Paper9 Lorentz

CUI Conference 14-1-2004
2003 Shell Global Solutions International B.V.
Shell Global Solutions
SHELL RISK-BASED INSPECTION (S-RBI)

Basics & Related Approach
to Corrosion under Insulation (CUI)
Presented by:
Maarten Lorenz
Materials & Inspection Technology
Shell Research & Technology Centre,
Amsterdam, The Netherlands
Shell Global Solutions Pacesetting Concept

PACESETTING
PROGRAM
sustained top 10%

performance for
more than 5 years
HSE PROGRAM
HYDRO CARBON MANAGEMENT
MERIT REVIEW
M
E
R
I
T
anufacturing
nhanced
eliability
mprovement
eam
ORGANISATION
MANAGEMENT OF ASSETS
Integrated versions of:

RISK AND
Reliability Centred Maintenace
RELIABILITY
Risk-Based Inspection
MANAGEMENT Instrumented protective functions
S-RBI in Relation to Risk & Reliability Management

RISK AND RELIABILITY MANAGEMENT (RRM):
RISK-BASED INSPECTION
-> optimised inspection plan
RELIABILITY CENTRED MAINTENANCE

-> cost effective maintenance plan
INSTRUMENTED PROTECTIVE FUNCTIONS

-> minimum design and testing requirements
Why Apply Risk-Based Inspection ?
To move away from time based inspection governed by

minimum compliance with rules, regulations and standards
for inspection.
To apply a strategy of doing what is needed for safeguarding

integrity and improving reliability as well as availability of the
plant by planning and executing those inspections that are
needed.
Risk-Based Inspection may provide economic benefits:

reduce inspection scope, shorter shutdowns, longer run
length, fewer unplanned shutdowns.
RBI = TEAM EFFORT

CORROSION ENGINEER
PLANT INSPECTOR
MAINTENANCE ENGINEER
PROCESS TECHNOLOGIST
OPERATOR
AUTHORITY REPRESENTATIVE (on request)
S-RBI RELATED TOOLS

Maintenance Electronic
and Inspection Drawings
Database
(VISIO)
Corrosion
Control
Manual
Trending
Software
S-RBI (RRM)
Manual
S-RBI ANALYSIS
S-RBI (RRM)
Software
Statistical
Recipe Book
Degradation
Library
NDT
Handbook
FFP
Handbook
S-RBI Analysis based on Corrosion Loops

What is a Corrosion Loop?
A PRACTICAL WAY TO DESCRIBE, UNDERSTAND
AND CHECK DEGRADATION MECHANISMS IN A UNIT
part of the unit subjected to:
the
the
the
same process conditions

same failure mechanisms
same materials selection criteria
one operating window
control of degradations via

process control
values agreed by team
(boundary conditions for RBI)
deviation should be reported
CORROSION LOOP
12-E-102
Loop
2
12-E-101
Loop 1
12-D-101
Loop 3
12-K-101
1st stage
12-G-101
to burn pit
same process conditions

same degradation mechanisms
The Shell Risk-Based Inspection (S-RBI) Process

DEGRADATION MECHANISM
SUSCEPTIBILITY
CONSEQUENCE
Criticality
Matrix
INHERENT
CRITICALITY
REMNANT LIFE
HISTORY &
CONDITION
Interval
Matrix
CONFIDENCE
RATING
INSPECTION
PLAN
Susceptibility To Failure
Determine potential degradation mechanisms for the Loop
For those degradation mechanisms, identify the StF per item
for each item since there can be differences in temperature etc.
For each item, analyse the different degradation mechanisms

separately since they may result in different failure modes
Different inspection techniques/intervals may be required
Monitoring scheme to be indicated for non-age realated

degradations
Assessment of Consequence of Failure

Score Table on:
Economic consequences
Health & Safety consequences
Environmental consequences
10
Susceptibility
S-RBI Criticality Matrix

HIGH
MEDIUM
LOW
NEGLIGIBLE
S-RBI
NEGLIGIBLE
NO INSPECTION
REVIEW ONLY
L
L
N
N
MH H
E
E
M MH H
E
L
M MH H
N
L
M MH
NEGLI LOW
GIBLE
MED
IUM
EXTREME
HIGH
HIGH EXTEN
SIVE
DETAILED
ANALYSIS
Consequences
LOW
RECTIFY
MEDIUM
MEDIUM-HIGH
INSPECTION PLAN
11
Confidence Rating
indicator for confidence in forecast of degradation
rating - very low to very high reflects:

stability/predictability of degradation
number and quality of previous inspections
process stability
BETTER CONFIDENCE YIELDS

LONGER INSPECTION INTERVALS
12
Maximum Inspection Interval

WALL
THICKNESS
INSPECTIONS
REMNANT LIFE
WT new
X
WT (min)
MAXIMUM INSPECTION
X
INTERVAL
MINIMUM ALLOWABLE THICKNESS
LIFETIME IN YEARS
13
Corrosion Under Insulation
14
The S-RBI Process for CUI:

remnant life not available
CORROSION UNDER INSULATION
SUSCEPTIBILITY
CONSEQUENCE
Criticality
Matrix
INHERENT
CRITICALITY
REMNANT LIFE
HISTORY &
CONDITION
Strategy
Matrix
CONFIDENCE
RATING
MAINTENANCE
& INSPECTION
STRATEGY
15
Determining CUI Susceptibility

