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Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Risk Based Inspection and Maintenance in Central Eastern Europe - Experience at the Hungarian Oil- and
Gas Company
Dr. Gyöngyvér B. Lenkey(BAY-LOGI, Hungary)
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Event based
Timebased
Conditionbased
Development of Development of maintenancemaintenance
strategiesstrategies
Reliabilitybased
Risk based
1950 1960 1980 1990 1995
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Risk matrix – modification of riskConsequence of failure
Prob
abili
ty o
f fai
lure
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
RBI application trend in Europe
RBI is approved
RBI is under way
RBI is not approved
At MOL – first time in Hungary!
Slovnaft (SK) isgoing to implement
as well!
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Basic objectives of the MOL project:
Condition-monitoring System for Pressurised Equipment
To reduce the number and length of the unplanned shut-downs,To increase the ratio of the planned maintenance work,To extend the shut-down periods,To provide fast and accurate access to system data for development, inspection and maintenance tasks,To optimise (minimise) the maintenance costs taking into account the expected level of system reliability.To implement the system for more than 50 units!!
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
InernationalInernational cconsortionsortiumumBAY-LOGI Bay Zoltán Foundation
Bureau Veritas France
R-Tech Germany
Facility Manager Ltd. Hungary
K-ép Stúdió Hungary
AGMI Plc.- Mat. Testing Lab Hungary
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Basic technical functions of the MOL System: defined by the
maintenance strategy of MOLInspection planning on the basis of RBI(Risk Based Inspection) strategy. The RBI methodology is based on API 581standard.Maintenance program planning based on RCM (Reliability Centered Maintenance) strategy.
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Structure of the Condition-Monitoring IT System
EXPERT SYSTEM SHELL
CADMATIC softwarer: - 2D and 3D
RCM database
software
RBI software
(API)
- Level I. - Level II. - Level III.
Existing MOL systems
(SAP, FIR)
User: MOL
Data exchange (e.g.. XML, Excel, Access)
DATABASE
Additional expert system
modules
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
DatabaseWEBPLM software:
Equipment-Inspection–Documents:– Unit– Equipment– Sub-equipment– Safety valves– Inspected piping– Inspection location identification– Material and other specific data– Inspection plans and results– Drawings, P&ID, PFD– Paper based documentation
(digitised)– RBI and RCM analyses results
and expert reports
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
3D model
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
RBI analysis RCM analysis
Qualitative an.(Level I):
- Unit based- Equipment based
Selected items
Failure mechanisms and effect analysis (FMEA)
Failure classification
Failure characteristic analysis (FCA)Inspection
program
Maintenance strategy selection
Level II Level III
Auxiliary functions (moduls)
Preparation of inspection plans
Trends
Query, riports
Identification of new failure
mechanisms
Corrosion defect assessment
Crack-like defect assessment
Failure case database
WEBPLM- database
Expert system
database
Expert system/WEBPLM
database
Expert system/WEBPLM database
WEBPLM- database
Expert system/WEBPLM database
Expert system
database
Expert system
database
Structure of the Expert System
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Inspection planningand evaluation
Selection ofequipment
RBI analyses(Level I, II or/and III)
Inspection plans(inspection locations, selection of
inspection methods)
Issuing inspectioninstructions
Performing inspections,uploading inspection data
Documentation andevaluation of inspections
R-Tech software,RB.eye software
WEBPLM
WEBPLM
WEBPLM
WEBPLM
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
RBI analysis
Analysis levels:– Level I: qualitative:
• Few input data• Based mainly on expert judgement (qualitative classification)• Mainly for selecting critical equipment, ranking of equipment
– Level II: semi-quantitative analysis: • More input data, but partly not accurate numbers (intervals)• Expert knowledge, judgement is needed
– Level III: detailed quantitative analysis:• Accurate data, many input data • More automatism, more modelled failure mechanisms (mainly
corrosion)
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Qualitative risk analysis for each equipment and inspected piping:
Risk matrix-Comparison of units
Unit-1 Unit-2
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Process of risk analysis and inspection planoptimization
Quantitative analysis
Data collection
Risk calculation
Inspection data analysis
Equipment analysis and breakdown
Acceptable risk?
Acceptability criteria
Process data
Process data
Inspection data
Inspection data
Material data
Material data
General data
General data
Process analysis
Damage mechanism evaluation
Inspection history,
initial insp. strategy
Inspection data
analysis
Risk calculationData input
Inspection strategy
Yes:Valid inspection strategy
No:Modify inspection parameters / optimization
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Analysis of inspection history –risk calculation before the inspection
Risk matrix
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Evaluation of future risk –without inspection
Risk levelchanging w
ith time
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Inspection program definition –future risk can be decreased
Effect of inspection
programon risk level
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Comparison of unitsRes ults o f quantitative RBI analys is
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Unit1 Unit2 Unit3 Unit4 Unit5
Units
LowMediumMedium-highHigh
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Comparison of analysis levelsLevel III.
(for selected equipment)Level I.
