3815105 - Supplementing RBI Program with IOWs

RBI and IOWs

1. Safety Driven Performance Conference 2013
Supplementing Risk Basked Inspection
Programs with Integrity Operating
Windows (IOWs)
Vishal Lagad - Sr. Corrosion Engineer
Asset Integrity
Lloyd’s Register Energy, Americas
October 9, 2013

2. Safety Driven Performance Conference 2013
Venue safety information
•Safety overview
•Location of emergency exists

3. 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

4. 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!

5. 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?

6. 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

7. 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

8. 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

9. Safety Driven Performance Conference 2013
IOW Limits

10. Safety Driven Performance Conference 2013
Early failure
Expected Rem
aining Life
IOW – Standard High
IOW – Critical High / SOL
Acceptable Risk Level
Expected Risk Profile
Time (years)
R
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(
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R
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Actual
Remaining
Life
0 4 10 25
Breached IOW level for 3 months
An Illustration

11. 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

12. 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

13. 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

14. Safety Driven Performance Conference 2013
Create Corrosion Loops / Circuits
Areas that have similar operating conditions, corrosion mechanisms, and
materials

15. 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

16. 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

17. 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 temperature
T=1050 °F
•2000 hour (12 week) creep life
T = 1210 °F (API 579 Omega)
•Rapid deterioration
T >1450 °F (API 530)

18. 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

19. Safety Driven Performance Conference 2013
Another example of IOWs – much closer to the heart!
High Blood Pressure
33.6% 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 variables
Obesity /Sedentary lifestyle
Tobacco / Alcohol abuse
Excess dietary sodium
Excessive alcohol intake
Stress
Cholesterol

20. 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

21. 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

22. 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

23. Safety Driven Performance Conference 2013
Thank you – Questions?