Professional Documents
Culture Documents
Main Points
Industry Goals - Reliability Losses continue to happen Are we learning from the past? Various programs should provide layers of protection
Focused information from various sources Industry standards Industry certifications Management Systems Management Leadership Practices Managing uncertainty, the role of inspection Metrics and Gap Analyses
Introduction
Losses in the refinery industry have continued to increase over the last few years and the causes highlight the aging facilities in this category. A significant number of larger losses (over $10,000,000) have been caused by piping failures or piping leaks, leading to fires and/or explosions. Several large losses due to piping failures were due to corrosion issues or using the wrong metallurgy..
Introduction
The explosion occurred when employees were attempting to isolate a leak on a condensate line between the NGL plant and the refinery. Three crude units were damaged and two reformers were destroyed. The fire was extinguished approximately nine hours after the initial explosion. Five people were killed and 50 others were injured. Initial investigation into the loss indicates a lack of inspection and maintenance of the condensate line.
June 25, 2000 Mina Al-Ahmadi, Kuwait $412,000,000 (2000 dollars) dollars)
$433,000,000 (2002
From the Marsh and McLennan Report, The 100 Largest Losses 1972-2001, 20th Edition: February 2003, a publication of Marshs Risk Consulting Practice
5
The Goal
Achieve regulatory and corporate compliance (business, safety, environmental), and ensure reliable use of fixed equipment for finite run times, by understanding, identifying, measuring, and managing risks and eliminating non-value adding activities and costs.
Improvement is Needed
The significant problems we have cannot be solved at the same level of thinking with which we created them.
~Albert Einstein
Plants are aging
Failure rates will increase without effective change See latest Marsh Consulting Report 2010
Five year loss totals in the refinery industry have continued to trend upwards over the last few years. Piping failures or leaks (corrosion or incorrect metallurgy) and start-up and shut-down events continue to be significant causes.
Safety Critical Equipment Inspection - Percent of inspections of safety critical equipment completed on time. This may include pressure vessels, storage tanks, piping systems, pressure relief devices, pumps, instruments, control systems, interlocks and emergency shutdown systems, mitigation systems, and emergency response equipment.
Safety Critical Equipment Deficiency Management - Response to safety critical inspection findings (e.g. nonfunctional PRDs and SISs). This may include proper approvals for continued safe operations, sufficient interim safeguards, and timeliness of repairs, replacement, or rerate. Management of Change (MOC) and Pre Start-up Safety Review (PSSR) Compliance - Percent of sampled MOCs and PSSRs that met all requirements and quality standards.
Specify Design Conditions and Identify Damage Mechanisms (API 571, WRC 488, WRC 489, WRC 490), Select Materials of Construction
In-Service Inspection (Establish Inspection Interval) Prescriptive (API 510/570/653,NBIC) Risk-Based (API 580/581,PCC3) Continue Service Anticipated Damage
Identify Damage Mechanisms (API 571, WRC 488, WRC 489, WRC 490)
Run/Rerate
Repair
Replace
Technology Integration
ASME PCC2
Sample components of ASME PTB-2-2009 Guide to Life Cycle Management of Pressure Equipment Integrity June 5, 2009
API RP 576 Inspection of Pressure Relieving Devices, 3rd Edition November 2009
API RP 574 Inspection Practices for Piping Components, 3rd Edition, November 2009 API RP 572 Inspection Practices for Pressure Vessels API 570 Piping Inspection Code: In-service Inspection, Rating, Repair, and Alteration of Piping Systems, 3rd Edition, November 2009
Inspector Certifications
Basic
510 Pressure Vessel
570 Piping 653 Above Ground Storage Tanks 936 Refractory QUTE
Inspector Certifications
Advanced Supplemental
580 RBI 571 Damage Mechanisms 577 Welding & Metallurgy Meaning of supplemental certifications
API DB Search
http://www.api.org/certifications/ICP/
Inspectioneering Journal Article Series January/February 2010 Issue Management Leadership and Support for PEI, by John Reynolds
Inspectioneering Journal Article Series January/February 2010 Issue Management Leadership and Support for PEI, by John Reynolds
