1-24-24_Wednesday AM_Leveraging RBI and Corrosion Management Programs .pdf

Wednesday AM_Leveraging RBI and Corrosion Management Programs

1. January 23 - 25, 2024 | Henry B. Gonzales Center | San Antonio, TX
Leveraging RBI and Corrosion
Management Programs

2. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Michael Collier, P.E.
•Marathon Petroleum
•Inspection Supervisor – Robinson, IL
•15 years Refinery Experience
•Fields of Expertise: Corrosion/Metallurgy, Inspection, FEMI
•Industry Involvement/Recognition: Former Vice-Chair of API 970
second edition, PE in Kentucky, API 510, API 570, API 936
certifications, CWI, NBIC IS and R certifications

3. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Matthew K. Caserta, P.E.
•Becht
•Mechanical Integrity Expert, Assistant Division Manager
•20 years of experience
•Field of Expertise: RBI, CCDs and IOWs, Mechanical Integrity
Programs, Inspection Programs
•Industry Involvement/Recognition: Current Chair of API 970 2
nd

Edition, API 510 certification, PE in Ohio and Texas

4. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Overview
•Corrosion Management Programs
•Damage Mechanism Identification
•Integrity Operating Windows
•Risk-based Inspection
•Link between Damage Mechanisms and RBI
•Combined Revalidation Efforts
•Lessons Learned
Presenters are presenting as industry professionals, not on behalf of their respective organizations. The
information in this presentation consists of industry common knowledge and/or API standards.

5. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Corrosion Management Programs
Where do damage mechanisms fit into the overall MI scheme?
DMs
Unit
records
Inspection
results
Industry
Experience
Equipment
StrategyProcess Hazard
Analysis
RBI UpdateIOW Alerting
System

6. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Damage Mechanism Identification
•Damage mechanisms fall into 4 categories
•Wall loss (general or localized)
•Environmental damage (stress corrosion cracking, HTHA, etc.)
•Physical changes (fatigue, erosion)
•Metallurgical changes (embrittlement, creep)
•API 571 and MTI #268 are good references for common damage mechanisms

7. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Damage Mechanism Identification
•Inspection Codes and RBI programs require all “credible” damage mechanisms be
considered
•Equipment can have more than one damage mechanism active at the same time
•Cumulative effects should be considered
•Damage mechanism can vary with different operating modes
•Changes in feedstocks
•More severe operation at start of run vs. end of run
•Equipment bypassed
•Some damage mechanisms occur during non-normal conditions (start-up, shutdown,
upsets)
•Polythionic acid SCC – shutdown related DM
•Temper embrittlement –change in metallurgical properties below operating temperature
•Chloride SCC –water left in equipment during startup

8. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Integrity Operating Windows
•IOWs are integrity limits (critical, standard, or informational). If the process
is kept within the limits, degradation should be predictable - not
necessarily low
•They are often programmed into the distributed control system or plant
historian software and alarm/notify responsible parties
•IOWs should focus on parameters that affect mechanical integrity.
Operational and Product Quality limits should not be included to allow
focus on key integrity concerns
•IOW exceedances are logged and responded to in a formal and
documented manner
•IOWs are developed by a team of Materials/Corrosion Engineers, Process
Engineers and Operations

9. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Integrity Operating Windows
•IOW Informational Limit
•A limit used primarily by SMEs to predict or
control longer-term integrity issues
•IOW Standard Limit
•A limit where exceedance over a specified
period of time would lead to increased
degradation or new damage mechanisms
•IOW Critical Limit
•A limit where exceedance would lead to
rapid deterioration. Typically, Operators
must take immediate, predetermined
actions
*From API 584 – 2
nd
Edition, 2021

10. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
What RBI Is and What It Isn’t
RBI is a risk management tool to determine appropriate inspection
strategies and frequencies relative to the overall risk
RBI isn’t:
1.A cost savings tool
2.A stopgap for missing data
3.A solution for poor programs/practices
4.A one-time effort
5.A method to push turnarounds

11. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
RBI and Damage Mechanisms
•Damage Mechanism Review (DMR) is a critical component of an RBI Program
•Determination of damage mode (pitting, cracking, wall loss, etc.)
•Determination of failure mode (pinhole, rupture, etc.)
•Probability of failure assessments
•Inspection planning and NDE assessment
•Severity of the expected damage mechanisms can be assessed qualitatively or
quantitatively
•Corrosion rates
•Cracking susceptibility
•Potential for metallurgical damage

12. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
RBI and IOWs
•The damage mechanism review (DMR) for an RBI analysis is completed
based on a set of assumptions:
•Feedstocks, Incoming contaminants, Operating conditions, etc.
•The output of the DMR can be considered a static estimation of the
process that continually changes.
•Key RBI inputs such as corrosion rates or cracking susceptibilities can vary
based on changes to the process and operations
•IOWs ensure that these estimated values continue to be valid over the
course of the analysis time period
•Review of exceedances of IOWs since the last RBI analysis also aids in
noting areas of potential change to the damage mechanism inputs

13. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Revalidation Efforts
•Periodic revalidations and reviews help keep MI programs updated
and working off the most current data.
Code/Standard Topic Revalidation Requirement Notes
API 510–Pressure Vessel Inspection
Code
RBI of pressure
vessels and relief
devices
10 year maximum More often if warranted by changes to process or
equipment
API 570 – Piping Inspection Code RBI of piping 10 year maximum More often is process/hardware changes or events
that impact damage mechanisms occur
API 580 – Risk-based Inspection RBI No provided limit API 580 provides examples of when to revalidate,
but leaves it to the inspection Codes to determine
revalidation intervals
API 584 – Integrity Operating WindowsIOW No provided limit Periodic reviews are recommended. Changes to
the process or damage mechanisms and relevant
MOCs for review.
API 653 – Tank Inspection, Repair,
Alteration, and Reconstruction
RBI of storage tanks10 year review Since tank inspection intervals are frequently
longer than 10 years, the RBI would need to be
reviewed at least every 10 years.
API 970 – Corrosion Control DocumentsCCD No provided limit Periodic reviews are recommended. Changes to
the process or damage mechanisms and relevant
MOCs for review. During PHAs, also suggested

14. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Revalidation Efforts
Combining IOW/CCD work process with RBI revalidation efforts have
many similarities that can be leveraged.

15. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Revalidation Efforts
There are many data sources that are common between an RBI
implementation/revalidation and a CCD/IOW assessment

16. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Revalidation Team Meetings
•Combined team meetings reduce time commitments for team members and
ensure good reviews are done.
•Process Overview Meeting
•Review of process constituents, contaminants, operating conditions,
upset/non- normal operation, etc.
•Damage Review Meeting
•Through a detailed review of the unit, the implementation team will determine
credible damage mechanisms and the potential damage rate and susceptibility
of those damage mechanisms

17. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Lessons Learned
•Properly planning for the length of time for the assessment is crucial
•There is an advantage in the same people providing information for
the RBI inputs and developing the IOWs to hold the inputs for RBI in
check.
•However, people changing roles in the middle of the project has created a
challenge in keeping consistency.
•It is important to understand the different inputs between RBI and
CCD/IOW processes
•For example: the tie between Corrosion Loops and RBI components
•Having a site lead knowledgeable in both CCD and RBI has helped the
project be successful

18. API INSPECTION & MECHANICAL INTEGRITY SUMMIT
Lessons Learned
•An RBI program without IOWs monitoring future
process conditions allow for risk to change as the
process conditions can vary over time.
•IOWs provide the feedback loop to ensure RBI
risks are communicated when needed
•Less time involvement at the site to complete the
combined projects because the amount of
overlap.
•Time efficiency results in lower cost and personal
time impacts.
•We estimate there is about a 33% personal
time savings.