20/03/2014

RBI 581

Development of Inspection Programs to Reduce Risk

Oleh: Dr. Ir. Haryadi

JURUSAN TEKNIK ESIN P!"ITEKNIK NE#ERI $ANDUN# %&'(

Contains
Introduction Development of Inspection Programs) that address the types of damage that inspection should detect and the appropriateinspection techni!ues to detect the damage. Reducing Risk T*roug* Inspection) discusses the application of "is#$%ased Inspection tools to reduce ris# and optimi&e inspection programs. Approac* To Inspection Planning

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1. INTRODUCTION

'he pro(a(ility of failure due to progressi)e damage is a function of four factors: Damage mechanism and resulting type of damage *crac#ing thinning etc.+. "ate of damage progression. ,ro(a(ility of detecting damage and predicting future damage states -ith inspection techni!ue*s+. 'olerance of the e!uipment to the type of damage.

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2. DEVELOPMENT OF INSPECTION PROGRAMS

.n inspection program is de)eloped (y systematically identifying: a. /hat type of damage to loo# for. (. /here to loo# for it. c. Ho- to loo# for the damage *-hat inspection techni!ue+. d. /hen *or ho- often+ to loo#.

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Data
Design and construction data: a. 0!uipment type *heat mass or momentum transfer+ and function *shell and tu(e e1changer trayed distillation column centrifugal pump etc.+. (. 2aterial of construction. c. Heat treatment. d. 'hic#ness. ,rocess data including changes: a. 'emperature. (. ,ressure. c. 3hemical ser)ice including trace components *such as chlorides 34s ammonium salts etc.+. d. 5lo- rate. 0!uipment history: a. ,re)ious inspection data. (. 5ailure analysis. c. 2aintenance acti)ity. d. "eplacement information.

2.2 Ho To Loo! Fo" Da#a$% &Ins'%(tion T%()ni*+%,

Inspection techni!ues are selected (ased on their a(ility to find the damage type6 ho-e)er the mechanism that caused the damage can affect the inspection techni!ue selection. 'a(le 7$8 !ualitati)ely lists the effecti)eness of inspection techni!ues for each damage type listed in 'a(le 7$2. . range of effecti)eness is gi)en for some damage type/inspection techni!ue com(inations (ased on comments from )arious sources including the .,I 9u(committee on Inspection. 9election of the inspection techni!ue -ill depend on not only the effecti)eness of the method (ut on e!uipment a)aila(ility and -hether or not an internal inspection can (e made.

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2.1 -)at T.'% o/ Da#a$% To Loo! Fo" an0 -)%"% To Loo!

Damage types are the physical characteristics of damage that can (e detected (y an inspection techni!ue. Damage mechanisms are the corrosion or mechanical actions that produce the damage. 'a(le 7$1 descri(es damage types and their characteristics. 'a(les 7$2 through 7$; list damage mechanisms (y (road categories. 'he types of damage that can (e associated -ith them are also listed. 'hese lists of damage mechanisms -ere de)eloped (y se)eral .,I mem(ers of the 5itness for 9er)ice ,rogram.

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1. REDUCING RIS2 THROUGH INSPECTION

1.1 M%as+"in$ Ris! Asso(iat%0 -it) E3istin$ Ins'%(tion S.st%#

In this case study a <usually effecti)e= inspection -as performed after si1 years. 5or the follo-ing analysis it is assumed that the inspection re)ealed an actual corrosion rate of : mpy )s. the predicted rate of 10 mpy. 5igure 7$3 sho-s the damage su(factor ta(le from the technical module for general corrosion. 'he thic# line on the ta(le sho-s the <path= traced (y an inspection plan *this is discussed further in the ne1t section+. >sing 'a(le 7$17 the follo-ing steps sho- ho- the damage su(factor is calculated for the ris# assessment.

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9tep 1: 3alculate the ratio ar/t. 'his is the e!uipment age *or time in current ser)ice+ *a) times the corrosion rate *r), in in./yr, divided by the original thic#ness *or thic#ness at time e!uipment -ent into current ser)ice+ *t). 01ample: : mpy *0.00: in./yr+ ; years old original thic#ness 0.38: in. ar/t = 6 x 0.005/0.375 = 0.08. 9tep 2: Determine the o)erdesign factor. 'his is a correction factor selected from the ta(le in 'a(le 7$12 that -ill (e applied to the damage su(factor. 'he correction is necessary (ecause the su(factors from the ta(le are (ased on a )essel that has a corrosion allo-ance of 2:? of the -all thic#ness -hile the )essel in this e1ample has a corrosion allo-ance of :0? of the -all thic#ness. @essels -ith a greater corrosion allo-ance should ha)e a lo-er damage su(factor -hile those -ith less corrosion allo-ance should ha)e a higher damage su(factor. 01ample: Original thic#ness A 0.38: in. 3orrosion allo-ance A 0.1B8:. tactual / (tactual orro!ion "llo#ance) = 0.375 / 0.$875 = %.0. 'he o)erdesign factor selected from the ta(le is 0.:6 that is the damage su(factors are to (e multiplied (y one$half *for su(factors greater than 1+. 9tep 3: "efer to 5igure 7$3 to find the damage su(factor for this )essel. .t one inspection *of any effecti)eness+ and ar/t = 0.08, the da&age !ub'actor i! $. 9tep 4: 2ultiply results of 9tep 3 (y results of 9tep 2.

