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RBI Implementation Challenges, Resolution Strategies and the Proven Benefits: A Case Study from a Crude Oil Refinery.
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RBI Implementation Challenges, Resolution Strategies and the Proven Benefits: a Case Study From a UK Refinery
Speakers Profile Years of Experience: 30 Brief Job Profile: Business Development Manager, LifeTech Engineering. Providing Asset Integrity Management software for RBI, NII, FFS and Asset Life Extension, associated support services and training. Professional Expertise: 30 years business experience (general management, operations management and business development) across several industry sectors, the last 20 years involved with the Aberdeen Oil & Gas industry in a number of AIM related roles. Keith Walton LifeTech Engineering
Agenda 1. About LifeTech Engineering 2. RBI Overview 3. RBI at a UK Refinery 4. Challenges and Resolution Strategies 5. Case Study - Cost Saving
About LifeTech Engineering LifeTech Engineering Ltd is a leading oil and gas Asset Integrity Management (AIM) consultancy, operating out of Aberdeen, UK. We provide specialist software, engineering services and training throughout the entire asset lifecycle to manage risk, reduce costs and improve Plant safety, efficiency, and productivity. We have developed innovative software: • RBLX for RBI, including a Non-Intrusive Inspection (NII) module • FITest for Fitness for Service Assessment • FUSIONfor Life Extension Assessment
Inspection Methodologies TIME BASED INSPECTION Everything inspected at the same interval COSTLY • Time-Based Inspection (CBI), Risk-Based Inspection (RBI). Inspection (TBI), Condition-Based • TBI: inspect all equipment on a rigid time schedule, however, this is costly if a lot of assets are involved. CONDITION BASED INSPECTION Trend analysis, consequences not considered. REACTIVE • CBI: inspect equipment based on knowledge of condition of equipment and perceived trends in condition. A reactive approach. RISK BASED INSPECTION Risk Analysis, Probability & Consequence PROACTIVE • RBI: prioritise equipment for inspection based on assessment of the risk of failure – RBI has benefits over TBI & CBI and is becoming the choice for the Oil & Gas industry and related industries.
Risk Based Inspection (RBI) Overview • Define inspection techniques • Prioritise high risk components How Where to Inspect to Inspect When What to Inspect to Inspect • Define inspection intervals • Identify damage mechanisms 9
Risk Based Inspection (RBI) RISK MATRIX Risk Based Inspection (RBI) identifies Assets for inspection based on their associated risks rather than a predetermined fixed time interval. Risks are managed primarily through equipment inspection. Inspections are based on a Risk Matrix where: Risk = Probability of Failure (PoF) x Consequence of Failure (CoF) RISK RANKING Risk is regarded as a better measure for prioritisation than either the PoF or CoF alone, because it is more descriptive of the actual damage/loss caused. HIGH MEDIUM-HIGH MEDIUM LOW 10
Background • Crude oil refinery commissioned in 1924. • Daily refining capacity: 210,000 barrels. • Recognised the need to take ownership and control of their RBI programme, therefore, decided to purchase RBI software and training, and to set up a joint team of Refinery personnel and RBI consultants.
Scope of Work Risk Based Inspection of: • Pressure Vessels • Storage Tanks • Heat Exchangers • Piping Following: API 580 RBI Concepts & API 581 RBI Inspection methodology
What did the refinery expect from RBI? Objective Improved inspection effectiveness and reduced risks. Result expected Risk addressed using RBI with resources focussed on high risk items. Maximised planned shutdown intervals. Condition of equipment known, therefore, unnecessary planned shutdowns eliminated. Minimised number of unplanned shutdowns. Equipment condition & reliability better known, therefore, suitable maintenance can be planned before FAILURE. Increased equipment uptime. Reduced costs. Approx 80% of low risk equipment inspections can be delayed, therefore, inspection costs reduced.
