A

C

D

P

R

Risk-Based

Inspection/Maintenance

Plan

Do

Check

Action

Completeness, predictability and logicality of

Maintenance management

Maintenance method by TECHNO-WINGS

Construction Design

Request for strategic maintenance in RCM, RBM, RAM scheme

Disposal

(Life cycle is 50 to 60 years or more)

P:Maintenan

ce plan

D:Inspection &

construction

A:Maintenan

ce standard

C:Maintenance

analysis

Operation & Maintenance

Aging facilities; increase the importance of maintenance

Disclosure of damage cases

Optimization of maintenance method

Optimization by long-term continuous operation

Completeness of aging deterioration management

Conventional maintenance cycle

Maintenance by RBI / RBM

Plan Do

Action Ceack

1. Evaluation of the

likelihood of deterioration /

damage

2. Maintenance technology

effectiveness evaluation

3. Impact Assessment of

damage

Conventional maintenance A new maintenance cycle incorporating RBI / RBM

Maintenance loop proposed by TECHNO-WINGS

Process diagram of atmospheric distillation unit for study of RBI / RBM

RT～140℃ 240～260℃

280～380℃

Crude oil tank

Ｃｒｕｄｅ

colu

mn

Heavy oil

LPRBM- 01

RBM- 02 RBM- 03 RBM- 04

RBM- 05

RBM- 06

RBM- 07

RBM- 08 RBM- 09

RBM- 10

260～380℃

RT

30～150℃

150～320℃

・Sulfide

・Chloride

・water

・Alkali

・Sulfide

・Chloride

・Naphthenic acid

・Sulfide

・Chloride

・water

・Hydrogen sulfide

150～320℃

RBM- 11

・Sulfide

・Naphthenic

acid・Hydrogen

・Sulfide

・Chloride

・Hydrogen sulfide

・Caustic soda

30～150℃

30～50℃

1.0 - 1.5Mpa

1.0 - 1.5Mpa

0.02 - 0.2Mpa

0.08 - 0.21Mpa

0.08 - 0.21Mpa

Ti Clad

SUS405

SUS405

クラッド

1.25Cr-0.5Mo

Ti Tube

Ti Tube

ConcreteLining

1.0 - 2.0Mpa

5.0Cr-0.5Mo

C-steelKerosene

Diesel

Heavy Diesel

2,9,46,47

A-2,3,14

2,9,18,19,20,46,47,61 A-2,3,14

9,18,19,20,46,61 A-2,3,14 1,3,5,6,9,18,14,17

18,19,20,23,39,44,461,3,5,6,1720,23,33,46A-19

8,9,46A-19

2,5,8,9,20,46,47,48,57

2,5,8,9,20,46,47,48,57

2,8,9,20,46,47

8,9,20,46,47A-2,3,14

1,6

2,18,1946,47

18,19,46,47

0.1 - 1.5Mpa

NaOH

NaOH

coating + neutralizer

coating + neutralizer

coating

Damage factor

・Sulfide

・Chloride

・water

・Alkali

・Sulfide

・Naphthenic acid

・Hydrogen

・Sulfide

・Chloride

・water

・Hydrogen sulfide

・Hydrogen

・Sulfide

・Chloride

・Hydrogen sulfide

Desalter

1 19 47

2 20 48

3 22 57

5 23 61 Sulfate Stress Corrosion cracking

6 30

8 33

9 39 A-1

11 42 A-2

14 44 A-3

17 45 A-14

18 46 A-19

885°F Embrittlement

Chloride Stress Corrosion Cracking (Cl-SCC)

Amine Cracking

Ammonia Stress Corrosion Cracking (SCC)

Sulfidic Corrosion (Sulfidation)

Creep/Stress Rupture

Polythionic Acid Cracking

Naphthenic Acid Corrosion

Ammonium Chloride Corrosion

Decarburization

Caustic Cracking

Amine Corrosion

Fuel Ash Corrosion

Dissimilar Metal Weld (DMW) Cracking

Corrosion under Insulation (CUI)