APPROACH TO INSPECTION PLANNING

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4.1 M%t)o05 M%t)o05T)innin$ M%()anis#s6

Implicit in the <ar/t= loo#up ta(les is a remaining life. /hen the damage factor rises to 10 or higher -ith 4 or more <highly= effecti)e inspections then the e!uipment is at or near the end of its life. In other -ords there ha)e (een enough inspections to ha)e relati)e certainty a(out the corrosion rate and additional inspections no longer impro)e the damage factor. 'he inspection planning method sol)es for the num(er of years at -hich this point occurs *roughly ar/t A 0.4 -ith corrections for pressure and corrosion allo-ance+. If this )alue is one year or less a <diagnostics= module is called to pro)ide a -arning that (ased on the entered corrosion rate age and num(er of inspections the e!uipment is already at or near its end of life. 3areful data chec#ing and/or confirmation of e!uipment condition are recommended. If the remaining life is greater than one year determine the num(er of inspections needed to achie)e a high confidence in the corrosion rate o)er the remaining life of the e!uipment. 'his is e1pressed as the num(er of inspections of -hate)er effecti)eness has (een performed in the past assuming that this is the <preferred= inspection type for this plant. 'he num(er of inspections can easily (e con)erted to an e!ui)alent num(er of inspections of a different effecti)eness (ased on the follo-ing relationships: One <highly effecti)e= is e!ui)alent to t-o <usually effecti)e = is e!ui)alent to four <fairly effecti)e.= If 3>I is applica(le in addition to internal thinning the target damage factor is set to : for each mechanism so that the com(ined mechanisms -ill not lead to a damage factor greater than 10.

4.2 M%t)o05 M%t)o05St"%ss Co""osion C"a(!in$6

Determine the current technical module su(factor. If this is less than 10 then use the 933 module <escalation= factor *years since last inspection+ of 1.1 to determine the num(er of years until a '295 of 10 -ill (e reached. .s a default perform a <5airly= effecti)e inspection at that time as a chec# on the 933 condition. If the current '295 is greater than 10 use the relationships in 'a(le 7$1: to determine the inspection le)el re!uired. It is recommended that the inspection (e performed -ithin three years of the last inspection or as soon as practical if more than three years has elapsed.

+urrent S++ T S,
10 < TMSF < = 100 100 < TMSF < = 1000 1000 < TMSF

Inspection "evel Recommended

Perform Fairly Effective Inspection Perform Usually Effective Inspection Perform Highly Effective Inspection

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4.1 M%t)o05 M%t)o05F+"na(%s Ins'%(tion P7annin$6

,art 1. Cong 'erm Damage: If the current '295 is less than 10 increment ti (o(erating hours+ (y 10 000 *D1 year+ until a '295 of 10 is reached. 'he num(er of increments is the time to the ne1t inspection )in!(. *!e )able +,$6 to deter&ine in!(ection re-uire&ent!. If the current '295 is greater than 10 use the follo-ing relationships to determine the inspection le)el re!uired: It is recommended that the inspection (e performed -ithin three years of the last inspection or as soon as practical if more than three years has elapsed. ,art 2. 9hort 'erm Damage: 5or the short term damage '295 perform follo-ing action.

F+"na(% Ins'%(tion Int%"8a7s -it) a TMSF L%ss T)an T%n

Tinsp E A 20 years Inspection et*od Inspection Time : years 10 years 20 years
3 years ; years 12 years 4ot .llo-ed 3 years ; years 4ot .llo-ed 4ot .llo-ed ' insp

5airly 0ffecti)e >sually 0ffecti)e Highly 0ffecti)e

5airly 0ffecti)e >sually 0ffecti)e Highly 0ffecti)e 5airly 0ffecti)e >sually 0ffecti)e Highly 0ffecti)e 5airly 0ffecti)e >sually 0ffecti)e Highly 0ffecti)e

E A 10 years F 20

E A : years F 10

F : years

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F+"na(% Ins'%(tion Int%"8a7s -it) a TMSF G"%at%" T)an T%n

+urrent S++ T S,
10 < TMSF < = 50 50 < TMSF < = 500 500 < TMSF

Inspection "evel Recommended

Perform Usually Effective Inspection Perform Highly Effective Inspection Perform Highly Effective Inspection (lu! (er'or& /e&aining 0i'e 0)aluation

A(tions R%*+i"%0 /o" a S)o"t9T%"# TMSF

10

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4.4 M%t)o05 M%t)o05Hi$) T%#'%"at+"% H.0"o$%n Atta(!6

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