Professional Documents
Culture Documents
What is ageing ?
Criticality Screening
Lifetime Extension
Plant Lifetime management
26 March 2012
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 3
Introduction
Definitions Managing Ageing Today
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 4
26 March 2012
What is ageing?
Ageing is not about how old your equipment is; its about its condition and how its changing over time
(Petroleum Safety Authority, 2008)
Ageing is a process of degradation related to the progression of time and/or the use of the facility and the systems related to the facility
(OLF, 2008)
Ageing plant is a plant which is, or may be, no longer considered fully fit for purpose due to age related deterioration in its integrity or functional performance More than 4500 high-tier Seveso plants in Europe are subject to ageing
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 5
INTRO
The potential degradation of plant and equipment due to age-related mechanisms such as corrosion, erosion and fatigue is becoming a key issue at worldwide scale, but most particularly in the USA, Europe and Scandinavia which have built a huge number of high-risk companies after World War II. These companies are now older than 50 years and ageing is an undeniable fact.
Nevertheless, ageing issues are seldom incorporated in an integrated HSE Management System They are not consistently traceable / retrievable as causal factor in incident investigations.
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 6
26 March 2012
Positioning
Stakeholders Offshore + Nuclear vs onshore Legal Framework
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 7
Stakeholders Map
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 8
26 March 2012
AMR 2
AMR 3
25 yrs
design lifetime
25+x yrs
extended lifetime
9 Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved.
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 10
26 March 2012
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 11
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 12
26 March 2012
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 13
Problemsetting
Major accidents trends Cost of ageing
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 14
26 March 2012
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 15
Sense of urgency
1. Trigger point : Trend of Major Accidents happening in the process industry 2. Conclusions from the HSE Plant Ageing Study : Overall it can be concluded that plant ageing does constitute a threat to health and safety performance of hazardous installations onshore. Within the uncertainties of the review conducted a reasonable statement to describe the size of the ageing issue is that approximately 60% of major hazard loss of containment incidents are related to technical integrity and, of those, 50% have ageing as a contributory factor. It therefore concluded that plant ageing mechanisms are a significant issue in terms of major hazard accidents.
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 16
26 March 2012
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 17
Possibilities
No change Risk Based Inspection & RCM Plant Lifetime Management
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 18
26 March 2012
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 19
Rejuvenation of specified assets via periodic turnarounds Compliance driven inspections Experience based THREATS: Increasing costs of production Increasing Major Accident Potential No insight on remaining plant lifetime and inadequate priorisation process for future investments Surprises may be waiting on the corner
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 20
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prioritize equipment for inspection based on risk Challenge prioritize inspection without compromising on safety identify inspection techniques and level of detail
rank equipment within scope according to risk DNVs approach focus on high risk items plan inspections based on risk acceptance criteria apply API581 using Orbit Onshore software
up-to-date (living) inspection plan Value to the client demonstrated value of planned inspections accurate inspection data management tool
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 21
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26 March 2012
Our Proposal
Plant Lifetime Management
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 23
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 24
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Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 25
Maintenance budget trending Trending in MTTR / MTBM Trending in % overdue regulatory inspections Trending in temporary repairs
HAZARD POTENTIAL
Status of knowledge about design, operation & deterioration mechanisms % Completion of action items from HAZOPs / PHAs Trending of reported incidents (LOCs)
OPERATIONAL INTEGRITY
Trends in process excursions from normal operating envelope Use of safety critical equipment in a failed state
ENVIRONMENTAL EFFICIENCY
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 26
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PLM Methodology /1
1. Initial BIP Scorecard
Criticality screening
Environmental efficiency
Operational integrity
2. Data collection
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 27
Plant and assets availability & reliability Level of repeated assets breakdown Trend of unscheduled unit or plant breakdowns / unplanned stops Trending in % availability of plant Trending in % availability of system / unit Trending in % reliability of assets MTBF (Mean-Time-Between-Failure) Trending in % of overdue RCA (Root Cause Analysis) actions from reliability assessments
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Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 29
PLM - Methodology / 2
Criticality Screening Criteria Business Impact Area
Data collection & Condition assessment Criticality screening Risk assessment & ranking Remaining lifetime of critical assets Mitigation Measures for Plant Lifetime Extension
Knowledge status
Asset condition Functionality Availability/Reliability Hazard Potential Maintenance/Inspection Spare parts availability Personal health & safety (PES) Process safety (PRS) Customer & product quality (CPQ) Environment and energy efficiency (EEF) Production downtime (PDT) Financial (FIN)
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 30
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Criticality screening
Unit A Unit B Unit C Unit D Knowledge status Asset condition Functionality Availability/Reliability Unit C Unit D Unit A Unit B
Unit E
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 31
component
equipment
system
Plant structure
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 32
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PLM - Methodology / 3
Data collection & Condition assessment Criticality screening Risk assessment & ranking Remaining lifetime of critical assets Mitigation Measures for Plant Lifetime Extension
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 33
Unit A Unit B
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 34
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PLM Methodology / 4
Life Extension Evaluation
Data collection & Condition assessment Criticality screening Risk assessment & ranking Remaining lifetime of critical assets Mitigation Measures for Plant Lifetime Extension
Detailed life extension study of equipment will be based on consequence of failure for critical assets with a high risk ranking. The study includes: - Status of ageing and history of equipment wrt. failures and maintenance - Maintenance study for the last 5-10 years (trends, failures) - Check that likely degradation mechanisms are part of inspection plans - Check maintenance plan - Check slow degradation that could lead to large overhaul - Check vendor support and spare part availability - Define changes in operation condition based on the production scenario - Predict how equipment will perform in changed operation Output : Estimation of remaining lifetime of critical assets conditions
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 35
PLM Methodology / 5
Data collection & Condition assessment Criticality screening Risk assessment & ranking Remaining lifetime of critical assets Mitigation Measures for Plant Lifetime Extension
Output : Extented Lifetime of plant or targeted critical assets & detailed Asset Lifetime Plans
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 36
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Concluding Remarks
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 37
Planning Forward
Proactively Managing Ageing
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 38
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Ageing is not about how old your equipment is; its about its condition and how its changing over time (Petroleum Safety Authority, 2008)
Contact person frank.candreva@ dnv.com Tel. +32 473 99 35 55 DNV Solutions Belgium
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Concluding Remarks
Expectations met ? Interest in a Joint Industry Project ? Remaining questions issues to discuss ?
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 41
Plant Lifetime Management & Lifetime Extension Warshaw - 20 March 2012 Det Norske Veritas AS. All rights reserved. 42
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