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Process and Critical Equipment Conference 24 th & 25 th September 2013

Integrity Management of Critical Equipment in the Digital Era

September 2013

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IntroductionNavigation through the Paper

The Necessity for Integrity Management; Challenges for RBI Methodologies; KPO RBI Methodology; Future Development.

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The Necessity for Integrity Management (1)Key Purposes of Integrity Management

Integrity Management is necessary to ensure that criticalequipment are managed in such manner that:

Maximises Process Safety;

Protects the Environment ;

Maintains Statutory Compliance ;

Ensures Business Viability through plant reliability;

Maintains the Corporate Reputation .

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The Necessity for Integrity Management (2) Key Elements of Asset Integrity Management

Asset Integrity Management

MechanicalIntegrity

FunctionalIntegrity

OperationalIntegrity

The Ability of theasset to withstandthe designmechanical load.

Includes:PressureEquipment;Piping;Structures.

The Ability of theasset to performits requiredfunction effectivelyand safely.

Includes:Safety CriticalProcess ControlSystems;Safety Valves,HIPPS Systems;Gas DetectionFire DetectionFire Fighting Ept.Etc.

The Ability of theasset personnel tooperate the asseteffectively andsafely.

Includes humanfactors such as:Operator training;Competence;ManagementSystems;ReportingSystems;

Anomaly tracking

Technical Integrity

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The Necessity for Integrity Management (3) Traditional Inspection versus Integrity Management

Traditional Inspection Asset Integrity Management

Focus Mechanical IntegrityMechanical IntegrityFunctional Integrity

Operational Integrity

ToolsPrimarily Visual Inspection &

Hydrotest

Risk Assessment, Inspection (primarilyvisual and NDE), process data, operatinghistory, inspection history, maintenancehistory, remaining life prediction, Fitness

For Service Assessment

FrequencyAll items inspected on a similar

frequencyHigh risk items inspected more frequently;

low risk items inspected less frequently

EffortAll items receive similar

inspection effortHigh risk items inspected more intensively

than low risk items

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Based on :Hirschberg, S., Burgherr, P., Spiekerman, G., Dones, R., Severe accidents in the energy sector: comparative perspective, Journal of Hazardous Materials, Elsevier, April 2004,pp57-66 ; and http://www.hse.gov.uk/offshore/statistics/stat1011.htm, Offshore Safety Statistics Bulletin 2010/11, UK HSE .

The Necessity for Integrity Management (4) Prescriptive Legislation versus Goal Setting Legislation

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Challenges for RBI Methodologies (1) Introduction

Risk based inspection is the explicit use of risk assessment to

define inspection activity.

Effective RBI, therefore, needs to identify all pertinent damagemechanisms for each pressure vessel and pipe, the likelihood oftheir occurrence and the consequence of any resultant failure .

The Quality of the RBI Risk Assessment is a Key Success

Factor for Integrity Management ofCritical Equipment.

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Challenges for RBI Methodologies (2) The RBI Process

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Challenges for RBI Methodologies (3) Type of RBI Methodology

Qualitative RBI Based primarily upon expert judgement using small, multi-discipline teams; Requires little data; Can employ experiential knowledge from actual operational plant.

Semi-Quantitative RBI Based primarily upon simplified quantitative calculations; Requires simple data; Can be over simplified & conservative; Cannot employ experiential knowledge from actual operational plant.

Quantitative RBI Based on fully quantitative calculations; Requires detailed data; Cannot employ experiential knowledge from actual operational plant.

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Challenges for RBI Methodologies (4) Code & Recommended Practice Compliance

API RP 580: 2009, Risk Based Inspection General RBI Guidelines No specific methodology defined Universal application Almost all RBI methodologies (both good and bad) comply

Compliance cannot provide any assurance of RBI quality

API RP 581: Risk Based Inspection Technology Detailed RBI Methodology Very specific calculations defined Compliance does offer assurance of RBI quality Can only be applied to single component fluids and so is not applicable for

most Critical Equipment in oil and gas facilities

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Challenges for RBI Methodologies (6) RBI Accuracy (1)

RBI Accuracy is the ability of the RBI methodology to accurately

define both the consequence and the likelihood of a failureoccurring.

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Challenges for RBI Methodologies (7) RBI Accuracy (2)

Risk Profile for a Plant Wide Qualitative RBI Assessment(1 = Extreme; 2 = High; 3 = Medium; 4 = Low; 5 = Negligible).