Electric Resistance Welded (ERW) Pipe and Tubing Exchanger Bundle Classification External Corrosion Prevention Inspection for Environmental Cracking Gray Zone Equipment Fabrication QA/QC Failure Analysis Fatigue Failures Field Surveillance Fitness for Service (FFS) Analysis Flange Bolting Procedures Flange Gasket Selection and QA Flare System Inspection Fraudulent and Counterfeit Materials Furnace Monitoring and Inspection Handling of Pressure Relief Devices Heat Tracing in Safety Systems Hot Spots Hot Tapping and Welding on Equipmentin-Service Hydrostatic Overpressures Hydrotest Water Quality Hydrotesting Safety
Idle and Retired Equipment Incidents Associated with Installation of Pollution Control Equipment Injection Point Inspection Inspection Recommendation Tracking Inspection Scheduling Inspection Procedures Inspection Staffing Inspection for Inaccessible Locations Inspection Record Keeping Systems (Effective)
Key and Critical (K/C) Materials Degradation Variables Knowledge Transfer to Operators Leak and Failure Investigation Reporting Leak and/or Pressure Testing Line of Authority and Management Leadership for Inspection Localized Corrosion (Inspection of) Management of Change (MOC) for PEI Issues Materials and Corrosion Engineering Material Degradation Risk Management Mixed Metallurgy Piping Systems
NDE Specialists NDE versus Pressure Testing Non-blowout Proof Valve Stems
On-Stream Inspection (OSI) Overdue (Equipment) for Inspection Paint and Coatings QA/QC Participation on Industry Standardization Committees Performance Testing of NDE Examiners Pipe Plugs Pipe Rack Inspections Piping Inspection Plugged Vents on Storage Tanks Positive Material Identification (PMI) Post Weld Heat Treatment Pressure Equipment and Inspection Codes / Standards Pressure Equipment Regulatory Activities Pressure Relief Device Auditing Process Creep
Additional Benefits
Inspection Planning & CBA
$1,400,000
Current Inspection Costs Current Maintenance Costs Total Current Costs RBI Inspection Costs RBI Maintenance Costs RBI Total Total Savings
$1,200,000
$1,000,000
$800,000
$600,000
$400,000
$200,000
-$400,000
137
210B 210C 865 860 862 864 210A 868 869
Crude
Crude Vac Kero HDS Reformer LERU Unifiner Crude FCC Sulfuric Alky
4
53 40 9 35 17 10 32 4 16
6
91 68 49 91 85 63 74 66 60
2
38 28 40 56 68 53 42 62 44
Inspection Planning
RBI vs. Traditional Inspection Plan
4000 3500 3000
DA 02
Green risk profile is with API RBI implemented in this process unit Blue risk profile is with traditional API 570/510 program in place Blue plan yields 1.7sq./year/$$ of risk reduction over 4 years Green strategy yields 2.7sq./year/$$ risk reduction over 4 years Net benefit is ~40% improvement in risk reduction ROI >> 10X
Best Practices Observations/recommendations Roadmap Strategy Cross-functional team with owner/operator experience and SMEs Trained team members Metrics and Priorities Jointly developed, may also use company HSE risk matrix
Metallurgy
Plant Processes Receiving Inspections Welding and Repairs
Inspection Management
Inspection Planning
Benchmarking
Working Practices Procedures Understanding Utilization of best practices Synergies & interdependent practices, processes & programs Metrics Kudos Good practices recognized Areas of vulnerability Recommendations for improvement Benchmarking metrics
The resulting scores are based both on the interview results, as well as, the file review. Each of the subject area statements are also weighted for relative importance. These weight numbers are used for the benchmarking of one facility versus another.
Scoring
One of the objectives of an assessment should be to provide a means of measuring the FER (Fixed Equipment Reliability) program performance of a facility, initially and over time. The scoring enables an owner to:
Compare the facility performance against a top performers
Measure the change in performance as a result of closing the identified gaps for each FERMI focus area Compare the site to other company sites and to compare against itself at periodic intervals
E2Gs specialists have reviewed fixed equipment groups and programs from many refineries.
The mix of subject matter experts and seasoned facility technical staff are able to not only determine if a particular MI procedure is in use, but are also able to determine a relative quality of the written material. For instance:
The interview determines that the facility does have a root cause culture. Follow up file review finds that the root cause analysis was performed, but the conclusions made were not reached in a logical manner. Generally this means that the obvious, immediate cause was determined to be the root cause.