rbi presentation inventure technologies
TRANSCRIPT
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Specialsists in Tank Integrity & Compliance
J.F. Rosendaal & R.H. Algra
RBI presentation
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• Asset Integrity Basics • Analysis example• Specific cases
Overview
2 Specialists in Tank Integrity & Compliance
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Asset Integrity Basics
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Component breakdown
Critical structural parts• Membrane plates• Roof support structure• Nozzles• Foundation• Roofplates• Etc.
Critical functional parts• Pumps• Valves• Roof seal• Mixers• Overflow alarm• Etc.
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Asset Integrity Basics
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Component breakdown
Dominant degradation mechanisms
Membrane plates
Foundation
General thinning of plates? (p.e. wear & tear)
Local soil side corrosion? (p.e. water or chlorides)
Local topside corrosion like pitting? (p.e. product)
Bacterial corrosion?
Other?
Edge Settlement?
Even settlement?
Differential Settlement?
Planar tilt?
Sagging?
Other?
Specialists in Tank Integrity & Compliance
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Asset Integrity Basics
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Component breakdown
Dominant degradation mechanisms
Corresponding Inspection
plan
Is the inspection/NDT actually adequate to monitor the degradation?
Example floorplate:Degradation mechanism: local soil-side corrosion.Wrong inspection: Spot-check UT from product-sideRecommended inspection: Floorscan
Does the plan cover sufficient area / is sufficiently detailed?
Degradations mechanisms that are not present (prevented) not need NDT!
Example floorplates:Foundation sufficiently high; floor-foundation transition adequatly sealed for rainwater; no soil contaminations (chloride), underside coated, etc. -> soil-side corrosion cannot occur -> Floorscan not required.
Example tankshell:Preferrent locations: liquid-to-vapour corrosion, increased corrosion at sun-side of tankshellWrong inspection: Spot-check UT along stairsRecommended inspection: UT magnetic crawler
UT points
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Asset Integrity Basics
6 Specialists in Tank Integrity & Compliance
Component breakdown
Dominant degradation mechanisms
Corresponding Inspection
plan
Analysis & Secure in RB-
IT
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Analysis using RB-IT 360
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Component breakdown
Dominant degradation mechanisms
Corresponding Inspection
plan
Analysis & Secure in RB-
IT
Is covered in the corporate methodology (modelomschrijving RBI)
What remains to be done: Perform analysis, discuss results and formulate plan for inspection & maintenance
How to analyse, assess and what to do step by step is covered in detail in the corporate methodology (modelomschrijving RBI)
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Analysis example: Remaining Lifetime calculation
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Historic inspection & repairs
Data Analysis
Rejection limitRejectedAcceptable
Structural strength
TimeRemaining
lifetimeToday
Remaining lifetime assessment specific component
Weighed extrapolation based on anticipated service
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Analysis example: Remaining Lifetime calculation
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Historic inspection & repairs
Data Analysis
Rejection limitRejectedAcceptable
Structural strength
TimeRemaining
lifetimeToday
Remaining lifetime assessment specific component
Weighed extrapolation based on anticipated service
IMPORTANT FACTS:
Trending historic data is not just connecting dots!!! A reliable degradation rate is essential for the assessment and requires skills & experience.
The objective of RBI is to determine inspection periods based on risks. If there is less historic data this will result in a higher risk (condition is unclear) and will automatically result in earlier inspections. RBI is possible without or with limited historic data.
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Analysis example: Determine inspection interval (RBI)
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RejectedAcceptable
Risk assessment
Structural strength
TimeYear of
next inspection
Remaining lifetime
Today
Remaining lifetime assessment+ RBI What to do?
How much does it cost?
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Dominant failure modes
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• Is trending analysis carried out reliably?
Trending (1)
Reliable trending needs contect, not just measurements.
Specialists in Tank Integrity & Compliance12
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• 1960: tank built for storage of low sulphur diesel• 1995: service change for storage gas condensate. The tank pad was renovated and a
leak detection foil installed, resulting in a 10-year fixed inspection term.• 2005: Component inspected. Lots of rust observed on the tankfloor, remaining WT =
4,2 mm. Pits more than 2 mm are repaired by welding.Question: Is the trending reliable?