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Challenges for RBI Methodologies (8) RBI Consistency (1)

RBI Consistency is the ability of the RBI methodology to produce

results which are repeatable and consistent. It may be evaluatedin two ways:External Consistency : How close the RBI Consequence and LikelihoodAssessment results agree with similar external or independentcalculations;

Internal Consistency : How close the RBI Consequence and LikelihoodAssessment results for one item agree with those for similar items inthe RBI assessment for the facility.

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Challenges for RBI Methodologies (9) RBI Consistency (2)

TAG Vessel 1 Vessel 2

Contents: Acid Gas (H 2S = 42 mol. %) Process Water (Trace H 2S)

Phase: Vapour Liquid

Flammable (Y/N) Y N

Inventory (Kg) 150 205,300

Pressure (BarA): 3.5 1.2

Temp. ( C) 60 68

Qualitative CoF Rank 3 Medium 2 High

Safety Hazard Area (m 2) 260 2.7

Semi-Quantitative CoF Rank 2 High 4 Low

Conclusion on Qualitative RBI CoF Underestimated CoF Overestimated

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Challenges for RBI Methodologies (10) Efficiency of Implementation

Qualitative RBI

Based primarily upon expert judgement, obtained through group discussion; Depends on intuitive judgements by experts that know the plant well; Requires only basic data; Very easy to initiate; Group discussion is very time consuming 1.

1) It is estimated that an effective assessment of KPOs Karachaganak facility would occupy a multi-discipline team

full-time for about four years.

Semi-Quantitative RBI Based primarily upon simplified assessment modelling; Simple data is available from standard engineering documents which can often be

captured electronically into the RBI assessment model; Assessments are very rapid.

Quantitative RBI Based on fully quantitative calculations using complex data; Data collection is prohibitively long for plant wide RBI.

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Challenges for RBI Methodologies (10) Auditability

Qualitative RBI

Although the RBI results are recorded, full records of the group discussion are rarelycaptured; It is possible to audit the RBI assessment to determine the assessed risk,

Consequence of Failure, and Likelihood of Failure; It is often not possible to determine the precise reason for the risk, Consequence of

Failure, and Likelihood of Failure results.

Semi-Quantitative RBI Full set of calculations performed; System is fully auditable.

Quantitative RBI Full set of calculations performed; System is fully auditable.

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KPO RBI Methodology (1) Introduction

The Modern Digital Era allows rapid application of accurate, consistent and

fully auditable semi-quantitative RBI systems; KPO elected to use an expert semi-quantitative system; In order to capture experiential knowledge from actual operational plant,

including upset or abnormal operation, KPO uses an Authoritative Reviewby technical experts to challenge the semi-quantitative RBI results;

The KPO system is based on API 581: 2008, but is modified to:a) Allow dispersion modelling of multi-component fluids;b) Add additional and more robust likelihood models;c) Simplify the Likelihood of Failure assessment by eliminating hole sizes;d) Simplify the Risk Assessment by using semi-quantitative models to determine

specific Risk Ranks in a 5 x 5 Risk Matrix

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KPO RBI Methodology (2) Consequence of Failure Assessment

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KPO RBI Methodology (3) Likelihood of Failure Assessment

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KPO RBI Methodology (4) Risk Matrix

The Risk Matrix is skewed in favour of Consequence of Failure

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KPO RBI Methodology (5) Authoritative Review

KeyBlue: As new condition

Green: Low rate of deterioration

Yellow: Medium deterioration rate(minor repairs anticipated).

Orange: :Significant deterioration rate

(major repair anticipated);

Red :High rate of deterioration(major repair necessary now).

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KPO RBI Methodology (6) Inspection Planning

Confidence Factor is based on IP 12 & IP 13 Inspection Grades

using the following criteria:Number of previous inspections (more inspections = more confidence)Previous inspection findings (less deterioration = higher confidence)Predictability of operation (higher predictability = higher confidence)

Inspection Intervals use maximum recommended intervalsdefined by the Safety Federation (SAFed) for the lowest riskitems.

Inspection Intervals for higher risk items is progressively

reduced from the SAFed recommended intervals according tothe risk rank.

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Future DevelopmentThe Use of Real Time Data in Integrity Management

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ConclusionsBringing the Pieces Together

Risk based inspection planning has greatly improved asset integrity

management of large complex plant. Many of the methods employed are:

Qualitative in nature;Lack consistency and repeatability;Are time consuming to apply;Are slow to react to changing plant operating conditions andfeedstocks.

Modern digital techniques offer the possibility of a robust yet rapid RBIassessment.

Linking predictive RBI tools to real-time operating data gives the potentialto predict the influence of changing operating variables as they occur, andoffers great potential for flexible plant operation.