Click to edit Master title style - TEF Kuwait RBI/128 Presentation-RBI-RISK BA… · CSWIP 3.2...
Transcript of Click to edit Master title style - TEF Kuwait RBI/128 Presentation-RBI-RISK BA… · CSWIP 3.2...
WELCOMEto one of the best
Petrochemical plants in the World
www.equate.comEQUATE Petrochemical Company
About EQUATEEstablished in 1995, EQUATE Petrochemical is Kuwait’s first-ever
international petrochemical joint venture, and is the single operator of a
fully integrated world-scale Kuwait-based manufacturing facility that
annually produces over 5 million tons of high quality petrochemical
products.
www.equate.comEQUATE Petrochemical Company
EQUATE at a glance
Providing valued products to the world
PROFIT PRODUCTS EMPLOYEES OFFICES AWARDS
US$ 1.1
Billion (2012)
PE / EG / SM
PX / BZ / HA / PP
1400
Employees
4 Offices
Globally
National &
International
Awards
www.equate.comEQUATE Petrochemical Company
The Greater EQUATE JV
Global Expansion
To meet increasing
worldwide demand for
first-rate petrochemical
products, EQUATE’s
shareholders and
Kuwait National
Petroleum Company
(KNPC) completed a
multi-billion dollar
expansion project in
2009 which greatly
increased output.
Ethylene GlycolCapacity: 600,000MT
Styrene MonomerCapacity: 450,000MT
ParaxyleneCapacity: 829,000MT
PolypropeleneCapacity: 140,000MT
Company Shareholders Product Capacity Market Outlet
EQUATE
PIC 42.5%
Dow 42.5%
BPC 9%
QPIC 6%
PE
EG
825,000
550,000
EMC
MEGlobal
TKOC
PIC 42.5%
Dow 42.5%
BPC 9%
QPIC 6%
EG 600,000 MEGlobal
TKSCKARO 57.5%
Dow 42.5%SM 450,000 EMC
KPPCKARO 100%
PX
HA
BZ
829,000
80,000
393,000
PIC
PIC
Not for commercial sales. Used only
for SM production.
PIC PP Plant(Operated by EQUATE)
PIC 100% PP 140,000 PIC
KARO PP Plant(Operated by EQUATE)
PIC 40%
KNPC 40%
QPIC 20%
All production of KARO is done by KPPC.
EQUATE as Single Operator
• All capacities are metric tons annually.
• Ethylene is only used as feedstock, not for sale.
• KARO: Kuwait Aromatics Company.
www.equate.comEQUATE Petrochemical Company
• Unipol Polyethylene Process• Leading Glycol Technology• Global Marketing Expertise
• Utility Infrastructure• Dedicated Port
Facilities• Overall Infrastructure
• Supply of Ethane• Plant Infrastructure• Skilled Personnel
Private Sectors to Promote downstream industries
Providing value through Partnership
www.equate.comEQUATE Petrochemical Company
OUR MISSIONWe provide valued products & services to the world
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OUR VISION We are a global leader &
world class producer
of petrochemicals
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OUR
VALUES
• Customer Centricity
• Safety & Reliability
• Teamwork & Partnership
• Sustainability
• Continuous Improvement & Progression
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Corporate
Strategy
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OUR PRODUCTS
www.equate.comEQUATE Petrochemical Company
As the proud owner and
operator of several world-class
petrochemical units, EQUATE
manages the production of the
highest grades of;
Ethylene, Polyethylene (PE),
Ethylene Glycol (EG),
Polypropylene (PP), Styrene
Monomer (SM), Paraxylene (PX),
Heavy Aromatics (HA) and
Benzene (BZ).
www.equate.comEQUATE Petrochemical Company
Environmental
Impact
www.equate.comEQUATE Petrochemical Company
Reduce CO2
emissions at our
facilitiesGOALUtilize internal
capabilities to
create a green
environment
Full compliance
with Environment
Public Authority
(EPA) - Kuwait
Achieve ZERO
loss of primary
containment of
category II and
III incidents
Optimize
development
of projects to
enhance the
environment
Reduce water
consumption
Reduce energy
consumption
and improve
energy
efficiency
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OUR AWARDS & ACCREDITATION
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EQUATE Petrochemical Company
RBI - Risk Based Inspection
TEF Conference, 2-Nov-2014
P. Sukumaran,Senior Mechanical Integrity Specialist,API - 510, 570 & 653 Inspector,ASNT ACCP & NDT Level-III-RT,UT,MT,PT,VT.CSWIP 3.2 Senior welding inspector
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What is Risk Based Inspection?
