Fitness for service and risk-based inspection for line piping leakage of hydrocarbon release at offshore northwest java topside facility

Abstract

Hydrocarbon leaks from offshore facilities can pose serious risks to workers, the environment, equipment, and operations. This study evaluated the safety and reliability of a repeatedly leaking three-phase piping system and assessed whether it could continue operating safely over the next 20 years. Fitness-for-Service (FFS) assessment based on API 579-1/ASME FFS-1 and Risk-Based Inspection (RBI) following API 581 were applied to evaluate the piping condition, risk level, remaining service life, and inspection requirements. Field observations and investigations were performed to evaluate piping conditions, while RBI and Estimated Life (EL) calculations were used to assess risk, remaining service life, and future piping conditions. Level 1 and Level 2 FFS assessments indicated that neither piping system could be considered fit for operation over the next 20 years, requiring a more detailed Level 3 assessment. Initially, both piping systems were classified in the yellow risk zone, but the risk was predicted to increase to the orange zone after 72 months. Therefore, The piping systems require further integrity assessment and risk mitigation to support safe long-term operation. Timely inspection, maintenance, repair, or replacement should be implemented to control increasing risk and ensure safe and reliable offshore operations.