Henry - Philip Asset Integrity Management Overview PDF

Life-Cycle Management of Pressurized Fixed Equipment
Tuesday 6 March 2012 API Singapore 2012 Singapore Marina Bay Sands Resort
Philip A. Henry, P.E. RBI Technical Advisor and Principal Engineer The Equity Engineering Group, Inc. Shaker Heights, OH USA
Asset Integrity Management Overview
Presentation Overview
Introduction Life-Cycle Management (LCM) Regulatory Viewpoints Refining & Petrochemical Industry Goals Owner-User Goals Cooperative Achievement of Goals The Life-Cycle Management Process LCM Case Study Benefits of the LCM Process Conclusions
Introduction Life-Cycle Management

Many process plants continue to operate pressurized equipment well beyond its intended design life Owner-users of pressurized fixed equipment, including pressure vessels, piping, and tankage, are becoming increasingly interested in Life-Cycle Management (LCM) of equipment to enhance reliability and availability LCM is the process of managing the entire life-cycle of fixed pressurized equipment from initial design, through construction and in-service use, and to retirement Questions
How do you get a LCM process started? How do you incorporate codes and standards that are not developed by ASME or API? Is there a process that can be used as a model?
Regulatory Viewpoints
A US Regulators View
Safety and production are inextricably linked.good safety performance makes good business sense.stable production means reduced risks.if integrity management is sacrificed for production, production will eventually suffer and lives may be lost. Actively manage your operations to achieve safety and environmental objectives.participate in standards development.conduct research and develop technology.share important safety information.
UK Health and Safety Commission

asset integrity will continue to be one of the main priorities .. it is for the industry itself to show leadership and face up to its responsibility.
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Refining & Petrochemical Industry Goals

Public and workforce safety; good safety performance is a key element of good business practice Global acceptance of industry codes and standards
Ensure safety and reduce losses through the sharing of technology and best practices that are promoted to a code or standard status Maximize efficiency through standardization; promoting the use of industry standards wherever possible to replace in-house corporate standards Regulatory Acceptance
Owner-User Goals
Industry and Owner-User goals are in alignment Additionally, want to achieve Optimized LCM costs, a balance between construction and in-service maintenance costs
Cooperative Achievement of Goals

The proposal:
A LCM process can be instituted that promotes public and workforce safety and utilizes international industry codes and standards while permitting optimization of life-cycle costs for fixed pressurized equipment
The proposed LCM process

Utilizes existing codes, standards and recommended practices; international documents may be substituted based on regulatory requirements Emphasizes proper use of these codes, standards, and recommended practices through industry committee participation and/or training Risk management techniques may be used
The Life-Cycle Management Process

Life-Cycle Management (LCM) for Pressurized Fixed Equipment: Key Elements
Damage Mechanism Identification Construction Codes & Standards In-Service Inspection Codes FFS Standard Post Construction & Repair Guidelines
Continue Service Anticipated Damage Specify Design Conditions and Identify Damage Mechanisms (API 571 & WRC 489) Select Materials of Construction
Construction Code ASME VIII-1, VIII-2, VIII-3, B31.3 API 530, 620, 650
Commissioning (Baseline Inspection)
In-Service Inspection (Establish Inspection Interval) Prescriptive (API 510/570/653,NBIC) Risk-Based (API 580/581,PCC3)
Inspection Results Unanticipated Damage
Important Aspects
Standards development including input from industry experts, owner-users and group sponsored JIPs Proper use of standards to address safety & reliability User training
Identify Damage Mechanisms (API 571, WRC 488, WRC 489, WRC 490)
Fitness-For-Service API 579/ASME FFS-1
Run/Rerate
Repair
Replace
ASME PCC2
Technology Integration

Calibration to Industry Segments
The LCM process shown on the previous slide is calibrated to the down-stream segment in refining and petrochemical in North America
Calibration of the LCM Process starts with Damage Mechanism Identification; API 571 and WRC 489 were specifically written to address damage mechanisms affecting fixed equipment in the refining industry ASME Construction codes are used in the down-stream segment for pressure vessels and piping and API Design and Construction codes are used for tankage and fired heater tubes In-service inspection standards are API and NBIC Fitness-For-Service (FFS) is API/ASME Post Construction & Repair Guidelines are ASME Note that the calibration also includes location, i.e. North America, to address regulatory requirements
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Damage Mechanism Identification
Damage mechanisms identification is an important part of the Life-Cycle Management Process