Score Table on:
Operating Temperature
Initial Coating Status
Insulation Type
Wall Thickness & Surface Features
Internal Corrosion/Erosion Rate
External Coil/Steam Tracing
External Environment
16
Determining CUI Consequence

Score Table on:
Economic consequences (including production loss!)
Health & Safety consequences
Environmental consequences
17
Confidence Rating
An items criticality basically determines the
inspection/maintenance strategy to be applied.
Depending on how well the condition of an item is known, a
limited degree of conservatism/opportunism is applied in
choosing the inspection/maintenance strategy.
CUI Confidence Rating depends on:
cladding & insulation condition
number & quality of CUI inspections
knowledge of CUI promoting conditions
18
CUI Strategy Matrix for CS/Low Alloy Steel

CONFIDENCE RATING
CRITICALITY
EXTREME
HIGH
MEDIUM-HIGH
MEDIUM
LOW
NEGLIGIBLE
(review only)
VERY LOW LOW
MEDIUM
HIGH VERY HIGH
STRATEGY 0
STRATEGY 1
STRATEGY 1
STRATEGY
2
STRATEGY
2 STRATEGY
3
STRATEGY 3
STRATEGY 3
STRATEGY 4
NO INSPECTIONS
19
CUI Inspection/Maintenance Strategies
Effectively five strategies have been developed for the six

criticality levels.
The coverage and quality of the applied coating/paint may add

up to 8 years of CUI protection.
Inspection intervals start at the moment the coating/paint

protection has ended.
Inspection intervals are based on recommended maximum

timing.
Initial inspection actions always involve delagging.
Inspection results may lead to adjusting the strategy level.

20
Inspection/Maintenance Strategys Loop

YES
Initial
Inspection
Corrective
Action
Significant
CUI?
NO
YES
Follow-up
Inspection
Corrective
Action
Significant
CUI ?
NO
Review
Strategy
(one cycle)
21
Non-Intrusive Inspection Techniques for CUI?
Thermography ?
- finds wet spots, not CUI

- requires experienced operator
Pulsed Eddy Currents ?
- local measurement of wall thickness

- difficult to apply on complex geometries
- excellent for determining wall thickness
through corrosion products
(real-time) Radiography ? - suitable for small bore connections

- accessibility and safety issues
Guided-Waves ?
- screening technique to detect wall loss

- requires experienced operator
- only simple pipe geometries
22
CUI Inspection/Maintenance Plan:
requires pre-screening of the assets prior to application

(not applied to items with negligible susceptibility to CUI).
does not rely too much on non-intrusive inspection results

(screening inspection techniques used to indicate susceptible
areas).
is harmonised with the S-RBI methodology.
is also available for insulated stainless steel items

(CUI = Chloride Stress Corrosion Cracking).
does not eliminate CUI failures completely, but reduces the

effects of these failures to your business to a tolerable level.
23

SHELL RISK-BASED INSPECTION (S-RBI)

Basics & Related Approach
to Corrosion under Insulation (CUI)
- thank you for your attention ANY QUESTIONS OR REMARKS?
Presented by:
Maarten Lorenz
Materials & Inspection Technology
Shell Research & Technology Centre,
Amsterdam, The Netherlands

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CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.

Shell Global Solutions

SHELL RISK-BASED INSPECTION (S-RBI)

CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.

Shell Global Solutions Pacesetting Concept

sustained top 10%

Integrated versions of:

CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.

S-RBI in Relation to Risk & Reliability Management

RELIABILITY CENTRED MAINTENANCE

INSTRUMENTED PROTECTIVE FUNCTIONS

Shell Global Solutions

CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.

Why Apply Risk-Based Inspection ?

To move away from time based inspection governed by

To apply a strategy of doing what is needed for safeguarding

Risk-Based Inspection may provide economic benefits:

Shell Global Solutions

CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.

RBI = TEAM EFFORT

Shell Global Solutions

CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.

S-RBI RELATED TOOLS

CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.

S-RBI Analysis based on Corrosion Loops

same process conditions

one operating window

control of degradations via

same process conditions

CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.

The Shell Risk-Based Inspection (S-RBI) Process

Shell Global Solutions

CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.

Determine potential degradation mechanisms for the Loop

For those degradation mechanisms, identify the StF per item

for each item since there can be differences in temperature etc.

For each item, analyse the different degradation mechanisms

Different inspection techniques/intervals may be required

Monitoring scheme to be indicated for non-age realated

Shell Global Solutions

CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.

Assessment of Consequence of Failure

Health & Safety consequences

Shell Global Solutions

CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.

S-RBI Criticality Matrix

Shell Global Solutions

CUI Conference 14-1-2004

2003 Shell Global Solutions International B.V.