PMI INSPECTION

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SAVING LIVES, INCREASING PRODUCTIVITY: How positive material identification is transforming plant process safety

References: https://www.csb.gov/bp-america-refinery-explosion

It could be something simple like accidentally switching a carbon steel elbow with an alloy steel elbow during a scheduled heat exchanger overhaul in a high temperature, high pressure hydrogen line. This is what happened back in July 2005 at BP Texas City refinery.

One of the key issues this incident identified was the absence of accurate material analysis procedures during maintenance work to prevent improper material substitutions in hazardous process systems.

As a result, the importance of conducting regular onsite inspections and keeping up-to-date records of critical process components has become the norm in refining, petrochemical and chemical industries.

As technologies used for analysis solutions evolve, we look at how industrial analysers used for positive material identification (PMI) are helping companies transform plant process safety.

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CONTENTS

A step-change in material inspection

Regulatory changesAsset Integrity management – setting a standard for safe operationsWhy trust but verify certificates – setting a standard for safe operations

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Being proactive

Solving modern industrial challengesAdvanced data management

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Creating safe and productive environments 11

Contact us 12

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A STEP-CHANGE IN MATERIAL INSPECTIONThe BP Texas City refinery incident led to a huge increase in the use of material inspection technology by petrochemical operators. This trend was driven by an increased awareness of the need to balance increased safety measures with minimal operational disruption and downtime. With high volumes and fine margins, faulty or incorrect components can lead to cost increases, lost or contaminated materials, or catastrophic failures.

A growing number of companies have turned to XRF (X-ray fluorescence) and OES (optical emission spectroscopy) technology in the last

two decades to assure the safety and compliance of materials and components used across a diverse range of sectors.

A tightening of safety regulations by governments and industry standards globally, combined with aging assets and heightened expectations of operational safety, has created demand for technology to support PMI practices.

References: https://www.prnewswire.com/news-releases/global-positive-material-identification-pmi-market-2018-2023---driven-by-stringent-safety-regulations-by-governments-and-quality-control-requirements-300621821.html

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Portable analysers have proven particularly popular, accounting for the largest share of the PMI market in 2017 with oil and gas industry holding the largest share equally. Ranging from handheld instruments either with XRF or LIBS (laser induced breakdown spectroscopy) technology weighing just 1.5 kg to portable OES analysers weighing 15 kg, they allow on-site examination of the chemical composition of relevant components.

Whereas previously PMI analysers were stationary fixtures in labs and needed to be fed pre-prepared samples, portable analysers allow users to inspect critical process components on site. By inspecting plates, pipes, flanges, welds and valves, operators can better ensure that their sites

remain safe and compliant over their lifetime. Portable PMI analysers are also an effective way to spot counterfeit building components, sulfidic and flow accelerated corrosion of piping and equipment, and components that don’t meet specifications.

1.5 kgHandheld analysers

can weigh as little as

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REGULATORY CHANGES

Following the Texas City incident, the CSB, an independent United States federal agency charged with investigating industrial chemical accidents, tasked the American Petroleum Institute (API) with reviewing the safety standards that apply to refining. The organisation currently has over a hundred standards relating to the safety of industrial processes. API RP 578 for example requires companies make use of PMI and obtain a certificate documenting that they have been trained in how to use the technology. In oil and gas processes, 100% positive material identification should also be carried out for any metal component used.

The US Department of Occupational Safety and Health Administration (OSHA) was also encouraged to implement a national emphasis programme of detailed refinery inspections. The chemical industry has followed suit, with the introduction of a similar range of standards and requirements. The European Union has also brought in the Pressure Equipment Directive, which sets out standards for the design and fabrication of pressure equipment, including piping and safety valves.

In petrochemical refining, API RP 570 and API RP 578 are established practices developed by the API to ensure that operators have the right processes in place to make use of existing technology safely and effectively. On top of this, governments have increasingly demanded greater focus on process safety.

positive material identification should also be carried out for any

metal component used.