Trending (2)
New construction
Inspection
rejection
20051960 1995
8mm
4,2mm
2,5mm
2015
Long inspection term but is this
adivsable?
theory
High risk through uncertainty
Specialists in Tank Integrity & Compliance13
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• Older and solely time-based regimes are usely insufficiently covering the various degradations that are dominantly active on the tank.
• This leads to an increased risk on incidents/unforeseen events.
• Continuation of that procedure is expected to result in an increase of incidents and an increase of the required maintenance budget (‘fire fighting’).
• Risks can be controlled by a solid asset integrity approach. In time this will result in a decrease of incidents and a decrease of the maintenance budget.
• RBI is about ‘operating responsibly’
In general
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• Visual external inspection following predefined checklist• Visual internal inspection following predefined checklist• Floorscan• 5 points per plate UT measurements tankfloor• Sagging• Edge settlement• Differential settlement• Scheefstand• Bulges and ripples in tankfloor• Annular toe thickness measurement• A-height cornerweld• UT crawler inspection tankshell• Manual UT grid tankroof• Manual UT nozzles + internal piping• Manual UT pontoons (bij EFR)
EEMUA offstream inspectie list
All critical components need to be checked for leading degradation mechanisms.
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Closing the loop (PDCA)
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Component breakdown
Dominant degradation mechanisms
Corresponding Inspection plan
Analysis & Secure in RB-
IT
Maintenance and inspection
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Closing the loop (PDCA)
17
Component breakdown
Dominant degradation mechanisms
Corresponding Inspection plan
Analysis & Secure in RB-
IT
Maintenance and inspection
Specialists in Tank Integrity & Compliance
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• RBI focuses on leakage or catastrophic failure
• RBI focuses on steel components
• RBI does not focus on functionality or operability of tank equipment
• PGS-29 has further requirements on this issue
• These are adressed in the equipment module
PGS-29 equipment
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Equipment tool
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Insulated tanks
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Component = insulated Shell
Degmech = CUI
CUI inspection plan
Analysis & secure in RBIT
API 581: Influencing factors assessment• Operating temp• Coating condition• Coating age• Cladding condition• Insulation type• Environment• External steam coil
• INCOtest is considered reliable above 8 mm remaining wallthickness with a small lift-off and no chicken wire in insulation.
• Crawler inspection can be used on the inside of the tank.
• Thermography for hotspots.• Visual external for condition of insulation
Suspect areas:•Remove insulation•Assess depth of damage using UT, pit gauge, profile comb•Use L-criterium to calculate equivalent wallthickness•Carry out fitness for service assessment•Define maintenance actions if needed
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Riveted tanks
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Component = rivet rows
Degmech = creep and corrosion
Inspection plan
Analysis & secure in RBIT
• Visual inspection for bleeding and corrosion
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Product updater module
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Component = floor, shell,
roof, nozzles
Degmech = pitting and
gencorr
Inspection plan
Analysis & secure in RBIT
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RVS tanks
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Component = floor, shell,
roof, nozzles
Degmech = non-existent
Inspection plan
Analysis & secure in RBIT
Inspection plan:•Essence is to confirm that no degradation is taking place•Scope is very small•Visual shoud be sufficientHowever: product stored should be fit for the tank material
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Wind Girders
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Component = Shell
Degmech = Buckling due to windload
Inspection plan
Analysis & secure in RBIT
Mean valuesfor wallthickness
Specialists in Tank Integrity & Compliance
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• Sometimes classified as pressure vessel and sometimes as pipe
• When classified as pressure vessel a steam spiral falls often in a legal inspection regime
• When classified as pipe there is normally no legal inspection regime
• If inspection is mandatory, normally a pressure test is conducted every 6 years
Steam spirals
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EEMUA 190•Soil settlement monitoring•Types of foundation•Inspection requirements•Design
Underground bullit tanks
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