Risk Based Inspection
The Risk-Based Inspection methodology, is used to manage the overall risk of a plant by focusing all inspection efforts on the process containment equipments as per their risk ranking levels.
Focusing more on high risk items by using RBI, rather than generic time based, fixed frequency inspection systems.
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Driving Forces for RBI• Increase Safety• Reduce Cost• Maximise Productivity• Deal with Aging Plants• Prevent Catastrophic Failures• From Fixed Inspection Intervals to
Flexible
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• Risk allows people to view potential hazards that simultaneously accounts for both the likelihood and consequences of an event.
• Risk-based inspection will be focused on processing plants and will be phased in over time as each component is thoroughly evaluated and analysed and improvements are made.
• RBI system has been designed using a fully transparent process that has drawn upon the input and expertise of all stakeholders.
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Processing Industry is recognising that benefits may be gained from adopting formal risk-based inspection (RBI) approaches to plant integrity management through improved targeting and scheduling of inspection and maintenance effort.
Is risk-based inspection designed to save money or eliminate inspection program personnel?
Applying risk-based inspection in processing plants will not reduce the amount of money, nor it reduce the number of inspection program personnel. Risk-based inspection is designed to apply the information regularly collected to better predict and prevent catastrophic failure and improve plant reliability.
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RBI provides the basis for making informed decisions oninspection frequency, the extent of inspection, and the mostsuitable type of NDE.
In most processing plants, a large percent of the total unitrisk will be concentrated in a relatively small percent of theequipment items.
These potential high-risk components may require greaterattention, perhaps through a revised inspection plan.
The cost of the increased inspection effort may sometimesbe offset by reducing excessive inspection efforts in the areasidentified as having lower risk.
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Define Role of RBI that supports Plant Site
Strategic Goals
Define RBI Objectives Define RBI Deliverables that supports the Site
Strategic Goals
Define Expected Benefits to Site.
Define KPIs
Get Estimate of RBI Implementation Costs
& Timeframe
Carry out ‘Costs vs. Benefits’ Analysis.
Allocate & Authorize Budget for RBI
Understand RBI and its Benefits
Nominate a Person at site with ‘Single
Point Accountability (SPA)’ for RBI
Implementation
Plant Site RBI Strategy – Management Commitment & Obligations
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Select a robust RBI Methodology and
RBI Service Provider
Finalize RBI Study Team composition &
Draft Project Plan
Management Review and Decision Making
Finalize RBI Implementation
Master Plan
Ensure RBI team studies are completed
as per Master Plan
Integrate RBI process and Study Output into existing site practices
KPI Reviews & Feedback
Set RBI Project Criteria to cover all static items
RBI Implementation Process – Plant Site Tasks
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Item Design DataInspection History
Operational Data /History
RBI Team Study & Updates Report plant Operational Changes
beyond RBI study defined limits
Inspection Dept implement –
RBI Procedures …..Guidelines …..
Ground Rules …..Competency …..
Training …..Audit …..
