The issue is registered and analyzed according to ISO 9001:2015, as of 2017. By special arrangement (in emergency cases) 24/7 support can be provided (to be specified with the client).

We have Steinbeis web-based CRM (Customer Relationship Management) for informal information exchange

Typically the application core and database structure is common and similar for all the clients. Client specific functionalities can be enabled/hidden as required on a modular basis. 

Tailored parts of the application can use the core tables in the database (e.g. equipment data). Specific modules can be assigned their own tables in the database, and can be hidden/enabled in different instances as required. 

During the development phase of a newer version, full version control is implemented. Regular backups of software versions and the database are created.

In case of the requested changes in a new version trigger changes to the database structure, the following delivery, installation and acceptance, reverting to an older version with an older database structure is not recommended because it could result in some degree of data loss. Instead, any work performed in the newer version would be incompatible with the previous database structure. If changes to the new version did not include changes to the database structure, then a full roll-back to a previous version is possible.

The previous major release was last year (2015), integrating the latest updates, improvements and modules for a client (including the NDT module). Development in the previous period focused on transition to a new database structure, web-based global access and operation under MS SQL. The customized customer-specific development model means that there is no exactly defined future major release date.

The user can make use e.g. only of the NDT module (used for input of equipment and piping wall thickness measurements, corrosion rate prediction, etc.) without having to use the RBI module. 

Workflow in the system follows the principles outlined in API 580 and RIMAP. It is currently not configurable but this can be discussed and specified with the client.

Roles are defined as per the user rights management – users defined as custodians of the software and database shall have full access rights.

Access rights for other users (e.g. inspectors) shall be defined and specified with the client but there is a possibility to limit the access and inputs of different users.

The system assists/supports large turnarounds by allowing users to plan their inspections and priorities based on both the current and future risk (at the set plan end date – e.g. over 6 years).

Users can assign actions and priorities based on the level of risk (e.g. high risk – immediate mitigation measures/prioritized for opportunity inspection, low risk – consider substitution of internal with onstream inspection, do not inspect at next outage if t1/2 will not be exceeded afterwards,…).

A number of Risk-Based Decision Making Tools are available (Financial Risk Module, Gain Loss, S-Factor, Cumulative Risk), which enable users to make risk informed decisions and inspect/act on the right equipment to ensure maximum risk reduction within the constraints of limited time or budget. 

If a vulnerability is identified by the client, it will be communicated to R-Tech using the customer service technical support and it is subsequently dealt with in the highest order of priority.

During the primary contract execution phase (when the software is customized according to the customer’s requirements) development and updates (including needed patching) are within the scope of the main contract.

Following the end of the main contract, further patching/updating will be covered by subsequent maintenance contracts, to be specified with the client. The developer actively works on making new versions and corrects bugs and vulnerabilities as they are found, based on constant feedback from the customer (an issue reporting and tracking system is developed and in place).

  IT QUESTIONS
 

PDF e-signatures available
The programming language is used by Steinbeis R-Tech solution is Microsoft .NET family

The software does not support remote user monitoring but the client can make use of the offered help-desk/assistance provided and sessions can be monitored e.g. though a skype connection.

An advantage of Finnish preferred implantation partners (Fortum, VTT) is the fact that knowledgeable experts can be made available to quickly respond in case needed (if specified by the client).


Custom user definable access can be exemplified in a role-module matrix. For every module, users with specific rights levels can have varying degrees of access and CRUD (create, read, update, delete) operations, as identified and defined by the client. 

The currently defined user rights levels are:

  • Administrator (full access),

  • RBI user (RBI full access),

  • RBI viewer (reads only for the respective modules)

Further specific roles with corresponding rights can be defined. E.g. in many instances the role of “Auditor” was needed and defined.

Additional/new user access level can be defined and specified in cooperation with the customer, according to his requirements.

Note: other types of user rights and profiles can be created as necessary, because the full software ownership is on our side.


In general, multiple language in User interface or other specific requirements can be customized as required by the client.

In particular, the system are available with English and Finnish language.

Available learning and e-learning material is available in English and Finnish language.

 


The software/solution can be accessed depending on the specification and agreement with the customer. Multiple instances can be created and enabled, allowing e.g. two completely separate plants.

User management is defined in a role-module matrix. For every module, users with specific rights levels can have varying degrees of access and CRUD (create, read, update, delete) operations, as identified and defined by the customer. The currently defined user rights levels are: Administrator (full access), RBI user (RBI full access), RBI viewer (reads only for the respective modules). Further specific roles with corresponding rights can be defined. E.g. in many instances the role of “Auditor” was needed and defined.

 

Additional/new user access level can be defined and specified in cooperation with the customer, according to his requirements.

Note: other types of user rights and profiles can be created as necessary, because the full software ownership is on our side.


Scope and type of connection with Maximo (live connection/import-export via intermediary buffer file, etc.) can be discussed and specified in detail in further discussions in cooperation with the client. The limitations are primarily on Maximo side, i.e. it’s Maximo often limiting the data exchange.

Example of an upgrade made for a client in 2018- 2019:

Partly by means of a direct search (built-in) or by the special BI (business intelligence modules) – see the example below (optional module based on Microsoft Power BI Business Intelligence add-on):

 

The solution database is created under MS SQL Server which contains comprehensive documentation about the database structure and integration methods.

