Prevention vs. Reaction The Importance of Asset Integrity

Transcription

1 Prevention vs. Reaction The Importance of Asset Integrity

2 How Your Assets Typically Age Inspections Potential Failure Condition Functional Failure Time P-F Interval

3 Why is Asset Integrity so Important? Sulfidation corrosion Stress corrosion cracking High velocity erosion High temp hydrogen attack Underside tank floor Corrosion Corrosion under insulation If not managed properly, they all have the same outcome.

4 We Want to Avoid this

5 Maintaining Compliance

6 Maintaining OSHA and EPA Compliance with Asset Integrity

7 What Type of Inspections?

8 Inspections for Oil & Gas / Chemicals ECOGNIZED ND ENERALLY CCEPTED OOD NGINEERING Your plant should be inspected based on the design code that it was built to and the damage mechanisms it is susceptible to there is no one size fits all here RACTICES

9 Overview of Non-Destructive Testing (NDT) Evaluating the properties of a material, component or structure without doing damage. Other terms Non-Destructive Evaluation (NDE) Non-Destructive Inspection (NDI) Non-Destructive Examination (NDE) NDT is a highly valuable technique that can save both money and time in equipment evaluation, troubleshooting, and research because it doesn t permanently alter the article being inspected. Must be done by certified individuals/companies

10 Non-Destructive Testing (NDT) Uses To assist in product development To screen and sort incoming materials ( Raw Materials) To monitor, improve or control manufacturing processes To verify proper processing (Example: Heat Treating) To verify proper assembly To inspect for in-service damage

11 Popular NDT Methodologies Ultrasonic (UT) Radiography (RT) Ultrasonic Shear Wave Visual (VT) Certifications & Non-Destructive Testing Methods Utilized Eddy Current (ET) Magnetic Flux Leakage (MFL) Penetrant (PT) Magnetic Particle (MT)

12 Visual (VT) Inspection Visual is the most basic and common inspection method Robotic Crawlers Borescope Fiberscope Magnifying Glass. Mirrors

13 Liquid Penetrant (PT) Inspection Penetrant Crack Developer Interpretation Application Cleaning Developing Interpretation

14 Magnetic Particle (MT) Inspection The part is magnetized. Finely milled iron particles coated with a dye pigment are then applied to the specimen. These particles are attracted to magnetic flux leakage fields and will cluster to form an indication directly over the discontinuity. This indication can be visually detected under proper lighting conditions.

15 Radiography (RT) Inspection The part is placed between the radiation source and a piece of film. The part will stop some of the radiation. Thicker and more dense area will stop more of the radiation. The film darkness (density) will vary with the amount of radiation reaching the film through the test object. X-ray film = less exposure = more exposure Top view of developed film

16 Radiography (RT) Inspection Examples Naked Eye Naked Eye Naked Eye Inspection Result Inspection Result Inspection Result

17 Eddy Current (ET) Inspection Eddy current testing is particularly well suited for detecting surface cracks but can also be used to make electrical conductivity and coating thickness measurements. Here a small surface probe is scanned over the part surface in an attempt to detect a crack.

18 Ultrasonic (UT) Inspection High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws. Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect sound. initial pulse crack echo back surface echo crack plate Oscilloscope, or flaw detector screen

19 Processing Plant Inspection Tube & Shell Heat Exchangers Tube with damage Eddy Current (ET) Inspection Periodically, 190P Condenser power plants, refineries, chemical August 1, 2015 plants, biofuels plants and other industrial processing plants are shutdown for inspection. Inspectors feed eddy current probes into heat exchanger tubes to check for corrosion damage. Signals produced by various amounts of corrosion thinning. Probe

20 Processing Plant Inspection Storage Tanks Robotic Crawlers - use ultrasound to inspect the walls of large above ground tanks for signs of thinning due to corrosion Camera - long articulating arms are used to inspect underground storage tanks for damage. Magnetic Flux Leakage use a magnetic field to map the top and bottom side of tank floors to identify corrosion

21 Processing Plant Inspection Piping & Pressure Vessels The failure of piping and pressure vessels can result in the rapid release of a large amount of energy. To protect against this dangerous event, the vessels can be inspected using many types of NDT including UT, RT, MT, PT, ET, VT and others your specific corrosion mechanism will define what s best for your situation!

22 Findings from Inspections in Oil & Gas / Chemicals Industry 1 2 3

23 Findings from Inspections in Oil & Gas / Chemicals Industry 4 5 6

24 Findings from Inspections in Oil & Gas / Chemicals Industry 7 8 9

25 Findings from Inspections in Oil & Gas / Chemicals Industry

26 Findings from Inspections in Oil & Gas / Chemicals Industry

27 Findings from Inspections in Oil & Gas / Chemicals Industry

28 Findings from Inspections in Oil & Gas / Chemicals Industry

29 Findings from Inspections in Oil & Gas / Chemicals Industry

30 Why Should you Care?

31 Fines / Citations EPA $37,500 up to $320,000 plus, depending on release size and how much your company benefited from not following regulations. OSHA Willful or Repeat Up to $70,000 per violation OSHA Other Than Serious Up to $7,000 per violation OSHA Serious Mandatory Minimum of $7,000 per violation

32 A Property Claim Will Cost You! INSURANCE COSTS Fully-Insured Oil & Gas / Chemicals Companies Property Damage Deductible (Generally $100,000 to $250,000 depending on company size and risk tolerance) Business Interruption Deductible (Generally 5 to 15 day Average Daily Value or no profit of continuing expenses paid) Self-Insured Oil & Gas / Chemicals Companies Pay total cost to rebuild Has no profit or continuing expenses covered while rebuilding

33 Other Costs (Uninsurable Portion) Legal / Attorney Insurance Employee Public Customers Production Civil Fees Rate Increases Lose Positive Morale Perception becomes Negative Contract Elsewhere Efficiencies Lawsuits

34 But it is OK because DUMB THINGS HAPPEN 100% of property damage events (excluding acts of God) are preventable Many of them will be prevented because of your Maintenance Activity

35 So What Can You Do? Educate yourself & company management Understand and explain your corrosion mechanisms Understand & explain legal requirements Understand and explain how this is about reliability, continued operations and compliance and how it is much more that a Check the Box activity Seek examples (To build your case) Other similar instances in Oil & Gas / Chemicals or in similar industries (some provided here, but can give you more fuel) Loss control, reliability, safety and compliance with regulatory agencies is the right thing to do, but it has also proven to be a very smart financial business decision

36 For more Information: (316) N. First Street Colwich, KS