safety driven performance conference 2013 supplementing risk basked inspection programs with...
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Safety Driven Performance Conference 2013
Supplementing Risk Basked Inspection Programs with Integrity Operating Windows (IOWs)
Vishal Lagad - Sr. Corrosion EngineerAsset IntegrityLloyd’s Register Energy, Americas
October 9, 2013
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Safety Driven Performance Conference 2013
Venue safety information
• Safety overview • Location of emergency exists
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Safety Driven Performance Conference 2013
Overview
• Review plant reliability goals• IOW and RBI basics• Benefits of an IOW program• Supplementing RBI program with IOWs• Examples in refinery application• Q & A
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Safety Driven Performance Conference 2013
Plant Reliability Goals
• Ensure equipment performs it’s required functions for a specific time period
• Maximize equipment availability
• Optimize maintenance
• Reduce risk and potential for leak/rupture
• Provide early recognition of equipment risks due to process deviations
• In short - No surprises!
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Safety Driven Performance Conference 2013
Risk Based Inspection - RBI
• Uses past operating conditions and inspection data to make future predictions
• Captures risk at a snap shot in time
• What happens when process conditions change?
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Safety Driven Performance Conference 2013
Existing Industry Standards
• Importance of monitoring operating conditions
• API RP 580 Section 6.4
• “It may be worthwhile to monitor key process parameters to determine whether operations are maintained within boundaries”
• API 510 Section 6.2
• “The likelihood of failure assessment should be repeated each time equipment or process changes are made”
• API 584 – Best practices, guidelines for IOWs
• Second Draft in review
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Safety Driven Performance Conference 2013
Process & Operational Impact
• Processes are not always stable• Feedstock variations• Upsets
• When changes to operating conditions affect key process variables
• New damage mechanisms may be introduced • Corrosion rates may accelerate
• These excursions are typically unaccounted and their impact not considered
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Safety Driven Performance Conference 2013
IOW Concepts
• IOWs are allowable operating limits for a process variable
• Established to manage corrosion and other damage mechanisms
• Different from SOL, Alarms for Pressure integrity (MAWP etc.)
• Requires a response within established timeframes if limit is exceeded
• Failure to bring the operating condition within the IOW limit within established timeframe will result in damage to the equipment outside of acceptable limits
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Safety Driven Performance Conference 2013
IOW Limits
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Safety Driven Performance Conference 2013
Early failure
Expected Remaining Life
IOW – Standard High
IOW – Critical High / SOL
Acceptable Risk LevelExpected Risk Profile
Time (years)
Rem
aini
ng
Life
(yea
rs)
Risk
Tem
pera
ture
Actual Remaining
Life
0 4 10 25
Breached IOW level for 3 months
An Illustration
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Safety Driven Performance Conference 2013
Benefits of an IOW Program
• Proactive approach to managing reliability and risk
• Real time notification of an increased risk
• Allows for timely intervention when process conditions change
• Extends operating life of an asset
• Enhances safety
• Cost savings - reduced inspection costs and capital expenditures
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Safety Driven Performance Conference 2013
IOW Implementation Team
Multidisciplinary team of SME’s
•Corrosion Engineer / specialist
•Process Engineer
•Reliability Engineer / RBI specialists
•Operations personnel
•Plant inspector
•Others – chemical treatment vendor, license technology specialists
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Safety Driven Performance Conference 2013
Steps in Establishing an IOW Program
• Collect and review data
• Create corrosion loops or circuits
• Corrosion study
• Damage mechanism review
• Establish IOW Limits
• Implement IOW program
• Identify actions and responsibilities
• Process historian and Alarm configuration
Collect and Review Data
Create Corrosion Circuits / Loops
Corrosion Study and IOW Limits
Implement IOW Program
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Safety Driven Performance Conference 2013
Create Corrosion Loops / CircuitsAreas that have similar operating conditions, corrosion mechanisms, and materials
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Safety Driven Performance Conference 2013
Implement the IOW Program
• Recommend Standard, Critical, and Informational limits
• Select response times for each IOW limit based on IOW Risk Matrix
• Other Considerations
• Review IOW limits in conjunction with operating limits already established for safety (e.g. via HAZOP) and product quality before implementing
• Consider instrumentation currently in place and sampling points
• Client participation and commitment is essential
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Safety Driven Performance Conference 2013
Example - IOW for Creep Damage in Heater Tubes
• Heater coils not susceptible to creep under normal conditions
• Flame instabilities can create locally hot areas
• Fouling can result in greatly reduced heat transfer
• Result – temperatures exceeding creep threshold temperature
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Safety Driven Performance Conference 2013
Creep Damage in 321 SS Heater Tubes
• Normal TMT T = 800 °F
• Lower limit for creep T = 1000 °F (API 579)
• Design temperatureT=1050 °F
• 2000 hour (12 week) creep life T = 1210 °F (API 579 Omega)
• Rapid deterioration T >1450 °F (API 530)
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Safety Driven Performance Conference 2013
Supplementing RBI - Risk Matrix for Assessing IOWs
• IOW Limit: Critical: 1210 ˚F
Standard: 1050 ˚F
• Response times: Critical IOW: 60 min
Standard IOW: 24 hr
Creep threshold: T = 1000 °F
Design temp: T=1050 °F
2000 yr. creep life: T=1210 °F
Rapid deterioration: T >1450 °F
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Safety Driven Performance Conference 2013
Another example of IOWs – much closer to the heart!
High Blood Pressure33.6% of US adults 20 years of age have hypertension.
The prevalence of hypertension is nearly equal between men and women.
Approximately 78% are aware of their condition, 68% are using antihypertensive medication, and only 44% of those treated had their hypertension controlled.
Controllable variablesObesity /Sedentary lifestyle
Tobacco / Alcohol abuse
Excess dietary sodium
Excessive alcohol intake
Stress
Cholesterol
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Safety Driven Performance Conference 2013
An “RBI Approach” + IOWs for Healthcare!
• Traditional RBI Approach• Assess individuals aged above 40• Focus on family and medical history• Treat symptoms with medications
• Incorporating IOWs • Yearly annual checkups for all age groups• Preventive care education – focus on monitoring
• Physical activity• Eating habits• Stress• Cholesterol levels• Smoking / Alcohol abuse
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Safety Driven Performance Conference 2013
IOW Limits - Other Considerations
• Is the limit practical – are operators constantly going to be responding to alarms?
• Balance between constantly reacting to alarms and having enough response time to prevent damage
• Consider which instruments or controls are already in place that could be used for monitoring
• Consider using information limits that do not generate operator alarms but capture and document a deviation
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Safety Driven Performance Conference 2013
Summary
• IOWs enhance traditional RBI programs by providing a proactive approach to managing reliability and risk
• Implementing an IOW program can provide better control and more confidence in managing the damage mechanisms
• Permits alternative feedstock/operations considerations by more clearly understanding the operating limits
• Can lead to improved facility safety and cost savings in terms of inspections and capital expenditures
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Safety Driven Performance Conference 2013
Thank you – Questions?