The standard ODBC protocols allow the possibility to build numerous integrations. An example is the current use of Microsoft OLE DB Provider, which provides integration of the solution with MS Office, and other tools developed by Steinbeis (e.g. Alias Risk, Bow-tie, Risk Optimizer, Creep Fatigue Monitoring, Inspection Result Evaluation, etc…). 

The system allows access databases through Open Data Base Connectivity (ODBC)

Full specification of direct data import/export to other systems shall be discussed, clarified and specified in detail in cooperation with the client.

In general:

  • Direct mass import through developed templates is currently possible.
  • Direct mass export to Excel, pdf Word is possible.
  • The database is MS SQL, and standard ODBC protocols can be used to facilitate mass import/export. 

Scope and type of connection with SAP (live connection/import-export via intermediary buffer file, etc.) will be discussed and specified in detail in further discussions in cooperation with the client.

Output possibilities to SAP (e.g. possible connection to SAP PMR) can be explored and specified in future upgrades, in cooperation with the client. The recommended implementation partner Fortum has extensive experience of creating various interfaces to SAP. This knowledge and expertise will be brought in as required.

The system protects against erroneous entries through limited input fields (specific input data types, ranges, auto-correction of inputs, based on other previous inputs made). A verification system (e.g. electronic verification and “sign-off” by responsible superiors) can be discussed and specified in cooperation with the client.

The use of the system and user identification is controlled via the user management and login. The current level of security can be increased in the case of specific customer requirements.

Physical access to the R-Tech data center (location of the server) is only granted to IT personnel responsible for management and administration of the server(s).

Client information is protected by the user login system. The current level of security can be increased in the case of specific client requirements. The entire process is duly covered by all the ISO 9000 and ISO 27000 principles. 
Encryption of information directly within the solution is not currently available but possible solutions can be explored and specified with the client and implemented in cooperation with the preferred implementation partners. 
The solution can be installed on virtual servers. For our own (R-Tech) servers, professional 3rd party antivirus and firewall programs are used. 

User activity is managed and monitored through the login and user rights system. Upon request from the client, an activity log for a defined period of time can be generated.

A specific process and associated documentation/procedure will be defined and developed in cooperation with the client. Please refer to the related questions where several possibilities of installation of the solution are given including installation and maintenance of all customer data on customer-specified locations. In such cases, destruction of customer data may not be required. 

If required and specified by the client, solutions can be implemented, e.g. connection to the solution (if located on R-Tech servers) through VPN.
  RBI-SPECIFIC QUESTIONS
 

The RBI-iRiS allows you to modify/customize the risk matrix as the illustrated picture below:


Corrosion Group/Loop definition (CG and associated equipment description, process stream description, expected damage mechanisms, associated drawings) is available as part of the iRiS integrated tool package, and is currently under further development.

Equipment assigned to corrosion groups will be organized in a dynamic tree structure (similar to the existing equipment type and process unit structures). Attached is an example of the current corrosion loop functionality. 

  Explanation of the question needed. Otherwise, see figure below:

 

Typical Damage mechanisms in Refining industries

DM#

Damage Mechanism

DM#

Damage Mechanism

1

Sulfidation

33

885°F (475°C) Embrittlement

2

Wet H2S Damage (Blistering/HIC/SOHIC/SSC)

34

Softening (Spheroidization)

3

Creep / Stress Rupture

35

Reheat Cracking

4

High temp H2/H2S Corrosion

36

Sulfuric Acid Corrosion

5

Polythionic Acid Cracking

37

Hydrofluoric Acid Corrosion

6

Naphthenic Acid Corrosion

38

Flue Gas Dew Point Corrosion

7

Ammonium Bisulfide Corrosion

39

Dissimilar Metal Weld (DMW) Cracking

8

Ammonium Chloride Corrosion

40

Hydrogen Stress Cracking in HF

9

HCl Corrosion

41

Dealloying (Dezincification/ Denickelification)

10

High Temperature Hydrogen Attack

42

CO2 Corrosion

11

Oxidation

43

Corrosion Fatigue

12

Thermal Fatigue

44

Fuel Ash Corrosion

13

Sour Water Corrosion (acidic)

45

Amine Corrosion

14

Refractory Degradation

46

Corrosion Under Insulation (CUI)

15

Graphitization

47

Atmospheric Corrosion

16

Temper Embrittlement

48

Ammonia Stress Corrosion Cracking

17

Decarburization

49

Cooling Water Corrosion

18

Caustic Cracking

50

Boiler Water / Condensate Corrosion

19

Caustic Corrosion

51

Microbiologically Induced Corrosion (MIC)

20

Erosion / Erosion-Corrosion

52

Liquid Metal Embrittlement

21

Carbonate SCC

53

Galvanic Corrosion

22

Amine Cracking

54

Mechanical Fatigue

23

Chloride Stress Corrosion Cracking

55

Nitriding

24

Carburization

56

Vibration-Induced Fatigue

25

Hydrogen Embrittlement

57

Titanium Hydriding

27

Thermal Shock

58

Soil Corrosion

28

Cavitation

59

Metal Dusting

29

Graphitic Corrosion (see Dealloying)

60

Strain Aging

30

Short term Overheating – Stress Rupture

61

Steam Blanketing

31

Brittle Fracture

62

Phosphoric Acid Corrosion

32

Sigma Phase/ Chi Embrittlement

63

Phenol (carbolic acid) Corrosion

 

Interactive damage maps: