PETRONAS TECHNICAL STANDARDS

PETRONAS Risk-Based Inspection (PRBI)

PTS 15.40.01
December 2016

© 2016 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.
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ANNOUNCEMENT

Please be informed that the entire PTS inventory is currently undergoing transformation exercise from
2013 - 2015 which includes revision to numbering system, format and content. As part of this change,
the PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition
to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and where required
make reference to other PTS in its revised numbering to ensure consistency. Users are requested to
refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For
further inquiries, contact PTS administrator at ptshelpdesk@petronas.com.my
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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 5
1.1 SCOPE .............................................................................................................................. 5
1.2 GLOSSARY OF TERM ........................................................................................................ 5
1.3 SUMMARY OF CHANGES ................................................................................................. 7
2.0 REQUIREMENTS..................................................................................................... 8
2.1 SPECIAL REQUIREMENT FOR FACILITIES OPERATING IN MALAYSIA ............................... 8
2.2 STAGES OF PRBI IMPLEMENTATION ............................................................................... 8
3.0 PRBI APPROACH .................................................................................................... 9
4.0 PRBI TEAM .......................................................................................................... 10
5.0 PRBI STUDY IMPLEMENTATION ........................................................................... 12
5.1 CORROSION ASSESSMENT ............................................................................................ 12
5.2 RISK ANALYSIS ............................................................................................................... 15
5.3 INSPECTION EVALUATION ............................................................................................. 16
6.0 PRBI MONITORING .............................................................................................. 18
7.0 PRBI REVIEW ....................................................................................................... 19
7.1 PRBI Reassessment ....................................................................................................... 19
7.2 PERIODIC REVIEW ......................................................................................................... 19
8.0 PRBI MANAGEMENT REVIEW ............................................................................... 20
9.0 BIBLIOGRAPHY .................................................................................................... 21
APPENDIX 1: REQUIRED DATA/INFORMATION FOR PRBI STUDY ...................................... 22
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1.0 INTRODUCTION

This PETRONAS Technical Standards (PTS) provides the minimum technical requirements for
PRBI system which is applicable for PETRONAS new projects or in-service inclusive of Special
Scheme of Inspection (SSI) program.

This PTS incorporates Factories and Machinery (Special Scheme of Inspection) (Risk-Based
Inspection) Regulation 2014 [P.U. (A) 96/2014] requirements gazetted in June 2014 to ensure
successful implementation of Special Scheme of Inspection (SSI) across PETRONAS. It also
incorporates related RBI best practices and lesson learnt from other OPUs.

1.1 SCOPE

1.1.1 PRBI methodology covers RBI analysis for metallic static equipment and piping which is
governed by applicable code and standard i.e. pressure vessel, column, boiler, furnace, heat
exchanger, launcher/receiver and storage tank.

1.1.2 Items such as civil structures, electrical equipment, electronic devices, rotating equipment,
pipeline, risers and non-metallic equipment/piping are excluded from this PTS.

1.2 GLOSSARY OF TERM

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition Of Terms, Abbreviations &
Reading Guide.

1.2.2 Specific Definition of Terms

No Term Definition

1 Corrosion Design Basis A comprehensive document which describes

Memorandum the corrosion management philosophy and
basis of materials selection for specific project.

2 CF70 Qualification of certificate issued by DOSH to an

equipment after it has been inspected, the
prescribed fee paid for, and the Inspector is
satisfied that the equipment meet the
requirement of Factories and Machinery Act
139, 1967.

3 Corrosion Management Plan A comprehensive document which describes

the technical basis and important information
regarding materials selection, corrosion control
and monitoring, inspection and corrosion
related incident prevention of a facility.

4 Risk-Based Inspection A systematic tools used to assess and manage

integrity of assets which provide
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No Term Definition
recommendation of Inspection Planning based
on associated risk of equipment or piping.

5 PETRONAS Risk-Based An in-house developed RBI methodology and

Inspection software. It is a balanced approach which
leverage on semi-quantitative analysis as
opposed to highly qualitative analysis or highly
quantitative analysis.
Table 1.1: Specific Definition of Terms

1.2.3 Specific Abbreviations

No Abbreviation Description

1 CDBM Corrosion Design Basis Memorandum

2 CF Certificate of Fitness

3 CMP Corrosion Management Plan

4 CoF Consequence of Failure

5 CSDS Chemical Safety Data Sheet

6 DOSH Department of Occupational Safety and Health

7 EPCC Engineering Procurement Construction and

Commissioning

8 FEL Front End Loading

9 GA General Arrangement

10 HAZID Hazard Identification

11 HAZOP Hazard Operability

12 HMB Heat Material Balance

13 IOWs Integrity Operating Windows

14 IRP Inspection Reference Plan

15 KPI Key Performance Index

16 MC Management Committee
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No Abbreviation Description

17 MDR Manufacturer Document Record

18 MSD Material Selection Diagram

19 NDE Non Destructive Examination

20 NDT Non Destructive Thickness

21 PHA Process Hazard Analysis

22 PoF Probability of Failure

23 PRBI PETRONAS Risk-Based Inspection

24 PSOE PETRONAS Scheme of Examination

25 RBI Risk-Based Inspection

26 RCFA Root Cause Failure Analysis

27 SA Situational Assessment

28 SES Standardized Engineering Solution

29 SHO Safety Health Officer

30 SME Subject Matter Expert

31 SSI Special Scheme of Inspection

32 TML Thickness Measurement Location

33 UFD Utility Flow Diagram

Table 1.2: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This PTS 15.40.01 (December 2016) replaces PTS 15.40.01 (September 2013).
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2.0 REQUIREMENTS

2.1 SPECIAL REQUIREMENT FOR FACILITIES OPERATING IN MALAYSIA

2.1.1 For onshore facilities, it shall be governed by Department of Occupational Safety and Health
(DOSH) Regulations:
i. Factories & Machinery (SSI) (RBI) Regulation 2014 (June 2014) shall be applied for
OPUs that embark on SSI whereby PRBI has been recognized as one of the RBI
methodologies. For standardization of SSI implementation, DOSH requirement
shall be complied
ii. Factories And Machinery (Notification, Certificate of Fitness and Inspection)
Regulations, 1970 shall be applied to a time-based DOSH equipment which
require renewal and extension of certificate of fitness i.e. CF70 at specific interval.
iii. It is a DOSH requirement for OPUs to submit PRBI assessment result during CF70
(Postponement and Extension) and SSI application. These application shall be
submitted through Online PRBI DOSH Module to expedite the DOSH approval
process and support government paperless initiative.

2.1.2 For offshore facilities, it shall be governed through the exemption order, P.U.A 106, Factories
& Machinery (Exemption to Petroliam Nasional Berhad) Order 2013, whereby RBI is
recognised as a tool to manage the Asset Integrity under Offshore Self-Regulation
Management System (OSRMS).

2.2 STAGES OF PRBI IMPLEMENTATION

2.2.1 The PRBI study for PETRONAS Group wide shall be applied for the following scenarios:

i. Project Stage: PRBI study to be conducted at this stage (i.e. Brownfield and
Greenfield) to provide basis for baseline database for equipment and piping
during in-service stage.

ii. Operation Stage: PRBI study to be utilized to optimize the inspection activities
based on updated risk rating and/or as a pre-requisite document for OPUs to
embark on SSI scheme and supporting document for postponement and
extensions of CF70 application.

Figure 2.1: Typical PRBI Roll-out Stages

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3.0 PRBI APPROACH

PRBI is a semi quantitative methodology that uses relative risk as a basis for prioritizing and
managing the inspection programs. It shall focus on inspection activities to specifically address
threats to the integrity of the equipment/piping’s capacity to operate as designed.

The Probability of Failure (PoF) and Consequence of Failure (CoF) are assessed separately and
then combine to determine the risk ranking. Risk ranking is analysed and prioritised for
inspection planning and risk mitigation (if any). The risk mitigation plan may include options
in addition to inspection program such as changes of material of construction, the use of
corrosion inhibitors, changes in operating condition, and/or installation of liners and coatings.

PRBI study shall be reviewed and updated periodically through suitable PRBI reassessment
cycle to ensure the results are reliable and reflecting the relevant operating conditions. The
details of PRBI reassessment is discussed in the section 7.0. The overall PRBI approach can be
depicted as in Figure 3.1.

Figure 3.1: Typical PRBI Approach

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4.0 PRBI TEAM

OPU shall establish PRBI team that consist of competent (i.e. skilled and knowledge) personnel
for the execution of the PRBI implementation which is involved s multidisciplinary activity as
shown in Table 4.1:

No Team Roles and Qualification SSI Regulation

Designation Requirement

1 Team Leader  Possess a minimum Bachelor Degree in Mandatory

Engineering, skilled and knowledgeable
in PRBI methodology and software
 Responsible for readiness and integrity
of the PRBI and/or SSI program including
PRBI database
 Responsible for quality of PRBI Risk
Review and reporting to management
 Accountable to development of IRP

2 Corrosion  Possess Corrosion Engineering Mandatory

Engineer knowledge
 Responsible for RBI Corrosion Study
(review/update based on current
process parameters and inspection
findings)
 Lead/participate in PRBI Risk Review
 Skilled and knowledgeable in PRBI
methodology and software

3 Inspection  Competent in PRBI methodology and Mandatory

Engineer software
 Lead/actively participate in PRBI Risk
Review
 Lead the development of IRP
 Responsible to update equipment status
and inspection status
 Timely review and evaluate equipment
inspection data
 Ensure inspection tools are calibrated
and still valid prior to testing/inspection

4 Operation /  Inform for any significant changes in Mandatory

Process process parameters
Representative  Provide quality input for process
consequences, operation philosophy
and production related.
 Participate in PRBI Risk Review
 Understand PRBI methodology
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No Team Roles and Qualification SSI Regulation

Designation Requirement

5 Safety and  Responsible to maintain or update OSH Mandatory

Health Officer program
NOTE(S): If work place
(SHO)  Provide quality input for HSE related e.g. does not require
environment, reputation registered SHO, a person
 Participate in PRBI Risk Review in charge of OSH (HSE
Representative) shall be
 Understand PRBI methodology appointed

6 Mechanical /  Provide equipment technical Not Mandatory

Maintenance information
Representative  Provide repair history and repair cost (but required as
estimation resource person)
 Participate in PRBI Risk Review
 Understand PRBI methodology
Table 4.1: PRBI Team Structure

Management of OPU shall issue an appointment letter to all respective team members with
specific role and responsibilities. Any changes of team members, new appointment letter shall
be issued and RBI team organization chart shall be updated accordingly.

PRBI methodology and software training shall be provided to all RBI team member to ensure
they are knowledgeable to conduct PRBI study.

Team Leader shall conduct a regular PRBI meeting for at least quarterly with the presence of
all team member to update and discuss on current PRBI implementation. Minute of meeting
shall be prepared after the meeting and kept for future reference.
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5.0 PRBI STUDY IMPLEMENTATION

Adequate dossiers containing essential data shall be made available and maintain to ensure
PRBI assessments are reliable. All assumptions made as an input to the study shall be properly
documented and maintained as per list in the Appendix 1.

All the data used in PRBI shall be up-to-date and reliable. Data entry can be performed by
Inspector with the supervision from Inspection Engineer. However, Team Leader shall ensure
proper validation shall be done on the data to be input into PRBI database by relevant team
members as follows:
i. Inspection data by Inspection Engineer.
ii. Degradation mechanism (if any) by Corrosion Engineer.
iii. Process data by Process/Operation Representative.
iv. Production data by Financial/Business Representative.
v. Repair cost and maintenance data including MOC by Maintenance/Mechanical
Representative.

5.1 CORROSION ASSESSMENT

Corrosion assessment is one of the important steps in PRBI implementation whereby all active
and credible damage mechanism shall be identified based on latest information regarding
process parameter and material used for the equipment/piping. The corrosion assessment
activities shall be led by the qualified Corrosion Engineer with the participation from RBI team
members which at least consist of Team Leader, Inspection Engineer and Process/Operation
Representative. The assessment consist of the following activities:

5.1.1 Corrosion Group Development

A Corrosion Group (CG) is defined as an assembly of static equipment and its interconnected
piping operated within similar operating parameters, having similar process stream, damage
mechanism and material of construction.

The CG shall be identified and marked-up on latest PFD and UFD. The development of CG for
in-service plant or facilities shall consider information obtained from inspection and/or repair
history and actual condition at site.

Any changes on current CG, it shall be reviewed at least by Corrosion Engineer, Inspection
Engineer and Process/Operation Representative prior to approval by Team Leader for
implementation. The changes shall be recorded for future reference.

5.1.2 Piping Circuits Development

The CG will be broken down further to smaller manageable segments of continuous piping
exposed to similar damage mechanism which are termed as Piping Circuit. A representative
line shall be selected for each piping circuit based on team member’s agreed criteria prior to
PRBI analysis. The piping circuit shall be identified and marked-up on latest P&ID.
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Any changes on current piping circuit, it shall be reviewed at least by Corrosion Engineer and
Inspection Engineer prior to approval by Team Leader for implementation. The changes shall
be recorded for future reference.

5.1.3 Corrosion Study

A Corrosion Study is a process of assigning the damage mechanism to the equipment’s

component under respective CG. The identified damage mechanism for each CG will be
categorised according to PRBI damage modes as follows;
i. Thinning
ii. Environmental Cracking
iii. Other Damage Mechanism

Corrosion Engineer shall ensure each equipment’s component has been assigned with correct
damage mechanism with verification from latest inspection findings and operation parameter
trending.

Any deletion or addition from current identified damage mechanism, it shall be reviewed at
least by Corrosion Engineer, Inspection Engineer and Process/Operation Representative prior
to approval by Team Leader for implementation. The changes shall be recorded for future
reference.

5.1.4 Corrosion Rate

In PRBI, Corrosion Rate (CR) can be obtained from the following sources:
i. Expected CR as per Subject Matter Expert (SME) advise, corrosion prediction
model or based reference standard e.g. API RP 581
ii. Measured CR is consists of Long Term CR or Short Term CR which calculated
based on thickness measurement trending records. Inspection Engineer shall
ensure all the thickness measurement has been carried out based on established
procedure.
iii. Monitored CR obtained from NDE, coupon and probe reading for specific
monitoring location
iv. Calculated CR for Corrosion Under Insulation (CUI) using PRBI calculator

From the above available CR information, Corrosion Engineer shall determine the most
appropriate corrosion rate to represent the anticipated damage mechanism to be used for
precise PRBI analysis.
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In the event of “Measured CR” and “Expected CR” are available, Corrosion Engineer may refer
the below approach to determine final CR:

Figure 5.1: Approach to Determine Final CR

Based on the Figure 3, the determination of CR are as follows:

i. If the measured CR is not available, the expected CR shall be applied. Corrosion
Engineer shall determine the CR based on reliable information or sources.
ii. If the measured CR value is higher/lower than the expected CR but the
inspection carried out had a high confidence factor as defined in Inspection
Confidence Criteria then the measured CR value shall be applied.
iii. If the measured CR value is higher/lower than expected CR but the inspection
carried out had a low confidence factor as defined in Inspection Confidence
Criteria then, site verification shall be conducted based on established
procedure to ensure the credibility of the measured thickness data.

Any deviation from the above mentioned approaches, Corrosion Engineer shall consult and
obtain approval from Team Leader. The deviation shall be recorded for future reference.
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5.2 RISK ANALYSIS

Risk is a product of the probability of failure (PoF) and the consequence of failure (CoF) and
defined by the below expression:
Risk = Probability of Failure x Consequence of Failure

As a result of PRBI analysis, each equipment component and piping circuit is classified into
one of the risk rating categories; High, Medium, Low and Very Low.

The results of the PRBI analysis are presented by 6x5 risk matrix with the PoF categories of A
to E and the CoF categories of 0 to 5. The lowest risk category will be 0-A, and the highest risk
category will be 5-E. The PRBI risk matrix is shown in Figure 5.2.

Figure 5.2: PRBI Risk Matrix

5.2.1 Validation Process before Risk Analysis

PRBI analysis is performed using PRBI web-based software. Team Leader shall ensure the
following tasks to be completed prior to PRBI risk analysis:
i. Verification of equipment/piping data
ii. Finalization of corrosion study and assignment of corrosion group to the
components of the equipment/piping circuit as well as ensure the right damage
mechanism and CR have been assigned
iii. Finalization of economic data
iv. Assignment of inspection confidence, if any
v. Updating of latest inspection data into the inspection database

5.2.2 Risk Result Review

Prior to risk finalizing, PRBI team members shall review with the risk results to ensure the
credibility and accuracy of the result. If there is any dispute on the risk result, all the tasks as
described in para 5.2.1 shall be re-verified.
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During this stage, the CoF rating for Environment and Reputation shall be assigned and
finalised in the PRBI software by Inspection Engineer/Corrosion Engineer with input from
SHO/HSE Representative.

5.2.3 Final Risk Result

Risk result only can be saved as final in the PRBI system after PRBI team members have
reviewed and agreed on the risk rating. Team Leader shall approve the final risk result for
future reference.

Any dispute on the final risk result, team member to re-verify all tasks as described in para
5.2.1. Team Leader to approve the changes (if any) and to update management on the final
risk results.

5.3 INSPECTION EVALUATION

Inspection evaluation is important process in PRBI analysis. It is crucial to ensure all the
inspection data input into PRBI software shall be verified and evaluated by Inspection
Engineer. The following are the activities for inspection evaluation in PRBI software:

5.3.1 Inspection Locations and Thickness Evaluation

Each inspection location shall be properly specified and marked on the relevant drawing e.g.
isometric drawing, GA drawing etc. based on established Thickness Measurement Location
(TML) Procedure. For in-service equipment and piping, the TML shall be based on credible
location identified during internal visual inspection or failure history record. Inspection
Engineer shall ensure the following has been verified:
i. all the active TMLs being registered in PRBI database
ii. all TMLs ID in PRBI database are similar with TML ID at site and drawing
iii. all “inactive” TMLs status in PRBI shall be justified e.g. due to insignificant CR,
inaccessible location etc. and to notify Team Leader
iv. Tmin calculation used is correct for respective TMLs

Corrosion Engineer shall evaluate thickness reading trending based on verified thickness data
recorded in PRBI database and decide on final CR to be used for PoF analysis of equipment/
piping circuit components. Any abnormality of CR i.e. growing of thickness or significant metal
loss detected, Corrosion Engineer shall inform Team Leader for his/her decision for any further
verification or assessment.

5.3.2 Inspection Records

Inspection Engineer shall ensure all inspection report for dedicated equipment/piping circuit
be recorded to the respective NDT method in PRBI database. After all inspection report have
been recorded, Inspection Engineer shall determine the inspection confidence rating in PRBI
software based on the following information:
i. Type of damage mechanism
ii. Inspection method
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iii. Inspection coverage

iv. Representative inspection location (if any)

Inspection confidence rating may be assigned based on PRBI Inspection Confidence Criteria or
using API RP 581 as guidance.

The final inspection confidence shall also consider other factors that contribute to the
accuracy of the result such as NDT operator competency, compliance to procedure and report
quality.

Any significant inspection findings, Inspection Engineer to notify Corrosion Engineer for
further evaluation.

5.3.3 Inspection Reference Plan

Inspection Reference Plan (IRP) is the final product of PRBI analysis. IRP shall be developed for
each equipment/piping circuit based on the PRBI risk analysis results. For each degradation
mechanism, the PRBI software will recommend the inspection method(s), extent and
frequency of inspection based on the Inspection Priority for respective equipment/piping
circuit.

Inspection Engineer and Corrosion Engineer (if required) shall review the recommended
inspection plan and may accept or modify the IRP as necessary. The Inspection Engineer shall
also review the recommended inspection interval to comply with statutory requirements and
company business strategy. Team Leader shall approve of the final IRP and accountable for its
execution. Any deviation from approved IRP, Inspection Engineer shall obtain approval from
Team Leader and all deviation/changes shall be recorded.

5.3.4 PETRONAS Scheme of Examination

PETRONAS Scheme of Examination (PSOE) is a documented summary of comprehensive

inspection activities describing types of examination or inspection and tests techniques that
need to be carried out on specific equipment. This document gives information on current
condition and susceptible damage mechanism that can affect integrity of the equipment. The
PSOE can be considered as a reference as well as checklist for inspection personnel when
evaluating condition and assessing integrity of the equipment.

It is recommended that PSOE shall be developed based on latest risk and IRP. SME shall be
consulted for the development of PSOE as it require involvement from multi discipline e.g.
maintenance, mechanical, turnaround team etc.
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6.0 PRBI MONITORING

6.1.1 For identified non-age related degradation mechanisms, Corrosion Engineer shall monitor the
critical parameters such as moisture content, chloride content, temperature and etc.,
accordingly. Monitoring of other critical parameters is also applicable to age-related
degradation mechanism (e.g. pH of acid corrosion, temperature for creep) in addition to the
thickness measurement.

6.1.2 Any deviation from Integrity Operating Windows (IOWs) value, Corrosion Engineer shall
evaluate the effect to the current identified damage mechanisms and to be recorded in PRBI
database (Corrosion Study). Corrosion Engineer shall inform PRBI team members on the
deviation for further discussion or decision.

6.1.3 For corrosion control, monitoring and testing purposes, the risk of degradation mechanism
analysed in PRBI may be used as an input for development of Corrosion Management Plan
(CMP) as part of risk mitigation plan. Any changes in CMP, Corrosion Engineer shall update the
information in PRBI database (Corrosion Study) to ensure its consistency and updated
information.

6.1.4 PRBI team members shall analyse all risk rating for equipment and piping to determine its
driven factors. Priority monitoring and inspection shall be given to the High risk rating that
driven by high PoF. Team Leader shall decide a suitable risk mitigation plan, if necessary.
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7.0 PRBI REVIEW

PRBI is a dynamic tool that can provide current and projected future risk assessment based on
data and knowledge during the assessment. PRBI assessment results shall be updated in the
system based on latest review findings (if any). The review process includes the following but
not limited to:

7.1 PRBI REASSESSMENT

7.1.1 PRBI Reassessment is an important review process to ensure recent inspection, process, and
maintenance information are incorporated and analysed which may have significant effects
on risks and subsequently, inspection plan. There are several events that might change the
risk rating whereby the PRBI Reassessment shall be conducted as below:
i. After significant changes in process parameter
ii. After a set of period; although significant changes may not have occurred, over
time many small changes may occur and cumulatively cause significant changes
in the RBI assessment. Users should set default maximum time periods for
reassessments.
iii. Upon completion of any inspection activities where inspection data and
verification has been performed.
iv. Major modifications have been made or new equipment is being introduced

7.1.2 PRBI Reassessment shall be conducted at specified interval of not more than 3 years by RBI
team members.

7.2 PERIODIC REVIEW

PRBI Situational Assessment (SA) shall be conducted once to provide a baseline assessment
from an independent third party review to assess the adequacy and comprehensiveness of
PRBI program. PRBI SA shall be followed by Periodic Peer Review to assess the effectiveness
and sustainability of PRBI program at interval frequency of 3-5 years. The results from this
review can be used to benchmark PRBI programs amongst the OPUs to ensure consistency,
effectiveness and sustainability across the PETRONAS Group wide as well as to ensure
compliance with local and national authority.
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8.0 PRBI MANAGEMENT REVIEW

8.1.1 The Plant Manager/Plant Head shall responsible for PRBI management review which to be
conducted yearly. The Plant Management Committee or designated committee, as
representatives of the Plant Manager/Plant Head, shall review the effectiveness of PRBI
implementation of their facilities for the past 1 year.