Refractory Degradation

Caustic Corrosion

HCl Corrosion

Oxidation

Erosion/Erosion Corrosion

Short Term Overheating

CO2 Corrosion

Crevice Corrosion

Under-deposit Corrosion

Wet H2S Damage (Blistering/HIC, SOHIC, SSC)

Atmospheric corrosion

Overlay Disbonding

Titanium Hydriding

General Corrosion

Pitting Corrosion

Key to Damage Mechanisms;

Risk-based maintenance plan for development

Engineering Data Collection & Review

Process & Components Material Review

Equipment Selection

Identification of Probable Damage Mechanism

Inspection Interval Decision

Interval Factor Decision

COF Assessment

Remaining Life & Corrosion Rate

Estimation

POF Assessment

Risk Assessment

Inspection Plan Development

High, Medium, Low

Risk

slight,Negligible

Risk

Age-related

Age-related Non age-related

Non age-related

Equipment factor /

operation factor (process

characteristics, operation

conditions, operation

management)

・Unacceptable risk

Secondary risk ranking

・Maintenance period set

and documented Responding to future issues

・Design books

・Maintenance

inspection

・Operation · daily

maintenance

・Classification

of importance

from environment,

production,

quality, security

・COF and POF due

to FEMA

Primary risk ranking

Worksheet for maintenance planning by RBI / RBM of the Desalter (1/2) Continuation

Damageprobability

Corrosionrate(mm/y)

Sensitivity

① Deterioration of O- Ring Viton 6.7 x 10- 1 Very High Very High

①- 1 Local corrosion of the adapters SUS- 312L 6.7 x 10- 1 0.025 Very High Very High

①- 2Entrance bushing (Deterioration ofTeflon)

Teflon Moderate Medium

2 Electrode plate ② Deterioration of the electrodeplates

FRP 1.4x10- 2 High High

②- 1Hanger support (Deterioration ofTeflon)

Teflon Low Low

3 Hanger straps ③Local corrosion of the electrodeplate straps

SS400Max

「0.22,0.6]High Very High

④ Local corrosion 1.0x10- 2 High High

④- 1 Fouling Very Low Very Low

5 Bolt & Nut ⑤ Fatigue failure C- Steel,SUS Very Low Very Low

6 Shell plate bottom ⑥ Hydrogen induced cracking SPV355 Very Low Very Low

7 Shell plate bottom ⑦ Macrocell corrosion SPV355 Very Low Very Low

8 Shell plate bottom ⑧ Sulfide stress corrosion cracking SPV355 Very Low Very Low

9 Shell plate bottom ⑨ Deposition of scale SPV355 Moderate Medium

4 Internal piping SUS- 304

Evaluation(for

likelihood)

1Seal Components ofthe electricalequipment body

No. Components name Damage mechanisms Materials

Failure probability between the SDM- SDM

Quantitative, Qualitative

Worksheet for maintenance planning by RBI / RBM of the Desalter (2/2)

Remarks

a ; Maintenance grades defines a scope for opening of equipment.

b ; Maintenance period defines the period of the inspection equipment.

c ; Maintenance period defining the period for implementing the inspection.

Likelihoodof

Failure

Consequenceof

Failure

① Deterioration of O- RingDecreasedfunction

Moderate Ⅴ C Ⅴ- C Replaced Ⅰ C A TBM 4SDM/OSI

①- 1Local corrosion of theadapters

Decreasedfunction

Moderate Ⅴ C Ⅴ- C Replaced Ⅰ C A TBM 4SDM/OSI

①- 2Entrance bushing(Deterioration of Teflon)

Decreasedfunction

Moderate Ⅲ C Ⅲ- C Inspection Ⅱ C A TBM 4 SDM

② Deterioration of theelectrode plates

Decreasedfunction

Moderate Ⅳ C Ⅳ- C Replaced/Repaired Ⅱ C A TBM 4 SDM

②- 1Hanger support(Deterioration of Teflon)