Optimized Inspection Interval & Inspection Method for each item,
based on its Damage Mechanisms & Risk profile
Inspection Dept implement – Risk Based Inspection plans
RBI Study defined Operational Limits
Manufacturing Dept implement –procedures to manage operational limits &
notify changes
Inspect item to RBI planReport Inspection findings
RBI Technology Implementation – ‘best practice’ Model
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The multi-discipline RBI Study Team
The RBI study must be carried out by a competent multi-discipline team, themembers of which each have suitable qualifications and experience. Normallythe team membership would be covered by four core disciplines:-• RBI team study Facilitator (RBI and Fitness-for-Service assessment
expertise)• Plant Inspection Engineer or Inspection SME• Plant Operations and Process Engineer• Metallurgist (or Corrosion Engineer)
It is imperative that experienced engineers assigned to the RBI study team and representing core disciplines such as inspection, operations and process must be from the plant site. Industry experience clearly shows that without their commitment and input to the team study, RBI cannot be successfully implemented and managed subsequently
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Damage Mechanisms at Plant Units Fuel Ash Corrosion Overheating – plastic collapse
Sulphidic Corrosion Refractory Damage – pyro-sulphates
Naphthenic Acid Corrosion Refractory Damage – acidic
Localised Corrosion Chlorides – SCC
Crevice Corrosion Caustic – SCC
Pitting Corrosion CO-CO2 – SCC
General corrosion Amine – SCC
Shielding Corrosion NH3 – SCC
Galvanic Corrosion Wet H2S – SCC
Wet H2S Corrosion Wet H2S – HIC & Blistering
NH4HS Corrosion Wet H2S – SOHIC
HCl Corrosion 475C Embrittlement
Dew Point Acid Corrosion Creep
Erosion Creep-Fatigue
Erosion Corrosion Fatigue – vibration induced
Corrosion under Insulation (CUI) Fatigue – pressure cycling induced
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THE ROLE OF NDT INSPECTION IN RBI PROCESS
When RBI process is used to justify extended inspectionintervals, in particular for high consequence items, or extendedplant run-length times between turnarounds, the role of NDTinspection and the accuracy required are very critical and keyimportance.
Need a very good NDT management at the plant site, with aproper interface with RBI system.
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assesses the likelihood and consequence of failure for fixed equipment and piping and produces a relative risk ranking for plant equipment
is convenient to use and can be easily learned as the risk model allows qualitative as well as quantitative input
includes a regular updated database with all relevant damage mechanisms, as well as guidance on formulating the consequence of failure
allows the user to appraise or focus/defocus the likelihood and consequence attributes for each component, eg the level of inspection and maintenance and thus mitigate the risk of loss or optimise the current inspection programme
identifies the most likely damage locations in each component and allows inspection to be properly targeted
determines the risk of failure with time which provides the rational basis for establishing the optimum period between major inspections
Advantages of RBI Methodology
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Design and Materials Selection
CorrosionControl
Risk-BasedInspection
Long Term Asset Integrity
Asset integrity management is a balancing process designed to achieve lowest total cost of ownership
Focused Asset Integrity Reviews
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Industry is recognising that benefit may be gained from more informed inspection. Certain sectors of industry, particularly the refining and petrochemicals sectors, are now setting inspection priorities on the basis of the specific risk of failure. Improved targeting and timing of inspections offer industry the potential benefits of:
• Improved management of Health and Safety and other risks of plant failure.
• Timely identification and repair or replacement of deteriorating equipment.
• Cost savings by eliminating ineffective inspection, extending inspection intervals and greater plant availability.
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API 580 Risk-Based InspectionAPI 581 RBI Technology
API RP 580 introduces the principles and presents minimum general guidelines for developing a RBI program for fixedequipment and piping.
API 581 provides quantitative RBI methods to establish an inspection program.
Together, these two documents comprise a widely-recognized standard for industry-accepted RBI practices.
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An RBI assessment may be used to increase or decrease the 10-year inspection limit described in Section 6.4. When used to increase the 10-year limit, RBI assessment shall be reviewed and approved by a pressure vessel engineer and authorized pressure vessel inspector at intervals not to exceed 10 years, or more often if warranted by process, equipment, or consequence changes.
6.2 RISK-BASED INSPECTION
API-510 Pressure Vessel Inspection Code:
API-570 Piping Inspection Code
5.1 RISK-BASED INSPECTION
When the owner/user chooses to conduct a RBI assessment it must include a systematic evaluation of both the likelihood of failure and the associated consequence of failure. The likelihood assessment must be based on all forms of degradation that could reasonably be expected to affect piping circuits in any particular service.
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• Risk Based Inspection – caution!!!!
Risk Based Inspection
As a word of caution, when it comes to implementing RBIsuccessfully at any plant site, it is the reliability of the RBI technology process used, as well as the comprehensiveness of the
team study method and the people involved in this from the
plant site which deliver the set objectives and goals and not the RBI software”.
The software must not be used to drive the best practices in RBI
technology process or team study method; instead it is a
supporting tool.
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It is critical therefore the senior management at plant site must be committed to support the best practices in RBI and provide the required resources from site and the time allocation for the RBI team study and implementation of the output.
This requires the plant site fully understanding the implications of implementing RBI and most importantly recognising the role it will play in confidently achieving a company’s overall strategic goals.
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Thank You
EQUATE
Petrochemical
Company