Required during the design phase, influences materials selection Required for inspection planning Required for FFS if un-anticipated damage occurs (i.e. damage found during inspection was not accounted for in design phase)
Understanding of damage mechanisms is also important for developing models with associated material properties for life assessment determination These models form the basis of FFS and RBI, but can also be used in construction codes with an appropriate design margin
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Damage Mechanism Identification
Documents covering damage mechanism identification

WRC Bulletin 488 Damage Mechanisms Affecting Fixed Equipment in The Pulp And Paper Industry WRC Bulletin 489 & API 571 Damage Mechanisms Affecting Fixed Equipment in The Refining Industry WRC Bulletin 490 Damage Mechanisms Affecting Fixed Equipment in Fossil Electric Power Industry ASME PCC-3 Inspection Planning Using Risk-Based Methods (Appendices B & C)
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Construction Codes & Standards
API Codes, Standards and Recommended Practices

API produced codes, standards, recommended practices, and technical publications cover all segment of the industry
Upstream Mid-stream Downstream Pipelines
Benefits
Promote the use of safe, interchangeable equipment and operations Reduce regulatory compliance costs through standardization Form the basis of API certification programs in conjunction with APIs Quality Program
The API standards program is global, through active involvement with the International Organization for Standardization (ISO) and other international bodies
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API Design & Construction Standards

API Std 530/ISO 13704 Calculation of Heater-Tube Thickness in Petroleum Refineries API Std 620 Design and Construction of Large, Welded, Low-Pressure Storage Tanks API Std 650 Welded Tanks for Oil Storage
Note the co-branding on API Std 530 with ISO
13

ASME Codes and Standards

ASME codes and standards are primarily used for construction of new equipment, some of the rules in these codes are referenced by the API in-service inspection codes ASME codes and standards are also provided for
Guidelines for assembly of bolted flange joints Repair of pressure equipment and piping Risk-Based Inspection, harmonized with API Standard 580/581
ASME has also produced a guideline document to provide a summary of the codes, standards and regulations that are used to assist manufacturers, users, regulators and other stakeholders in maintaining the integrity of fixed pressure equipment in general industrial use
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ASME Codes and Standards

Pressure Vessels
ASME B&PV Code, Section VIII Division 1 Rules for Construction of Pressure Vessels ASME B&PV Code, Section VIII - Division 2 Rules for Construction of Pressure Vessels Alternative Rules ASME B&PV Code Section VIII Division 3 Rules for Construction of Pressure Vessels Alternative Rules for Construction of High Pressure Vessels (VIII-3)
Piping
ASME B31.1 Power Piping ASME B31.3 Process Piping
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In-Service Inspection Codes
In-Service Inspection Codes

API 510 Pressure Vessel Inspection Code: Maintenance Inspection, Rerating, Repair and Alteration API 570 Piping Inspection Code: Inspection, Repair Alteration and Rerating of In-Service Piping Systems API 653 Tank Inspection, Repair, Alteration, and Reconstruction NB-23 National Board Inspection Code
Inspection codes listed above use half-life inspection interval; also permit use of Risk-Based Inspection (RBI) planning as provided in:
API RP 580 Risk-Based Inspection, 2nd Edition, 2009 API RP 581 Risk-Based Inspection Technology, 2nd Edition, 2008 ASME PCC-3 Inspection Planning Using Risk-Based Methods
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Other Inspection Resources
Other Inspection Resources

API RP 572 Inspection Practices for Pressure Vessels API RP 574 Inspection Practices for Piping Components API RP 576 Inspection of Pressure Relieving Devices
Development of the following new references is under way:

API RP 583 Corrosion Under Insulation API RP 584 Integrity Operating Windows API RP 585 Pressure Equipment Investigation API RP 681 Risk-Based Inspection of Rotating Equipment
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FFS Standard
ASME and API jointly produce a co-branded Fitness-ForService document, API 579-1/ASME FFS-1 2007 FitnessFor-Service
Incorporates planned technical enhancements to the 2000 Edition of API 579 Organized into 13 Parts that address various damage mechanisms; 11 Annexes provide additional information and guidance on conducting stress analysis for FFS Provides three assessment levels of increasing complexity; Level 3 permits use of alternate FFS procedures such as BS 7910 and FITNET Includes modifications to address the needs of fossil electric power, and the pulp and paper industries
May be applied to pressure containing equipment constructed to international recognized standards

