The Keys to Success in Maintaining Pressure Equipment Integrity and Reliability

Owner-User Panel Discussion

John Reynolds - Moderator Principal Consultant Pro-Inspect, Inc. A Moody International Co.

The Keys to Success in Maintaining Pressure Equipment Integrity and Reliability Owner-User Panelists 240+ years PEI experience
Mike Urzendowski 26+ years experience with leading PEI
programs most recently with DNV, Shell and now Technology Director for Metallurgy with Valero Energy in San Antonio. Mike is co-chair of the API T/G on IOWs Joey Poret 15+ years experience with leading PEI/NDE programs; now with Chevron Corporation as Fixed Equipment Inspection & Reliability Supervisor in the Gas Project in Nanba, China, and Co-chair of the API Inspection Summit Dave Wang 20+ years with leading PEI programs in the Shell Companies, as a PEI & NDE engineer; currently is a Principal Inspection and Asset Integrity Engineer located at the Shell Westhollow Technology Center in Houston. Dave is the on API SCI and Chair of API T/G on Inspection Codes and RPs and the NDE Technology T/G Joe Krynicki 19+ years experience and leading PEI/NDE programs; now an Advanced Engineering Associate with ExxonMobil Research and Engineering in Fairfax, VA. Joe is the XOM representative for the API SCI and Vice Chair of the NDE Technology T/G

The Keys to Success in Maintaining Pressure Equipment Integrity and Reliability Owner-User Panelists 240+ years PEI experience

Steve Bolinger 28+ years with several companies

contributing to and leading PEI programs most recently with Shell and now with the BP Texas City Refinery as Asset Integrity Manager and Engineering Authority. Clay White 27+ years experience with leading PEI/RBI programs; previously with Equity Engineering and now the Corporate Fixed Equipment Network Leader with ConocoPhillips in Houston. Clay is the COP representative and Vice Chair on the API SCI & Chair IOW T/G Mark Geisenhoff 31+ years experience with leading PEI programs; now the Global Fixed Equipment Leader with Flint Hills Resources in St. Paul. Mark is the FHR representative on the API SCI and Chair of API 510 T/G on the pending 10th edition Art Jensen 31+ years experience in fixed equipment integrity and reliability programs in Sunoco; now the Corporate Mechanical Reliability Specialist with Sunoco in Philadelphia

The Keys to Success in Maintaining Pressure Equipment Integrity and Reliability

What are the keys to success?

Its not about the 75+ metallurgical and corrosion degradation mechanisms in our industry. Those are just the final physical causes of failures; you can learn about them by studying for the API ICP Exam on API 571. They are not the root cause of most pressure equipment failures. The root causes of 95%+ of pressure equipment failures are embodied in lack of effective employment of adequate preventive Pressure Equipment Integrity Management Systems (PEI MSs). The best operating sites have all 10 of the required PEI MSs in place and functioning effectively to prevent the physical causes of failures from occurring. Its the key elements of those 10 PEI Management Systems that we are going to talk about this morning.

What is a Pressure Equipment Integrity Management System (PEI MS)?

Its simply a compendium of all the necessary information that is required in order to maintain pressure equipment reliability and integrity at each operating site. Each PEI management system and subsystem describes in detail how the operating site is going to manage every important PEI issue: what must be done, why it needs to done, how it is to be done, what triggers the need for it, how often it needs to be done, when it needs to be done who is responsible for it, and everything else you need to know about it.

The Keys to Success in Maintaining Pressure Equipment Integrity and Reliability

What are the top 10 PEI MSs?

Management Leadership and Support for PEI Integrity Operating Windows (IOW) Management of Change (MOC) Deterioration Management and Control Risk Assessment and Inspection Planning Life Cycle Management (LCM) PEI Codes and Standards (C&S) Site Procedures and Work Processes for PEI PEI Record Keeping and Data Management Continuous Improvement for PEI

Each of these top 10 PEI MSs is then subdivided into multiple subsystems to fully define the content of each PEI management system

Anything Missing?

Management Leadership and Support

Integrity Operating Windows

Continuous Improvement

Record Keeping and Data Management

Excellence in PEI

Management of Change

Deterioration Management and Control

Site Procedures and Work Processes

Codes , Standards and Regulations

Life Cycle Management

Risk Assessment and Inspection Planning

The Keys to Success in Maintaining Pressure Equipment Integrity and Reliability

PEI Excellence the bulls eye! What does it mean?

It means achieving Pressure Equipment Integrity & Reliability

Ideally with all the effective PEI MSs in place, each site should be able to maintain pressure equipment integrity (i.e. no breaches of containment) and to achieve pressure equipment reliability (i.e. having pressure equipment available to function as designed to meet the business plan) PEI excellence does not mean over-blown, expensive systems or Cadilacing; it simply means doing all the right things at the right time to maintain pressure equipment integrity and reliability Vince Lombardi, one of the most famous football coaches in the history of the NFL, once said Perfection is not attainable, but if you chase perfection, you will catch excellence That is certainly true when it comes to maintaining pressure equipment integrity and reliability of our process plants

The Keys to Success in Maintaining Pressure Equipment Integrity and Reliability

Organizing for Success in PEI

These 10 PEI MSs are the back bone of all PEI organizations

Knowing what needs to be accomplished in order to achieve excellence in pressure equipment integrity is one thing; but knowing how to organize it all into effective management systems to achieve continual success is quite another The structure of the human organization chart can vary widely from site to site, and any one of those various organizations can succeed IF all the right PEI MSs are in place and being effectively implemented We will not be talking today about organizing the human hierarchy for success in PEI; but rather organizing around the 10 most important PEI MSs; and we will provide some examples of what happens when they are not in place or not functioning well

The Keys to Success in Maintaining Pressure Equipment Integrity and Reliability

Creating and Implementing PEI MSs

The top 10 PEI MSs are only what you see from the 10,000 foot level Down in the trenches, each of those top 10 PEI MSs includes 101 detailed subsystems, procedures, work practices and site standards that must be effectively implemented day after day in order to achieve success And it almost goes without saying that creating these PEI MSs is just half the process If they are not followed up with very effective implementation and continuous improvement, then the best written words of the PEI MSs will not likely achieve excellence in PEI

Anything Missing?

Management Leadership and Support

Integrity Operating Windows

Continuous Improvement

Record Keeping and Data Management

Excellence in PEI

Management of Change

Deterioration Management and Control

Site Procedures and Work Processes

Codes , Standards and Regulations

Life Cycle Management

Risk Assessment and Inspection Planning

PEI PEI Management Management System System Reviews Reviews

PEI PEI Resources Resources

PEI PEI Staffing and Staffing and Contracting Contracting

OEMI OEMI Teams Teams

Shared Shared Stewardship Stewardship of of Assets Assets

Management Management Leadership Leadership and and Support Support for for PEI PEI

PEI PEI Training and Training and Certification Certification

PEI PEI Competency Competency Improvement Improvement

PEI PEI Knowledge Knowledge Transfer

Gray Zone Equipment MS Roles Responsibilities Accountabilities

Walking the Talk

Integration with Other PEI MS

Degradation Assessment and IOW Creation

Establishing Upper and Lower Limits

Laboratory Sampling

Process Monitoring

Integrity Operating Windows

Standard or Critical Classification

Establishing Corrective Actions

Updating IOWs
Field Implementation Risk Analysis of Recommended Actions

Establishing Action Timing

Integration with Other PEI MS

PEI Involvement in the MOC Trigger Process

PEI Involvement in the MOC Assessment

Temporary Repairs

Temporary Installations

PEI Management of Change

Involvement of the Right PEI Knowledge Resources

Assessment of Physical Changes

Implementation of Inspection Changes

Updating Inspection Plan

Approval of MOC

Assessment of Process Changes

Corrosion and Process Monitoring Systems Cathodic Protection Systems

Proactive Corrosion Control

Deterioration Control Manuals

Corrosion Control Industry Standards

Corrosion Management and Control

Deterioration Mitigation Strategies

Coatings And Linings

Input to Inspection and Maintenance Plans

Materials Selection

External and CUI Corrosion Control

Water and Chemical Treatment

Integration with other PEI MS

Identification of Degradation Mechanisms

Risk Based Inspection Planning and Scheduling

Risk Analysis for Inspection Deferrals

Field Surveillance

Risk Assessment and Inspection Planning

Risk Based Decision Making for PEI Options

Risk Based Decision Making for Turnaround Planning

Risk Assessment for HX Bundles

Special Emphasis Inspections

Execution of Inspection Plan

Non-Invasive vs. Invasive Inspections

Integration With Other PEI MSs

Design and Materials Selection for PEI

Qualified Suppliers and Fabricators

PEI for Idle and Retired Equipment

Preventive Maintenance

Life Cycle Management for PEI

Fabrication & Construction QA/QC

Fitness for Service Assessments

Materials Receiving PMI &QC

Maintenance QA/QC

Temporary or Permanent Repairs

Repairs and Replacements

Integration with All other PEI MS

New Construction

In-Service

OTHERS?

ASME PTB-22009

Codes, Standards And Regulations

API CRE SCI

ASME PCC
Staying Connected with PEI Regulators

State and Local Regulations

OSHA Regulations

Other SDOs

Integration with All Other PEI MS

Company Standards

Company and Site Best Practices

PMI and Materials Receiving

Turnaround Planning Process

Site Procedures and Work Practices

Site Inspection Procedures

Site Management Systems

PEI Contracting Process

NDE Procedures

Welding, Bolting and Gasketing Procedures

Site Work Practices

Integration with All Other PEI MS

Original Construction Records

Baseline Data Records

Records Retention Requirements

PEI Reports

PEI Records and Analysis

Progressive Inspection Records

Electronic and Paper

Inspection and Repair Recommendation Tracking Calculations of Remaining Life Data Analysis Deterioration Rate Calculations

Integration with All Other PEI MS

Leak and Failure Reporting and Tracking

Company Failure Memory System

PEI Metrics and Goal Setting

PEI MS Auditing

PEI Continuous Improvement

Incident and Near-miss Investigations

Failure Analysis

PEI Networking
Learning from Incidents Solution Development

Corrective Actions

The Keys to Success in Maintaining Pressure Equipment Integrity and Reliability The Keys to Success in Maintaining Pressure Equipment Integrity and Reliability Would you like to learn more about the top 10 PEI Management Systems?
In our limited amount of time this morning, we can only cover a

few of the highlights of the top 10 PEI Management Systems It would take a week to even begin to go into any depth for each of the important issues within each of the top 10 PEI MSs

For more information, check out the series of 10 articles currently running in the Inspectioneering Journal (IJ), as well as the overview paper on the subject published with the proceedings of this conference - API Inspection Summit.
The first six articles in the series have already been published in the IJ with four more to follow in 2011. Some sample copies of the IJ available during the break