100%In oil and gas processes

References: https://www.ogj.com/articles/print/volume-106/issue-34/general-interest/special-report-refiners-apply-safety-lessons-from-bp-texas-city-explosion.html

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ASSET INTEGRITY MANAGEMENT – SETTING A STANDARD FOR SAFE OPERATIONS

Asset integrity is an increasing issue for industrial operations, particularly in the oil and gas sector. In 2016, it was estimated that 50% of offshore platforms built in the 1970s and 1980s had exceeded their operational life by over 15 years. Similarly, around half of all US crude oil pipelines currently in use across North America were built before 1960.

In 2002, NACE International put the cost of dealing with corrosion across the US at $276 billion a year, approximately 3.1% of the country’s then GDP. Also in 2016, the organisation estimated that the global cost of corrosion was $2.5 trillion, or 3.4% of global GDP. The study found that implementing better corrosion prevention methods could lead to a global saving of between $375-$875 billion.

While PMI analysers can’t detect corrosion, they do help with corrosion control as an important prevention technique. Dissimilar metals that don’t match at welding points can represent an increased risk of failure.

WHY TRUST BUT VERIFY CERTIFICATES

Before the arrival of PMI analysers, inspection tended to be a long-winded and costly process. The main compliance vehicle was Material Test Reports (MTR) and certificates of composition from suppliers. This method has been shown to have significant room for error.

Some estimates place the number of MTRs that don’t match the actual chemistry of components and materials at between 20-30%. An analogue solution in an increasingly digital world, certificates are also prone to loss, misfiling or mislabelling.

For companies needing to comply with increasing safety regulations, this approach involves a margin of error that is simply too large to ignore. It’s good to verify any components before they are put into the use in the wake of mis-certification scandals around the world.

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References: http://www.hydrocarbonprocessing.com/magazine/2017/november-2017/columns/safety-process-safety-and-risk-management-an-industry-view https://www.ey.com/Publication/vwLUAssets/EY-spotlight-on-oil-and-gas-megaprojects/%24FILE/EY-spotlight-on-oil-and-gas-megaprojects.pdf

BEING PROACTIVEPortable, robust PMI analysers mark an important change in the way operators ensure their sites are working in a safe, compliant and efficient manner. They make it simpler to take a proactive approach to process safety and integrity management, and to detect safety and process risks early. This is important because operators still tend to default to a reactive approach, only addressing issues with equipment and systems after they have begun to show signs of degradation or damage. This reactive strategy often leads

to higher maintenance costs, more unscheduled downtime and increased risk, while making it harder to hit strategic and commercial production goals.

PMI analysers provide a long-term solution to unforeseen problems by making it simple to get an overview of the health of a site’s assets. The increasing use of data management solutions, like cloud storage, also make it less costly to store, analyse and share inspection data across an organisation in real time. This creates the possibility that managers and safety officials can analyse inspection results as they come in from the field and flag up potential problems fast.

A 2017 survey of senior leaders

of process safety, asset integrity and operational risk management across the hydrocarbon industry found that 71% thought reducing operational and major hazard risk was the main driver of improving site safety. The same survey found that 61% also saw it as the primary step towards achieving operational excellence, whereby risk is minimised and productivity is increased. Interestingly, only 31% saw a clear link between increasing site safety and reducing operational costs.

Making sure that assets and components are secure is important, but operators also need a quick and accurate way of measuring and monitoring the natural degradation of their

safety barriers. This not only requires devices that operate effectively wherever they are needed, but also robust data infrastructure to allow inspection data to be stored, managed and available to those who need it.

saw a clear link between increasing site safety and

reducing operational costs.

only 31%

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SOLVING MODERN INDUSTRIAL CHALLENGES

PMI analysers provide a way for operators to bring lab-quality analytical instruments into the heart of their operations. They can also positively impact several key challenge areas faced by industrial companies.

