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API-580 Exam Format | API-580 Course Contents | API-580 Course Outline | API-580 Exam Syllabus | API-580 Exam Objectives

Exam Code: API-580

Exam Name: Risk Based Inspection Professional

Duration: 3.25 hours

Question in Exam: 90

Scored Question: 80

Unscored Question: 10

Question Type: multiple-choice

Passing Scores: 56 (70%)



1. Understanding the Design Premise



- Design Basis: The set of conditions (pressure, temperature, material properties) used to design equipment.

- Operating Conditions: Actual conditions under which equipment operates, which may differ from design.

- Equipment Integrity: The ability of equipment to perform its intended function without failure.

- Material Selection: Choosing materials based on corrosion resistance, strength, and environmental compatibility.

- Integrity Operating Windows (IOWs): Established limits for process variables (e.g., temperature, pressure) that affect equipment integrity if exceeded.

- Fitness-for-Service (FFS): Assessment to determine if equipment is suitable for continued operation (referenced in API 579).

- Understanding how design assumptions impact risk exams and inspection planning.



2. Planning the RBI Assessment

- RBI Assessment Plan: A documented strategy outlining steps, data requirements, and resources for RBI.

- Risk Criteria: Terms of reference (e.g., safety, cost, environmental impact) used to assess the significance of risk.

- Stakeholder Involvement: Engaging relevant parties (e.g., operations, maintenance, engineering) in the RBI process.

- Qualitative RBI: Risk exam using descriptive or categorical data (e.g., high/medium/low risk).

- Quantitative RBI: Risk exam using numerical data to calculate probabilities and consequences (often based on API RP 581).

- Risk Matrix: A tool to plot probability of failure (POF) against consequence of failure (COF) to prioritize risks.

- Ability to outline key steps and considerations for a comprehensive RBI plan.



3. Data and Information Collection

- Process Data: Information on operating conditions, fluid composition, and process parameters.

- Inspection History: Records of past inspections, findings, and repairs.

- Equipment Data: Specifications, materials, and design details of equipment.

- Corrosion Loops: Groups of equipment or piping systems exposed to similar corrosion mechanisms.

- Data Validation: Ensuring the accuracy and completeness of collected data.

- Non-Destructive Exam (NDE): Techniques (e.g., ultrasonic testing, radiography) used to inspect equipment without causing damage.

- Identifying critical data sources and ensuring data quality for RBI exams.



4. Identifying Damage Mechanisms and Beginnings and Failure Modes

- Damage Mechanism: A process that causes deterioration (e.g., corrosion, cracking, erosion).

- Failure Mode: The manner in which equipment fails (e.g., leak, rupture, brittle fracture).

- Corrosion Mechanisms:

- General Corrosion: Uniform material loss over a surface.

- Localized Corrosion: Pitting or crevice corrosion in specific areas.

- High-Temperature Corrosion: Oxidation, sulfidation, carburization, or metal dusting.

- Environment-Assisted Cracking (EAC): Stress corrosion cracking (SCC), hydrogen-induced cracking (HIC), or sulfide stress cracking (SSC).

- Erosion: Material loss due to mechanical action of fluids or particles.

- Fatigue: Failure due to repeated stress cycles.

- Identifying applicable damage mechanisms based on material, process, and environmental conditions.



5. Assessing Probability of Failure (POF)

- Probability of Failure (POF): The likelihood of equipment failure within a given timeframe.

- Damage Rate: The rate at which a damage mechanism degrades equipment (e.g., corrosion rate in mils per year).

- Inspection Effectiveness: The ability of inspection techniques to detect damage (e.g., highly effective, moderately effective).

- Remaining Life: The estimated time until equipment reaches an unacceptable condition.

- Confidence Level: The degree of certainty in POF calculations based on data quality.

- Event Tree Analysis: A method to model possible failure scenarios and their probabilities.

- Calculating POF using qualitative or quantitative methods and understanding factors affecting reliability.



6. Assessing Consequence of Failure (COF)

- Consequence of Failure (COF): The severity of outcomes if failure occurs.

- Safety Consequence: Potential for injury or loss of life.

- Environmental Consequence: Impact on air, water, or soil (e.g., oil spills).