5 16 1 - 2.86%
4 5 22, 24 15 4 - 11.43%
3 32, 4 3 10, 12, 14, 18, 26, 20
7, 29 11 - 31.43%
2 8, 28, 30 9, 11, 17 1, 6, 2, 13, 25, 19, 27, 21, 23
15 - 42.86%
L I K E L I H O O D
1 31, 33, 34, 35 4 - 11.43%
A B C D E
2 - 5.71% 1 - 2.86% 6 - 17.14% 11 - 31.43% 15 - 42.86% 35
C O N S E Q U E N C E S
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Preparation of inspection plans -WEBPLM
MOL Rt. TDK Finomítás, Százhalombatta 174 jelű HDS üzem; 100-as blokk Vizsgálati terv
Készítette:
Tóth László
Készült:
2004. 05. 18.
W-105.2 jelű Cirkulációs gáz utóhűtő Gyári szám: 34767 Gyártó vállalat: IAB Leipzig Gyártás éve: 1993 Veszélyességi osztály: ...
A k é s z ü l é k a d a t a i köpenytér csőtér
Tervezési nyomás [bar] 89 5 Engedélyezési nyomás [bar] … …
Üzemi nyomás [bar] 71 3 Tervezési hőmérséklet [°C] 120 50
Üzemi hőmérséklet [°C] 46 45 Térfogat [m3] 5.20 …
Közeg Cirkulációs gáz+könnyű szénhidrogén (bázikus)
Víz
Anyagminőség St. 355 St 37.4
3400
8890
O1620
P2BP3B
P1BP2AP4BP3A
P1AP4A
P7B
P8B
P7A
P8A
P6AP8A
P1AP4A
P5B
P6BP5A
P6A
P1BP2A
P3B P2B
P4BP8B
P7B
P3AP7A
P8AP4A P1A
Felülvizsgálati helyek és módszerek
Szerkezeti elem Mérési hely Mérési eljárás
Köpeny A, B, C, D TT1 Csonkok (P1A,P1B, P2A, P2B) A, B, C, D TT Készülék belső varratoldalon Varrat találkozások 150-150 mm, + az
edény közepén 300 mm-es hosszban MT
2 kijelölt helyen ST2 Csövek 20 % ET Belső felület VT
1 A belső felület szemrevételezéses vizsgálata (VT) alapján kijelölve. A kijelölt TT mérési helyekre a külső felületen mérési helyeket lehet szükségszerűen kialakítani. 2 Szemrevételezéses vizsgálat (VT) alapján kijelölve azon helyeken (min 2db.), ahol érzékelhető lokális belső korrózió indult meg. A kijelölt ST mérési helyeket fel kell tüntetni a külső felületen.
Preparation ofinspection plans
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Evaluation of inspection results, documentation
Corrosion trend
Assessment of corrosion defects
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Planning other maintenance tasks - RCM
Reliability Centered Maintenance (RCM) is a logical, systematic decision making process for defining optimum maintenance tasks:– An auxiliary method to RBI, since both considers the
probability and the consequence of a possible failure. – Evaluation of the failure probability is based on failure
statistics. – Evaluation of consequences is based on expert judgement. – The result of the evaluation is obtained by the decision of an
expert team, using a systematic analysis. – It is used typically for those functions that are not covered
by RBI and related NOT to containment and transport(e.g. reactors, furnaces, fin-fan coolers, heat-exchangers)
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Number of RCM analysis in the pilot phase
Unit Number of
RCM analysis
Number of identified functions
Number of possible failure
modes
Number of failure modes
covered by RBI
Number of failure modes related to
the functional failure of the
control system
Number of failure modes related to
the failure of other equipment
Unit1 2 5 13 6 0 2 Unit2 13 30 96 19 17 30 Total: 15 35 109 25 17 32
Many failure modes are related not to the equipment itself, but to the instrumentation (which was not subject of the project)
Importance:– operational experiences can be documented and stored– maintenance tasks can be optimised and aligned
Detailed RCM is very time consuming ⇒ needed to use a simplifiedRCM (based on classification of equipment and failure modes)
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Some initial experiencesThe shutdown period is in many cases determined by the technology, not by the inspection need (e.g. fouling of heat exchangers)Significant part of the overhaul cost is related to the opening up of the equipment – but it can be necessary due to technological reasons (e.g. need to clean heat exchangers’ tubes in every 4 years)Economical benefit (it is difficult to assess after that short period) – main achievements so far: to reduce slightly the number of unnecessary inspections (e.g. UTFor less critical units the possibility of the extension of the shutdown period is realistic
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
Main benifits – so far To collect and update the equipment dataAll the data and documents of the equipment and piping are collected and stored in a structured database – data availability for many peopleTo document the state and the possible failure mechanisms of equipment in a reproducible wayThe whole inspection planning process is more transparentOptimisation of the inspection efforts – e.g. to reduce the extent of unnecessary UT
Bay Zoltán Foundation for Applied ResearchInstitute for Logistics and Productions Systems BAY-LOGI
SummaryAt MOL Plc. the RBI methodology has been implemented first time in HungaryA complex system has been developed with which: – Economical condition-monitoring can be realised, – Up-to-date information can be acquired,– Supports the maintenance-inspection activity and their cost
optimisation,– Which can be adapted to other industrial sectors (power,
chemical, pharmaceutical, etc. – considering the results of the RIMAP EU project – CEN Workshop Agreement!)