ABB Life Extension

© ABB Group February 20, 2012 | Slide 1

CSC 2011 Life Extension for Ageing Equipment

Neil Henry, ABB Consulting, September 2011


Life extension for ageing plant

§  Why is it necessary?

§  What is required for process equipment?

§  A different approach from existing codes and methods

§  Examples

§  Typical result from studies

§  Learning from the work carried out


Asset Life - issues faced by production operations

CHANGING PRODUCTION REQUIREMENTS

Different production methods, constituents and profiles

CHALLENGING WORLD ECONOMIC CLIMATE!

Operate beyond original design life

Run for cash

New plant build scale rising

1970’s 1990’s 2010’s 2030’s 2050’s Investment Justification

AGEING EQUIPMENT Pressure from Regulators

CHANGES to Engineering Standards


Why is it necessary? Process safety in older plant

Why is age important – “what is an expected service life?”

§  HSE concern resulted in Research Report (RR)509, 2006

§  Further work leading to RR823 published 2010, concluded

§  “Ageing” influenced over 30% of equipment failures

§  …HSE have to consider Operators safety justification for continued use of ageing plant

§  OSHA – National Emphasis Programs in refinery and chemical (for mechanical integrity)

It is far more than a compliance issue – equipment reliability is an essential business requirement: confidence in assets


Asset categories v UK legislation

Pressure Energy

Hazardous Fluids Business

Critical

Pressure Systems Safety Regulations

(PSSR)

COMAH, IPPC, PUWER

Non-critical equipment (remainder)

Corporate Governance


OSHA CFR 1910.119 (Process Safety Management)

Quotes from standard

!! effective process safety management program requires a systematic approach to evaluating the whole process

!! employers need to develop the necessary expertise, experiences, judgment and proactive initiative within their workforce to properly implement and maintain an effective process safety management program

!! that the design and construction along with the testing, inspection and operation are still suitable for the intended use. Where the process technology requires a design which departs from the applicable codes and standards, the employer must document that the design and construction is suitable for the intended purpose.


Process

Safety

Integrity

Management

There are many common aspects

Many benefits result from an Integrated approach to Safety and Integrity


Why does equipment fail? Lab Data.

No of Failures

0

5

10

15

20

25

30

35

40

Co

rro

sio

n

SC

C

Fa

tigu

e

We

ldF

ailu

re

Ero

sio

n

Bri

ttle

fra

ctu

re

Me

cha

nic

al

Fa

ilure

Cre

ep

Ove

rhe

atin

g

Ove

rP

ress

ure

We

ar

No of Failures


Identifying root causes

0

10

20

30

40

50

60

70

80

Operation Design flaw MaintenanceError

FabricationDefect

Failed repair Other

Series1


Failure of process plant

!! There are very few failures reported on pressure equipment

!! Statistics suggest failure rates of 1x103 to 1x104 yrs:

!! But what level of ‘failure’? (deterioration, leak, major loss)

!! When could failure occur?

!! This year, next!..in 5 years or more

!! Most failure statistics exclude corrosion damage

Objective is Avoiding unplanned ‘failure’ - production impact


Ageing plant - The ageing stage

• Approaching design limits • Evidence of significant accumulated damage • Changes in process use • Repairs, refits, modifications • Deficiencies in systems and skills

Acc

umul

ated

Dam

age

Time

Initial Operation

Mature Stage

Ageing Stage

Terminal Stage

Ref: HSE RR 509 – Plant Ageing – Management of equipment containing hazardous fluids or pressure


What affects asset life? Understanding the challenge

Design

Construction

Operation

Maintenance

Inspection

Modifications

Suppliers

Asset life factors across the life cycle

Quality of the original fabrication and installation

Obsolescence of equipment

Operating within original design limits

Knowledge of equipment condition e.g. Inspection of static equipment or condition monitoring of rotating equipment

Change of equipment or operations that negates original design

Maintaining equipment in ‘fit for service’ condition Quality of spare parts and repairs

Design quality - Life-limiting factors assumed at design stage


Life extension - challenges

!! Application of life extension practices change to equipment and operating regimes,

incremental over time

!! Not simply fatigue or creep life

operating cycles and / or time related factors not in design (fatigue or thermal)

!! Progressive corrosion model for life & inspection

time of initiation of corrosion

operational change over time

!! Condition Monitoring systems

knowing what to monitor?

!! Primarily containment of high hazard substances – not pressure


Asset life extension

How to understand remaining Asset Life?

Remnant Life

Asset Life


Process change examples

§  Peak load operating – eg power plants

§  Product demand cycles

§ Overnight shutdowns

§ Week-end shutdowns

§  Product grade change

§  Feedstock change

§  Process optimisation – temperature changes


Ti centrifuge suffering wear

§  New grades of product contained higher residual acid and increased abrasion

§  Spare scroll installed when required - repair was carried between shutdowns

§  Limited management of repair – no evaluation of damage extent

Actions taken

§  Evaluation & application of surface coating to scroll tips to extend life

Wear & Corrosion of centrifuge scrolls


Life extension “Management Cycle”

Corporate production planning

Business strategy

Prioritisation of assets

Condition & life

assessment

Data gathering

Project Delivery

Project priority

evaluation

Project Scoping

Asset Life Actions

Asset Sustenance plan


Typical results of Ageing Plant Study

ALS Category

7% 1%11%

73%

8%

A

B

C

D

E

Items need to be replaced within next 20 years

Items need major repairs within next 20 years

Items need minor repairs within next 20 years

Items can continue to be operated for the next 20 years

Items need further evaluation


Deterioration Mechanism(s)

Over required lifetime

£ £ ££££ £££ ££

Not significant Minor

Major

No routine maintenance –

“operate to failure”

Routine maintenance

Minor repair Significant

repair

Replacement

Interpreting the results financially


Typical study output. Spend map is predicted

20062007

20082009

20102011

20122013

20142015

20162017

20182019

20202021

20222023

2024

2025

2026

Total

0

10000000

20000000

30000000

40000000

50000000

60000000

Total

Total

Sum of Cost

Year Required

Estimated Investment per Year (overall)


Asset life extension – part of an integrated study

Process Hazard Review

SIL

Asset Life Studies Criticality and

Management of Risk

Training, Coaching

and People Development

Total Plant Reliability

Effective Turnaround Management

RBI+ and RCM

Specialist Technical

Consultancy

Rotating & Machines Electrical

Control Instrumentation

Civil & Structural Vessels Piping

Fired Equipment Materials Process


Example of top down asset life assessments

Impact of Deterioration Mechanisms

Normal Design Life

Assessed Asset Life

Heat Exchanger

40 years plus

Service & process

Corrosion fretting

20 years or less

Original Design Standards

Best Practice

Maintenance Practices

Inspection Methods & History

Operating Practices

Environmental Conditions

Process Pump

30 to 40 years

Corrosion or Erosion

10 years or less


Asset life extension

Effective & efficient application:

§  Criticality or vulnerability study

§  Identified investment required

§  Actions necessary to maintain integrity

§  Achieving Safety Standards

§  Sustain or achieve operating performance

§  Meet future production requirements

§  In the short term (typically up to 5 years)

§  In the longer term (typically 10 to 20 years)


Conclusion – life extension to avoid this!

Humber Refinery 2001 Texas City 2005

Piper Alpha 1988 Pembroke Refinery 1994

Piper Alpha 1988

Texas City 2005

Pembroke Refinery 1994

Humber Refinery 2001

ABB Life Extension

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