- Economic Consequence: Costs of downtime, repairs, or lost production.

- Risk Driver: The primary factor(s) contributing to the risk value (e.g., high POF or severe COF).

- Area of Impact: The physical area affected by a failure (e.g., blast radius, spill spread).

- Assessing COF in terms of multiple impact categories and prioritizing based on severity.



7. Risk Determination, Assessment, and Management

- Risk: The combination of POF and COF (Risk = POF × COF).

- Absolute Risk: An ideal, precise quantification of risk.

- Acceptable Risk: A risk level deemed tolerable by the owner-operator.

- As Low As Reasonably Practicable (ALARP): Reducing risk to a level where further reduction is not justified by cost or feasibility.

- Risk Ranking: Prioritizing equipment based on risk levels for inspection or mitigation.

- Risk Evaluation: Comparing calculated risk against risk criteria to determine significance.

- Risk Identification: Listing and characterizing risk factors (e.g., source, event, COF, POF).

- Performing risk calculations, interpreting results, and making risk-based decisions.



8. Risk Management with Inspection Activities and Process Control

- Inspection Plan: A strategy detailing the scope, methods, locations, and timing of inspections.

- Condition-Based Monitoring (CBM): Monitoring equipment condition to trigger inspections or maintenance.

- Time-Based Inspection: Inspections scheduled at fixed intervals.

- Risk-Based Inspection (RBI): Inspections prioritized based on risk levels.

- Process Control: Maintaining operating conditions within IOWs to minimize damage.

- Mitigation Inspection: Inspections aimed at reducing uncertainty in POF or COF.

- Designing inspection plans that optimize risk reduction while balancing costs.



9. Other Risk Mitigation Activities

- Material Upgrade: Replacing materials with more resistant alloys (e.g., stainless steel for corrosion resistance).

- Re-rating: Adjusting equipments design parameters (e.g., lowering maximum allowable working pressure).

- Process Modification: Changing operating conditions to reduce damage (e.g., lowering temperature).

- Equipment Replacement: Substituting high-risk equipment with new or redesigned units.

- Redundancy: Adding backup systems to reduce COF (e.g., secondary containment).

- Identifying and evaluating alternative mitigation strategies beyond inspection.



10. Reassessment and Updating RBI Assessments

- Reassessment Triggers: Events prompting RBI updates (e.g., new inspection data, process changes).

- Evergreening: Continuously updating RBI exams to maintain accuracy.

- Data Integration: Incorporating new inspection or monitoring data into the RBI model.

- Risk Recalculation: Revising POF, COF, or risk based on updated information.

- Assessment Frequency: The interval for reassessing RBI (e.g., every 3–5 years or after significant changes).

- Understanding when and how to update RBI exams to ensure ongoing relevance.



11. Roles, Responsibilities, Training, and Qualifications

- RBI Team: Multidisciplinary group including inspectors, engineers, and process specialists.

- Competency: The knowledge, skills, and experience required for RBI tasks.

- Training: Formal education or on-the-job learning to understand RBI methodologies.

- Qualifications: Certifications (e.g., API 580, API 510) or experience validating expertise.

- Roles:

- RBI Analyst: Performs risk exams and calculations.

- Inspector: Conducts field inspections and reports findings.

- Management: Approves RBI plans and allocates resources.

- Assigning appropriate responsibilities and ensuring team qualifications.



12. Documentation and Recordkeeping

- RBI Documentation: Records of risk exams, inspection plans, and mitigation strategies.

- Inspection Reports: Detailed findings from inspections, including damage observed.

- Audit Trail: A chronological record of RBI activities for regulatory or internal review.

- Data Management System: Software or databases for storing and retrieving RBI data.

- Regulatory Compliance: Adhering to standards or legal requirements for recordkeeping.



- API RP 581: A quantitative RBI methodology complementing API 580s framework.

- Pressure Equipment: Vessels, piping, or tanks subject to internal or external pressure.

- Components: Individual parts (e.g., pipes, nozzles, shells) forming equipment.

- Professional Development Units (PDUs): Credits earned to maintain API 580 certification through training or activities.

- Closed-Book Exam: The API 580 exam format, where no reference materials are allowed.

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