The Refinery Project – The 4 Stages of RBI Implementation Stage 1: Project Preparation Stage 2: Data Gathering Stage 3: Risk Assessment & Insp. Planning Stage 4: Reports & Presentations
The 4 Stages of RBI Implementation Stage 1: Project Preparation (5% of project time) • Establish RBI Team and define Roles, and Responsibilities • Create Project Plan-Gantt Chart • Prepare Scope Document • Kick-off Meeting • Site Visit-Familiarisation • 1st Workshop-Kick off 18
The 4 Stages of RBI Implementation Stage 2: Data Gathering (60% of project time) • Line List/PIDs Gap Analysis • Develop/Review Corrosion Loops (circuits) & Select Representative Line(s) • Markup new Corrosion Loops • Prepare DMs Diagram based on API 571 • Validate Corrosion Loops • Develop Inventory Groups and Calculate Masses • Select Representative Fluid • Identify and Register Dead Legs • Create hierarchy and Identify Component(s) for each Equipment in Import Sheet • Data Gathering and Import sheet population • Validate Collected Data • Review & Summarise Inspection Records and Assign inspection Effectivenesses • Import Data Into RBLX • Review Data in RBLX and Identify Additional Data Required • Additional Data Gathering • Input Additional Data into RBLX • 2nd Workshop-Resolve any Issues • Lesson Learned workshop 19
The 4 Stages of RBI Implementation Stage 3: Risk Assessment & Insp. Planning (20% of project time) • Analise, Validate and Comment on Damage Mechanisms and POFs in RBLX • Analise, Validate and Comment on COFs in RBLX • Validate and Comment on Risks • Prepare WSEs (Inspection Plans) • Validate WSES and Confirm if NII Assessment is Required • Perform NII Assessments • Validate NII Assessment • Update WSEs in RBLX based on NII Analysis 20
The 4 Stages of RBI Implementation Stage 4: Reports & Presentations (15% of project time) • Prepare Draft Report for Review • Finalize DMs Diagram • 3rd Workshop-Present RBI Results to Plant Specialists • Incorporate Comments and Issue Final Report • Final Presentation to Management • Final Report • Mark Up CMLs/TMLs on Isometric Drawings 21
A Multi-Discipline RBI Team RBI assessments are much more effective when an experienced team is assembled to pool their knowledge of the facility and the equipment under evaluation. The RBI team should contain as a minimum: RBI Facilitator Corrosion Engineer Process Engineer Inspection Engineer… …and be able to call upon Technical Authorities in: RBI Corrosion Process Inspection Non-Destructive Testing 23
Roles & responsibilities of team members: Facilitator: responsible for assembling all of the data and carrying out the RBI analysis. Corrosion Engineer: the corrosion engineer provides plant inspection personnel with a sound of potential deterioration mechanisms to develop a practical and effective strategy to limit technical understanding the risk of potential equipment failures. RBI Engineer: responsible for the execution of RBI initiatives, RBI configuration, implementation and review of damage mechanisms and inspection plans generated by the RBI assessment tools. Inspection Engineer: keeps track of the condition of oil & gas pipelines, pumps, tanks, vessels, valves, structural supports and other equipment. Ensures that all hardware functions properly and efficiently and complies with government codes and standards. Process Engineer: designs and implements systems and equipment procedures used in production facilities. Main duties include testing and monitoring equipment, updating current system processes and conducting risk assessments.
Challenges • Data Availability and Quality • Identification of Damage Mechanisms • Non-Intrusive Inspection Assessment • Dead Legs and Nozzles Assessments • Proposed Inspection Date
Challenge Data Availability and Quality • Data quality has a direct relation to the relative accuracy of the RBI analysis. Data inputs and assumptions should be validated by qualified personnel (Process Engineer/Operator) to review operating parameters used. • The current operator of the refinery has tried hard to convert inherited hard copies of drawings, reports, etc to electronic format, however, there have been some issues with availability and quality of data due to the age and changing ownership since 1924. Solution • Gap Analysis between Line List and P&IDs. • Quality assessment of Line List, P&IDs, GADs, Material Specs, Inspection Reports, Remedial Actions, etc.
Challenge Identification of Damage Mechanisms • Identification of the credible damage mechanisms and failure modes for equipment included in a risk analysis is essential to the quality and the effectiveness of the risk analysis. • API 581 RBI guidelines do not address all the applicable damage mechanisms present in the refinery. For example, creep as an important DM in a refinery, is not covered. Solution • Additional documents were referenced and the RBI software enhanced to cover all Damage Mechanisms covered in API 571 in addition to API 581. • A special module, covering Creep damage mechanism was developed and added to RBLX software.
Challenge Non-Intrusive Inspection (NII) instead of Internal Visual Inspection (IVI) • Traditionally the Refinery conducted internal visual inspection (IVI) involving shutdown and entry into vessels and tanks with associated risks, loss of production and expense. • API 581 does not cover detailed calculations for Non-Intrusive Inspection (NII), therefore, a detailed methodology was needed to cover NII on specific equipment. Solution • A module for NII (Non-Intrusive Inspection) was developed within the RBLX software to avoid IVI and the need for vessel isolation, confined space entry and decontamination. • A robust NII Module provides assurance that risk levels are not adversely affected by replacing IVI with NII.