8.1.2 The PRBI management review shall discuss, but not limited to:
i. Sharing of PRBI risk results and the effect to the asset integrity
ii. Adequacy of resources (i.e. financial, staff, etc.) to sustain PRBI implementation
iii. SSI Audit Readiness and Compliance (applicable for OPU that embark on SSI)
iv. RBI team member competency and qualification
v. PRBI identified gaps and gap closure plans
vi. PRBI IRP and monitoring implementation status and effectiveness
vii. Changes in legislation requirement, if any
viii. Opportunities for risk reduction and mitigation
ix. Related MOC which will effect on PRBI assessment, etc.

8.1.3 During the review, the Management shall set suitable Key Performance Indicators (KPI) for all
RBI team members and its related department to ensure the effectiveness of PRBI
implementation.

8.1.4 Minutes of the meeting shall be taken and proposed actions shall be assigned to individuals
for implementation and tracking purposes.
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9.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each Standards/Publications shall be used, together
with any supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS

Index to PTS PTS 00.01.01
PTS Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide

MALAYSIAN REGULATIONS & ACTS

The Factories and Machinery Act 1967 Act 139
The Factories and Machinery (Notification, Certificate of 1970
Fitness and Inspection) Regulation

INTERNATIONAL STANDARDS
Risk-Based Inspection Technology API RP 581: April
2016
 PTS 15.40.01
PETRONAS RISK-BASED INSPECTION (PRBI) December 2016
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APPENDIX 1: REQUIRED DATA/INFORMATION FOR PRBI STUDY

The following are the minimum essential data/information required for the PRBI assessment:

No Required Data Details

(a) Design basis memorandum (DBM), if any

(b) P&IDs, PFDs & MDRs

(c) HMB & MSD, if any

(d) Piping list, specifications & isometric drawings

(e) Engineering specification sheets

(f) Materials of construction records

(g) Construction QA/QC records

Design and
(h) Codes and standards used
1 Construction
Records/Drawings (i) Leak detection and monitoring systems, if any

(j) Operating Philosophy

(k) Layout

(l) Equipment technical information e.g. As-built drawing (GA

and Isometric), mechanical datasheet, stress calculation
sheet etc.

(m) Cathodic Protection, coating, linings and insulation

specifications

(n) Materials and Corrosion Philosophy, if any

(a) Design/Operating parameters e.g. pressure, temperature,

flow rates. To include upset conditions parameter, if any

(b) Fluid composition analysis including contaminants, if any

(applicable for in-service equipment/piping only)

(c) Operating history e.g. operating parameters trending,

2 Process Data
boiler tube skin temperature (applicable for in-service
equipment/piping only)

(d) Start-up and shut-down procedures, operating procedures

(e) Process safety reports e.g. Process Hazards Analysis

(PHA), HAZOP, HAZID.
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PETRONAS RISK-BASED INSPECTION (PRBI) December 2016
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No Required Data Details

(f) Materials Safety Data Sheet (MSDS)/Chemical Safety Data

Sheet (CSDS)

(a) Inspection history records

(b) Repairs, replacement, re-rating and alterations reports, if

Inspection any
Records
(c) Bad actors records (record of equipment exhibiting
(applicable for in-
3 repetitive failure)
service
equipment/piping
(d) Fitness for service reports, if any
only)
(e) Corrosion monitoring records

(f) Root cause failure analysis (RCFA) reports, if any

Management of
Change (MOC)
(a) Process changes
records
4 (applicable for in-
(b) Equipment modifications/ change of material of
service
construction
equipment/piping
only)

(a) Equipment/piping production loss impact (percentage)

5 Economic impact (b) Latest product prices

(c) Equipment/piping repair cost

Table A1: Required Data/Information for PRBI Study