18

Post Construction Standards & Repair Guidelines
ASME Post Construction Publications

ASME PCC-1 Guidelines for Pressure Boundary Bolted Flange Joint Assembly ASME PCC-2 Standard for the Repair of Pressure Equipment and Piping ASME PCC-3 Inspection Planning Using Risk-Based Methods ASME PTB-3 Guide to Life-Cycle Management of Pressure Equipment Integrity
Provides a roadmap to identify the codes, standards, and other documents that apply to the LCM of pressure equipment integrity Does not address pressure equipment in; Oil and gas exploration and production, LNG, and LPG transport and storage, Pipeline and transport service, Nuclear industry Mainly references ASME & API Codes and Standards
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Important Aspects
The LCM process is dependent on the existence of effective industry codes, standards, and recommended practices that is dependent on input from
Owner-Users Industry Experts Regulatory Bodies Group Sponsored Joint Industry Project (JIPs)
Note that Owner-User input is critical for the successful development of industry codes and standards; this is recognized by standards writing bodies and most have active recruitment and indoctrination programs in place Input from regulatory bodies provides the safety expectations for both the public and workforce employees
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A key aspect of the successful implementation of LCM process is consistency in the technology used for design and in-service codes and standards Consistency in the technology avoids ambiguities that typically arise when rules for construction are used for in-service inspection, FFS, and repair Standards writing organizations need to develop consistency in approach not only in development of construction codes, but also in the development of inservice codes such as FFS and inspection standards
ASME launching common rules effort; rules in codes will be published once and appropriately referenced Benefit to end-users, simplifies training and easier to use Owner-Users need to be involved!
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Best Practices
The LCM Process described thus far relies on industry codes and standards What about Best Practices instituted by corporations that do not reside in industry codes, standards or recommended practices? Definition:
For purposes of the LCM process, a Best Practice is a technique or methodology that upon rigorous evaluation through experience and research, demonstrates success, has had an impact, and can be replicated
Many corporations document their Best Practices in internal engineering standards; these internal standards address both construction and in-service equipment issues such as inspection, FFS, and repair guidelines.
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Best Practices
In the proposed LifeCycle Management (LCM) for pressurized fixed equipment, a best practice is an overlay in the process based on the corporate knowledge Best Practices in pressurized fixedequipment technology are becoming more difficult to cultivate because of lack of expertise; owner-users must rely on industry forums and/or codes, standards and recommended practices
Specify Design Conditions and Identify Damage Mechanisms (API 571 & WRC 489) Select Materials of Construction
Continue Service Anticipated Damage
Run/Rerate
Repair
Replace
ASME PCC2
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Best Practice
Analysis of Tubesheet Corrosion TEMA Class R Shell & Tube Heat Exchanger Hydrocarbon Service Shellside Design conditions
DP: 300 psig DT: 150 F
LCM Case Study
Tubeside Design conditions

DP: 800 psig DT: 550 F
Continue Service
Materials of Construction
Shell: CS Tubesheet: CS
Anticipated Damage
Design Corrosion Allowance

SS: 0.125 in TS: 0.125 in
Run/Rerate
Repair
Replace
ASME PCC2
26
Best Practice
Analysis of Tubesheet Corrosion TEMA Class R Shell & Tube Heat Exchanger Construction Codes
ASME B&PV Code, Section VIII, Division 1 TEMA Class R
LCM Case Study
Run/Rerate
Repair
Replace
ASME PCC2
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Best Practice
Analysis of Tubesheet Corrosion TEMA Class R Shell & Tube Heat Exchanger Corrosion Monitoring Locations (CML) assigned Initial thickness readings taken at commissioning
LCM Case Study
Run/Rerate
Repair
Replace
ASME PCC2
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Best Practice
Analysis of Tubesheet Corrosion TEMA Class R Shell & Tube Heat Exchanger Local corrosion on the shellside of a tubesheet found during a shutdown Unanticipated damage based on operating conditions, fluids, and materials of construction
LCM Case Study
Run/Rerate
Repair
Replace
ASME PCC2
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Best Practice
Analysis of Tubesheet Corrosion
LCM Case Study
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Analysis of Tubesheet Corrosion TEMA Class R Shell & Tube Heat Exchanger Damage Mechanism, accelerated corrosion from carbonic acid corrosion
LCM Case Study
Run/Rerate
Repair
Replace
ASME PCC2
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Best Practice
Analysis of Tubesheet Corrosion FFS Assessment performed per API 579-1/ASME FFS-1, Part 5, Level 3 3D FEA model constructed to simulate metal loss profile, worst case metal profile modeled Comparative analysis performed between corroded and un-corroded cases FFS assessment indicated the vessel is acceptable for continued operation based on assumptions made for the future corrosion allowance
LCM Case Study
Run/Rerate
Repair
Replace
ASME PCC2
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Best Practice
LCM Case Study
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LCM Case Study
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Analysis of Tubesheet Corrosion Recommendations

