API 580 (4th edition) Required Elements

, 6/17/2024 Be the first to comment

Tags: API 580 Risk Based Inspection

What are the requirements of API 580, 4th edition? It can be tedious sorting out the "shalls" from the "shoulds". Fortunately, our training team has been kind enough to do this for us. But don't tell them I told you.

API 580 (4th edition) Required Elements

I recently had the opportunity to sit in on our new API 580 class that includes the new updates in the 4th edition of the recommended practice. As usual, when reading the 580 document, it can be rather tedious to sort out the requirements from the recommendations. The document is very consistent about identifying those elements which are required (i.e. "shall") for a program to be considered API 580 compliant vs. those elements which are recommended (i.e. "should"). However, in my experience, while reading the document I find it very easy to overlook a "shall".

Fortunately for us, AOC's training team has gone through the document with a fine-toothed comb and compiled this handy table enumerating the various requirements established in the 4th edition of API 580. And what's more, they have even grouped them by RBI Work Process Step. So, if you have been struggling to sort out what, exactly, you need to do to call yourself 580 compliant, read on.

What are the required elements of API 580, 4th edition?

API 580 (4th edition) Required Elements
RBI Process StepSectionRequirement
Entire RBI Work Process5.4.2Use of expert opinion shall be included in a risk assessment regardless of type or level.
5.9All users shall review applicable jurisdictional code and legal requirements for acceptability of using RBI for inspection planning purposes.
6.1.1Essential elements that exist in any RBI program shall include documentation of the following:
  1. management systems for maintaining documentation, personnel qualifications, data requirements, consistency of the program, and analysis update.
  2. method for POF determination.
  3. method for COF determination.
  4. methodology for managing risk through inspection, process control, and mitigation activities.
6.3.2Boundaries for physical assets included in the RBI assessment shall be documented.
6.3.6When initial screening methodologies are used, the methodology and results shall be documented.
7.2.2In cases where the team leader is unfamiliar with the facility to be evaluated, the facility shall provide a team member that is familiar with the facility and its associated requirements.
7.2.2In all cases, the team leader shall be familiar with the RBI methodology employed and should be familiar with the types of operating processes to be assessed.
15.1Thus, an RBI program shall be maintained and updated to ensure that the most recent inspection, process conditions, equipment modifications, mitigation strategies, and maintenance information are considered and used in the RBI assessment.
15.1.2The RBI program shall document all applicable RBI reassessment intervals.
15.2.1The owner-operator's RBI program shall have a work process that identifies when a reassessment is necessary.
15.3.2The governing inspection codes (such as API 510, API 570, and API 653) and jurisdictional regulations, if any, shall be reviewed in this context and the appropriate time intervals applied.
16.1A documented management system to implement and sustain the RBI program shall be developed and documented by the user.
16.2The required data shall be captured and maintained such that the RBI assessment can be recreated or updated at a later time by others who were not involved in the original RBI assessment.
Acquire/Update Data5.6.1Change information shall be communicated so that modifications in the risk-based management plan can be made.
5.7As new data (such as inspection results and industry experiences with similar processes) becomes available, or when changes occur (e.g. operating conditions), a reassessment of the RBI program shall be made that will provide a refreshed updated view of the risks.
5.7Risk-based management plans shall be adjusted as needed based upon triggers that require an RBI assessment to be updated (changes listed in Section 15).
6.4.2Process conditions during start-up and shutdown shall be evaluated for all equipment covered by the RBI assessment.
8.3Data inputs and assumptions shall be validated by qualified personnel such as process engineer/operator to review operating parameters used (see Section 7).
Assign/Update Damage Mechanisms7.2.4A corrosion specialist shall be responsible for assessing the types of damage mechanisms and the applicability and severity to the equipment considering the process conditions, environment, metallurgy, age, and other relevant data pertaining to the equipment.
9.1The corrosion specialist shall define the credible damage mechanisms for each item addressed by the RBI assessment.
9.1All process conditions (e.g. start-up, shut-down, idle, anticipated abnormal and normal runs), as well as planned process changes shall be considered.
9.1The data and basis for assumptions used in the DMR shall be recorded in the RBI assessment documentation.
9.2A DMR shall analyze and evaluate the combinations of process conditions, the external environment, the materials of construction, and the inspection history for each equipment item to identify the active and credible damage mechanisms.
9.2The DMR shall also be used to determine the associated deterioration rates and susceptibilities of these mechanisms.
Assess Risk and Rank5.5The RBI process shall be capable of generating a ranking of relative risk of all equipment evaluated
10.1The POF analysis shall address all credible damage mechanisms to which the equipment being reviewed is or can be susceptible.
10.1Further, it shall address the situation where equipment is or can be susceptible to multiple damage mechanisms (e.g. thinning and creeping).
10.3.1The process used to estimate/calculate the POF shall be documented.
10.3.1When general failure data are being modified, the owner-operator RBI programs shall define what qualified persons can perform this task.
10.3.3Owner-operator RBI programs shall define what qualified persons can make modifications to general failure data on a case-by-case basis.
10.4.2After the credible damage mechanisms have been identified, the inspection(s) shall be evaluated to determine the effectiveness to detect, characterize (e.g. sizing of flaws, identification of area of indications, accuracy of technique used, etc.) each identified mechanism.
11.1.1The COF analysis shall be performed to estimate the COF that is likely to occur due to a failure mode typically resulting from an identified damage mechanism(s) (see Section 9).
11.1.2If these other types of functional failures are used, they shall be documented in the user's program.
11.5.1Regardless of whether a qualitative or quantitative analysis is used, the major factors to consider in evaluating the COF shall include the following:
  1. flammable events (fire and explosion);
  2. toxic releases; and
  3. release of other hazardous fluids.
12.1Risk shall be determined by combining the POF (results of work done as described in Section 10) and the COF (results of the work done as described in Section 11).
12.1The general form of the risk equation shall be as follows: Risk = POF × COF
Inspection Planning, Process Monitoring, Risk Mitigation5.6.2.2The inspection plan shall describe the type, scope and timing of inspection /examination recommended.
13.3Once a risk assessment has been completed, the items with unacceptable risk to the owner-operator shall be assessed for risk management through inspection plans or other risk management strategies.
13.4When an inspection strategy is developed, it shall be documented.
Review Results15.2.2As part of the reassessment, the operating histories over the past run, including operating limit exceedances and trends, shall be reviewed to better predict if non-time-dependent damage mechanisms could have occurred.
15.2.2When inspection activities have been performed, the results shall be reviewed to determine if an RBI reassessment is necessary.

Hopefully you will find this list as useful as I have. For a deeper dive into 580, you might be interested in taking one of our upcomming training offerings. AOC's RBI professionals will walk you through the standard to help you with your own RBI program and/or prepare for API 580 Certification.

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