Risk Based Inspection for Boilers

Transcription

1 การอบรมส มมนา เร อง Risk Based Inspection for Boilers 7 ม ถ นายน 2557 น าเสนอโดย สมาคมว ศวกรหม อไอน าแห งประเทศไทย ร วมก บ Lloyd s Register International (Thailand) Ltd. Risk Based Inspection for Boilers Chamni Mosagul Operation Manager, ASME Authorized Inspector and Supervisor (AI, AIS) Energy, Inspection Business, Lloyd s Register International (Thailand) Ltd. 7 June

2 Risk Based Inspection (RBI) Agenda RBI Introduction Time based vs Risk based inspection(rbi) RBI Methodology Boiler Deterioration Mechanism Criticality assessment RBI result implementation for inspection & maintenance strategy RBI Workshop (if time available) 2

3 RBI Introduction 3

4 What is Risk? Risk Has Two Components:- Risk is a measure of BOTH PROBABILITY of a failure AND CONSEQUENCE of a failure What is RBI? Risk Based Inspection (RBI) is a risk assessment and management process that is focused on loss of containment of pressurized equipment in processing facilities, due to material deterioration. These risks are managed primarily through equipment inspection. Referenced Code API Recommended practice 580 (Risk Based Inspection) API Recommended practice 581 (RBI Base Resource Document) 4

5 ให ความสนใจใน ความเส ยงท สามารถตรวจสอบได ผลเส ยหายท เก ดข น ม ผลต อความปลอดภ ยถ งข นเส ยช ว ตช ว ตเน องจากการร วไหลของสารอ นตราย ม ผลต อความปลอดภ ยถ งข นเส ยช ว ตช ว ตเน องจากความด นภายใน ส งผลกระทบต อส งแวดล อม ส นค า - ผล ตภ ณฑ เส ยหาย Risk Matrix in RBI 5

6 Reliability Based Mechanical Integrity Criticality Measures Probability Ranking Very High (1+ per yr.) High (10-1 per yr.) Moderate (10-2 per yr.) Low (10-3 per yr.) Very Low (10-4 or less per yr.) Consequence Ranking Catastrophic ($10 7 ) Very Serious ($10 6 ) Serious ($10 5 ) Significant ($10 4 ) Minor ($10 3 ) 6

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8 RBI (Time based vs Risk Based Inspection (RBI) 8

9 Advantage of RBI comparing to Time Based inspection Previous and existing resolution (Time Based) Time based inspection and Maintenance:- - Inspecting before knowing where to go - Lower safety, reliability - waste a lot of money to do unnecessary inspections and maintenances cost - Higher risk level - Low level of assets performance management - low Economical competitiveness capability level 9

10 Alternative Technology (RBI) for assets performance management Risk Based Inspection and Maintenance - Inspectors can identify:- - where the damage mechanisms are, - how to inspect them, and - how frenquently - Inspection is about finding where the problems are before they find you. RBI helps we do that. Alternative Technology (RBI) for assets performance management Risk Based Inspection and Maintenance - RBI is about doing the right things - It is about getting to mechanical integrity and safety, -It is not about saving money, saving will come after our facilities are safe and reliable. - Inspection and Maintenance based on realtime evaluated risk level - Not doing unnecessary/waste inspection and maintenance activities 10

11 Alternative Technology (RBI) for assets performance management - Maintain high safety level at Lowest risk - Highest performance/lowest cost - Maximize profit and economical competitiveness capability The RBI process reducing costs, reducing risks and measuring value R I S K Risk Using RBI Risk with time driven asset management program INSPECTION COSTS 11

12 FCC Calculated Risk and Risk Reduction As-Found Risk Risk Distribution E D C B A Initial Risk Study 90% Risk Reduction Achieved by Addressing 12% of Fixed Equipment Items Calculated as the mid value consequence multiplied by the likelihood Risk Distribution E D C B A After Risk Mitigation Industry Best Practice Case Study #3 U. S. Refinery Piping in All Units 5,000,000 Cumulative Risk - $/ Yr 4,000,000 3,000,000 2,000,000 1,000,000 As Found As Left 0 HF Alky FCC Gas Con Contract Inspection Resources #2 Crude #1 Crude MEA & #1 SRU #1 Reformer Distillate Unifiner HDH Sat Gas/Dehex C5/C6 Isom Foul Water Sep Units Hydrogen C5/C6 Desulf Reformer #2 Fuel Gas DDS Hydrotreater Flare, Oil Sep, BD #2 SRU BOILER SCOT 12

13 การกระท าโดยเจตนา 13

14 RBI Methodology RBI Methodology There are 3 methods commonly used:- - Qualitative -Quantitative - Semi-Quantitative 14

15 RBI Qualitative methodology Data collection 30 fields per asset Corrosion engineer 1 Subject Matter Expert 2 Subject Matter Expert 3 Subject Matter Expert 4 Facilitator RISK Calculator Manual Inspection planning per asset RBI Quantitative methodology Data collection 130 fields per asset RISK Calculator Manual Inspection planning per asset 15

16 RBI Risk Modeling Calculate Likelihood of Failure (events per year) Asset type, components Degradation mechanisms Failure modes Age, usage, environment, etc Asset condition (based on past and future maintenance and condition monitoring) Probability Ranking HIGH MED HIGH MEDIUM LOW 5 E D C B A Consequence Ranking Calculate Consequence of Failure (impact per event) Safety, Health or Environmental impact Maintenance costs Disruption to use Reputation Public/Political M&I Task Plan optimized to the asset and the business Includes industry best practices May increased or decrease current maintenance requirements Will change with time RBI Implementation step 16

17 Semi - Quantitative methodology (Capstone RBMI) Data collection 30 fields per asset Plan Update Asset Perform Corrosion engineer Suggested inspection plan generated by system Evaluate RISK Calculator RISK Calculator API 573 (Insp. of Fired Boilers/heaters 17

18 Data collection step Evaluate Risk level for each Component/item 18