Pressure boundary and tubesheet were suitable for four years of operation Tubesheet corrosion did not significantly increase likelihood of flange joint leakage at channel/shell joint Limits were placed on bolt assembly stress for any future joint assembly or re-tightening Allowed for 4 years of additional service until planned bundle replacement $200K saving identified for not having to expedite bundle No additional plant shutdowns required
LCM Case Study
Continue Service Anticipated Damage
Benefits
Run/Rerate
Repair
Replace
ASME PCC2
35
Best Practice
Benefits of the LCM Process

The proposed LCM Process is based on the use of industry codes, standards, and recommended practices as well as corporate best practices to construct and maintain in-service equipment; the inherent benefits include
Improved Safety & Risk Reduction Maximizing Equipment Availability
Fewer Incidents Extended Lifetimes Shorter Turnarounds Predictable Outcomes Enhanced Plant Performance
Optimization of Maintenance and Inspection Costs Regulatory Compliance
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Conclusions
The LCM Process for fixed pressurized equipment has been defined for the refining and petrochemical industry Key elements parts of the LCM Process are
Damage Mechanism Identification Construction Codes & Standards In-Service Inspection Codes FFS Standard Post Construction & Repair Guidelines
The LCM Process can be calibrated to other industry segments and international locations by substituting appropriate documents for the key elements described above
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Philip A. Henry email: pahenry@equityeng.com

20600 Chagrin Blvd. Suite 1200 Shaker Heights, OH 44122 USA Phone: 216-283-9519 Fax: 216-283-6022 www.equityeng.com
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Life-Cycle Management of Pressurized Fixed Equipment

Asset Integrity Management Overview

Introduction Life-Cycle Management

UK Health and Safety Commission

Refining & Petrochemical Industry Goals

Cooperative Achievement of Goals

The proposed LCM process

The Life-Cycle Management Process

Commissioning (Baseline Inspection)

Inspection Results Unanticipated Damage

Fitness-For-Service API 579/ASME FFS-1

The Life-Cycle Management Process

The Life-Cycle Management Process

Damage mechanisms identification is an important part of the Life-Cycle Management Process

The Life-Cycle Management Process

Documents covering damage mechanism identification

The Life-Cycle Management Process

API Codes, Standards and Recommended Practices

The Life-Cycle Management Process

API Design & Construction Standards

Note the co-branding on API Std 530 with ISO

The Life-Cycle Management Process

ASME Codes and Standards

The Life-Cycle Management Process

ASME Codes and Standards

The Life-Cycle Management Process

In-Service Inspection Codes

The Life-Cycle Management Process

Other Inspection Resources

Development of the following new references is under way:

The Life-Cycle Management Process

May be applied to pressure containing equipment constructed to international recognized standards

The Life-Cycle Management Process

ASME Post Construction Publications

The Life-Cycle Management Process

The Life-Cycle Management Process

The Life-Cycle Management Process

The Life-Cycle Management Process

Commissioning (Baseline Inspection)

Continue Service Anticipated Damage

Inspection Results Unanticipated Damage

Fitness-For-Service API 579/ASME FFS-1

LCM Case Study

Commissioning (Baseline Inspection)

Tubeside Design conditions

Inspection Results Unanticipated Damage

Design Corrosion Allowance

Fitness-For-Service API 579/ASME FFS-1

LCM Case Study

Commissioning (Baseline Inspection)

Inspection Results Unanticipated Damage

Fitness-For-Service API 579/ASME FFS-1

LCM Case Study

Commissioning (Baseline Inspection)

Inspection Results Unanticipated Damage

Fitness-For-Service API 579/ASME FFS-1

LCM Case Study

Commissioning (Baseline Inspection)

Inspection Results Unanticipated Damage

Fitness-For-Service API 579/ASME FFS-1

Analysis of Tubesheet Corrosion

LCM Case Study

LCM Case Study