Challenge Dead Legs and Nozzles Assessment • Dead Legs can be areas of increased corrosion requiring special attention, due to concentration of corrosive species, especially those that are part of primary piping systems. There are also many nozzles connected to vessels that are sometimes critical requiring separate assessment. • API 581 does not address assessment of Dead Legs and nozzles in sufficient detail. These components are potentially high-risk areas, therefore, separate procedures were required for their assessment. Solution • Due to a large number of Dead Legs and Nozzles, it is difficult to assess all individually, therefore, a screening process was developed to filter the most critical items for detailed assessment. • Selected items were assessed in RBLX and specific inspection plans were developed.
Dead legs, Nozzles and Representative Lines Assessment
Challenge Proposed Inspection Date • Based on API 581, inspection date is defined based on the predicted risk, however, the Refinery wanted to add a Minimum Thickness Alert to this criterion. Also, the Refinery internal guidelines had to be incorporated into RBLX procedures when defining inspection plans and dates. Solution • The RBLX software predicts risks and normally calculates inspection dates based on a Risk Target, however, the software was amended to include the Refinery defined maximum inspection interval of 12 years and to consider the Minimum Thickness Alert.
Conclusion This project was a great success due to the following: ✓ The teamwork and commitment demonstrated by both the Refinery personnel and Consultancy team was outstanding ✓ Open communication (daily talks, weekly review meetings and monthly RBI steering team meetings) to address issues arising and willingness to propose solutions ✓ Support from the Refinery senior management ✓ Lessons Learned workshops throughout the project (not just at the end) ✓ Speedy customisation of RBLX software based on Refinery/Consultant Review Meetings
Evergreening Evergreening Is the process of updating the previous RBI assessment due to changes affecting the RBI results, e.g., additional inspections, process/mechanical changes. Evergreening RBI assessment is conducted to maintain and update RBI assessment (including RBLX software database, report, and records) by capturing the most recent inspection, process, maintenance and risk mitigation information. Evergreening RBI assessment shall be conducted: • After Significant Changes in process conditions or damage mechanism rates • After Implementation of Risk Mitigation Strategies • After Maintenance Turnarounds to reflect new risk levels • After a Set Time Period to take into account the many small changes that may have occurred • After major revision of API RP 581 or RBI software version
Proven benefits of using RBI • Meaningful risk reduction and improved plant availability and safety • Optimised use of the budget of the inspection and maintenance departments • Extended intervals between shutdowns and inspections • Optimised inspection methods and avoidance of over-inspection • Legislative compliance
Solution Strategies – Points to Note Create a team of competent specialists, comprising of Client and RBI Contractor personnel. Involve plant inspectors, corrosion engineers & process engineers from the start. Make data assumptions for low risk equipment & piping (e.g. utility) to save time. Decide about risk matrix & risk targets at beginning of the project. Register inspection effectiveness per each inspection for future references. Use representative dead legs/nozzles instead of assessment of all dead legs/nozzles. Do several tasks in parallel to save time e.g. data gathering in parallel with inspection reports review. Note the challenges and have a robust strategy in place for each Stage. Define and agree clear Scopes of Work. Hold regular meetings with open communication between all parties, this is essential. Lessons learned workshops should be conducted at set periods of the project. Present & discuss RBI results with technical authorities & management; agree future programme of work. • • • • • • • • • • • •
RBI Limitations – Points to Note RBI is based on sound, proven risk assessment and management principles. Nonetheless, RBI will not compensate for: • Inaccurate or missing information • Inadequate designs or faulty equipment installation • Operating outside the acceptable IOWs • Not effectively executing the plans • Lack of qualified personnel or teamwork • Lack of sound engineering or operational judgment
Case Study - Cost Saving due to Implementing RBI Client: A Refinery Operator, Location: UK, Year: 2020 Aboveground Storage Tank Capacity: 21 Million Litres Material: Carbon Steel to BS 15 Tank Installation Date: 02/10/1958 Last Bottom Plate Replacement Date: 30/04/2005 Age of New Bottom: 15.2 Years Fluid: Ultra Low Sulphur Diesel, including Water, Sulphur & Oxygen Last Internal Inspection Date: 30/04/2005 Current Endorsement Period: 12 years RBI Analysis Result: PoF Category: 2 (out of 5) CoF Category: 4 (out of 5) Risk: Medium New Endorsement Period: 20 years Saving: £126,667 / Year for only one Tank Budget Overhaul Cost, (£) 3,800,000 Current Endorsement, (years) 12 Annualised Cost, (£) New New Saving/year (£/Year) Endorsement Period, (years) 20 Annualised Cost, (£) 190,000 316,667 126,667
THANK YOU & STAY SAFE LifeTech Engineering Ltd Aberdeen, UK Keith Walton, Business Development Manager Keith.Walton@Lteng.co.uk Reza Shahrivar, Asset Integrity Manager Reza.Shahrivar@Lteng.co.uk +44 (0)1224 824112