Handheld XRF analysers can be used in any environment, including measuring hot process components up to 400 degrees Celsius, and don’t require operations to be stopped for testing to be performed.

So inspection can be performed alongside the commercial operations of a site. Operators can also achieve increased efficiency by providing a clear picture of the overall performance of process critical components. Whether they decide to bring inspection in-house or outsource it to third party inspection companies, the ability to get in and out quickly without disruption could greatly increase process safety without negatively impacting a site’s commercial performance.

Perhaps the biggest advantage of portable PMI analysers is the ability to accurately test materials in tough environments. The current trend towards unconventional oil and gas projects in frontier areas will only make this reliability more important. Many components and assets are designed to work in the harshest and most demanding of environments, so the ability of analysers to go where the components are is a big advantage.

The portable nature of these devices means that on large sites, limited access to analysis points is not such a logistical challenge for operators. This portability would not mean a great deal if the devices themselves were not capable of standing up to the rigours of the environment. One of the key developments in the PMI analysers available on the market is increasingly robust and hardy designs, meaning that formerly lab-bound technology has become a long-term mobile solution for operators.

400℃measure up to

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ADVANCED DATA MANAGEMENT

Continued innovations across a range of technological areas are converging in a way that could make the process of regulatory compliance an automated one for operators. The last half decade has seen cloud storage emerge as a fully-fledged data management solution across nearly every sector in the global economy.

The ability for organisations to outsource the storage and security of the data they create and rely on has led to a number of benefits for large organisations. Firstly, the savings that come from no longer having to maintain and secure costly servers and data storage.

Secondly, companies have been able to expand their own offerings to their customers based on the capabilities of cloud storage.

Thirdly, and perhaps most significantly, the transition to widespread cloud storage has created a number of opportunities to connect devices and enable collaborative working.

This has several important implications for PMI as both a compliance and process safety tool. When connected to a Wi-Fi or cloud network

including via a phone, portable devices can be used to perform analysis across a geographically large and environmentally challenging organisation. The results can instantly be sent to anyone in the organisation or to the cloud for safe storage.

Making measurement, analysis and distribution of inspection data a seamless and fluid process could create a system whereby problems are acted upon much faster and the costs of downtime and maintenance are reduced. Perhaps of most interest to operators, however, is the idea of using reporting software and cloud storage to automate the compliance process.

By allowing real-time inspection data monitoring, software can analyse, monitor and present results in an audit-friendly way. For inspection companies, where the presentation of the data they collect is mission critical, this development could lead to huge efficiency gains.

cloud storage

Utilise

References: https://www.csb.gov/assets/1/20/rhubulletin1.pdf?13897 http://www.managingagingplants.com/

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CREATING SAFE AND PRODUCTIVE ENVIRONMENTSCompanies should continue to harness technological innovations to improve the productivity and safety of their operations.

By putting accurate and fast materials analysis into people’s hands, the latest range of portable PMI analysers can have many benefits for industries looking to put process safety at the heart of their operations.

Inspection no longer needs to be a costly or time-consuming process, and when matched with cutting-edge data management solutions like cloud storage, it can help minimise unscheduled downtime, operational disruption, unforeseen costs and catastrophic failures.

PMI analysers will continue to grow in importance for inspection as operators discover their capability for savings costs, saving time and, most importantly, creating safe and productive environments for their workforces.

ABOUT HITACHI HIGH-TECH

With over 45 years experience in providing cutting-edge analysis solutions to companies all around the globe, Hitachi High-Tech has a full range of PMI inspection analysers. This means we never have to compromise for our clients and can always provide an inspection solution that is tailored to their needs. We provide reliable, robust and fast PMI inspection analysers so that you can have powerful materials analysis wherever you need it, whatever the environment.

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To explore the Hitachi High-Tech complete toolbox of PMI analysers for inspection further, book a demo or to talk to a member of our team, contact us today.Visit: www.hhtas.net/inspectionor Email: contact@hitachi-hightech-as.com