Decreasedfunction

Moderate Ⅱ C Ⅱ- C VT Inspection Ⅱ C A TBM 4 SDM

③Local corrosion of theelectrode plate straps

Decreasedfunction

Moderate Ⅴ C Ⅴ- C Replaced Ⅰ C A TBM 4 SDM

3 Shell plate bottom ④ Macrocell corrosion Leakage significant Ⅰ E Ⅰ- E No actions Ⅰ E A TBM 4 SDM

4 Shell plate bottom ⑤ Hydrogen induced cracking Leakage significant Ⅰ E Ⅰ- E No actions Ⅰ E ACBM+TBM

4SDM/OSI

5 Shell plate bottom ⑥ Sulfide stress corrosion crackingLeakage significant Ⅰ E Ⅰ- E No actions Ⅰ E A TBM 4 SDM

⑦ Local corrosionDecreasedfunction

Moderate Ⅳ C Ⅳ- C NDI/Cleaning Ⅰ C A TBM 4 SDM

⑦- 1 FoulingDecreasedfunction

Insignificant Ⅰ A Ⅰ-A NDI Ⅰ A A TBM 4 SDM

8 Bolt & Nut ⑧ Fatigue failureDecreasedfunction

Insignificant Ⅰ A Ⅰ-A No actions Ⅰ A A TBM 4 SDM

9 Shell plate bottom ⑨ Deposition of scaleDecreasedfunction

Moderate Ⅲ C Ⅲ- C VT Inspection Ⅰ C A TBM 4 SDM

6 Internal piping

Primary riskrankings

Consequenceof

Failure

Seal Components of theelectrical equipment body

No. Components name

2 Electrode plate

1

Risk reduction measures

Countermeasures

Damage mechanisms Secondary risks rankingsa b

Likelihoodof

Failure

Consequence(Economic loss

assessment) SDM/OSI

Failuremode

c

Maintenance planning

Primary

Risk Ranking

Secondary

Risk Ranking

No.1 CD

No.2 CD

WN Water

BL

Unit A

Unit A

Ma

in d

istilla

tion

colu

mn

coating +neutralizer

coating

coating +neutralizer

NaOH

NaOH

2.MTBF primary Risks rank

1.MTBFTBM

3.MTBF 2nd Risks rank

Increasing of coking

Increasing of the Chemical Treatments

Increasing of soiled

Increasing of corrosion thinning

An unplanned shutdown

Increasing of catalyst poisoning

Degree of influence that are expected MTBF

(mean time between failures)

Downstream units(FCC)

Visualization Schematic diagram of a Degree of influence

The degree of influence dotted lines

MTBF; Mean Time Between Failures

Desalter

Furnace

Tray

Tubes Tubes

TBM=Time Based Maintenance

The Primary Risk Ranking

Legend

O-Rings

End adapters

Straps

Basic Risk Assessment Concepts

Ⅴ

Ⅳ

Ⅲ

Ⅱ

Ⅰ

A B C D E

Risk ranking of 48 months after the start of operation

Lik

elih

oo

d C

ate

go

ry

010

110

210

Conseqence Cat egor y

310

410

610

許容

保有分散

低減回避

除去

移転

O-Rings

End adapters

Straps

replace

Countermeasure

Ⅴ-C categories

As an action examples

Lik

elih

ood C

ate

gory

Conseqence Category

The Secondary Risk Ranking

The secondary risks rank

Ⅴ

Ⅳ

Ⅲ

Ⅱ 3

Ⅰ 10

A B C D E 13

Risk ranking of 48 months after the start ofoperation(The secondary risks rank)

Lik

elih

oo

d C

ateg

ory

010

110

210

Conseqence Cat egor y

310

410

610

Reduced lines

Schematic diagram of CSCC / ASCC inspection plan

by ultrasonic backscattering wave

LSg

loadL

strengthS ,

KIC: fracture toughness,

σ n: residual stress, D: diameter,

t: wall thickness, P: pressure,

a: crack depth, Y: Shape factor

Yat

PDg

nICK ・2

Limit state function

Ris

k

Str

eng

Time (years)

Threshold

Present state by ultrasonic backscattering wave

Expanded inspection level

Expected line of strength

reduction based on experience

It is absolute requirement that

corrosion protection material is

sound

Low

External corrosionInternal corrosion

Estimated line of linear regression

The next on stream inspection

will be after 4 years

Midium

Midium High

High(Damage)

corrosion allowance

0),( LSg