A
C
D
P
R
Risk-Based
Inspection/Maintenance
Plan
Do
Check
Action
Completeness, predictability and logicality of
Maintenance management
Maintenance method by TECHNO-WINGS
Construction Design
Request for strategic maintenance in RCM, RBM, RAM scheme
Disposal
(Life cycle is 50 to 60 years or more)
P:Maintenan
ce plan
D:Inspection &
construction
A:Maintenan
ce standard
C:Maintenance
analysis
Operation & Maintenance
Aging facilities; increase the importance of maintenance
Disclosure of damage cases
Optimization of maintenance method
Optimization by long-term continuous operation
Completeness of aging deterioration management
Conventional maintenance cycle
Maintenance by RBI / RBM
Plan Do
Action Ceack
1. Evaluation of the
likelihood of deterioration /
damage
2. Maintenance technology
effectiveness evaluation
3. Impact Assessment of
damage
Conventional maintenance A new maintenance cycle incorporating RBI / RBM
Maintenance loop proposed by TECHNO-WINGS
Process diagram of atmospheric distillation unit for study of RBI / RBM
RT~140℃ 240~260℃
280~380℃
Crude oil tank
Crude
colu
mn
Heavy oil
LPRBM- 01
RBM- 02 RBM- 03 RBM- 04
RBM- 05
RBM- 06
RBM- 07
RBM- 08 RBM- 09
RBM- 10
260~380℃
RT
30~150℃
150~320℃
・Sulfide
・Chloride
・water
・Alkali
・Sulfide
・Chloride
・Naphthenic acid
・Sulfide
・Chloride
・water
・Hydrogen sulfide
150~320℃
RBM- 11
・Sulfide
・Naphthenic
acid・Hydrogen
・Sulfide
・Chloride
・Hydrogen sulfide
・Caustic soda
30~150℃
30~50℃
1.0 - 1.5Mpa
1.0 - 1.5Mpa
0.02 - 0.2Mpa
0.08 - 0.21Mpa
0.08 - 0.21Mpa
Ti Clad
SUS405
SUS405
クラッド
1.25Cr-0.5Mo
Ti Tube
Ti Tube
ConcreteLining
1.0 - 2.0Mpa
5.0Cr-0.5Mo
C-steelKerosene
Diesel
Heavy Diesel
2,9,46,47
A-2,3,14
2,9,18,19,20,46,47,61 A-2,3,14
9,18,19,20,46,61 A-2,3,14 1,3,5,6,9,18,14,17
18,19,20,23,39,44,461,3,5,6,1720,23,33,46A-19
8,9,46A-19
2,5,8,9,20,46,47,48,57
2,5,8,9,20,46,47,48,57
2,8,9,20,46,47
8,9,20,46,47A-2,3,14
1,6
2,18,1946,47
18,19,46,47
0.1 - 1.5Mpa
NaOH
NaOH
coating + neutralizer
coating + neutralizer
coating
Damage factor
・Sulfide
・Chloride
・water
・Alkali
・Sulfide
・Naphthenic acid
・Hydrogen
・Sulfide
・Chloride
・water
・Hydrogen sulfide
・Hydrogen
・Sulfide
・Chloride
・Hydrogen sulfide
Desalter
1 19 47
2 20 48
3 22 57
5 23 61 Sulfate Stress Corrosion cracking
6 30
8 33
9 39 A-1
11 42 A-2
14 44 A-3
17 45 A-14
18 46 A-19
885°F Embrittlement
Chloride Stress Corrosion Cracking (Cl-SCC)
Amine Cracking
Ammonia Stress Corrosion Cracking (SCC)
Sulfidic Corrosion (Sulfidation)
Creep/Stress Rupture
Polythionic Acid Cracking
Naphthenic Acid Corrosion
Ammonium Chloride Corrosion
Decarburization
Caustic Cracking
Amine Corrosion
Fuel Ash Corrosion
Dissimilar Metal Weld (DMW) Cracking
Corrosion under Insulation (CUI)
Refractory Degradation
Caustic Corrosion
HCl Corrosion
Oxidation
Erosion/Erosion Corrosion
Short Term Overheating
CO2 Corrosion
Crevice Corrosion
Under-deposit Corrosion
Wet H2S Damage (Blistering/HIC, SOHIC, SSC)
Atmospheric corrosion
Overlay Disbonding
Titanium Hydriding
General Corrosion
Pitting Corrosion
Key to Damage Mechanisms;
Risk-based maintenance plan for development
Engineering Data Collection & Review
Process & Components Material Review
Equipment Selection
Identification of Probable Damage Mechanism
Inspection Interval Decision
Interval Factor Decision
COF Assessment
Remaining Life & Corrosion Rate
Estimation
POF Assessment
Risk Assessment
Inspection Plan Development
High, Medium, Low
Risk
slight,Negligible
Risk
Age-related
Age-related Non age-related
Non age-related
Equipment factor /
operation factor (process
characteristics, operation
conditions, operation
management)
・Unacceptable risk
Secondary risk ranking
・Maintenance period set
and documented Responding to future issues
・Design books
・Maintenance
inspection
・Operation · daily
maintenance
・Classification
of importance
from environment,
production,
quality, security
・COF and POF due
to FEMA
Primary risk ranking
Worksheet for maintenance planning by RBI / RBM of the Desalter (1/2) Continuation
Damageprobability
Corrosionrate(mm/y)
Sensitivity
① Deterioration of O- Ring Viton 6.7 x 10- 1 Very High Very High
①- 1 Local corrosion of the adapters SUS- 312L 6.7 x 10- 1 0.025 Very High Very High
①- 2Entrance bushing (Deterioration ofTeflon)
Teflon Moderate Medium
2 Electrode plate ② Deterioration of the electrodeplates
FRP 1.4x10- 2 High High
②- 1Hanger support (Deterioration ofTeflon)
Teflon Low Low
3 Hanger straps ③Local corrosion of the electrodeplate straps
SS400Max
「0.22,0.6]High Very High
④ Local corrosion 1.0x10- 2 High High
④- 1 Fouling Very Low Very Low
5 Bolt & Nut ⑤ Fatigue failure C- Steel,SUS Very Low Very Low
6 Shell plate bottom ⑥ Hydrogen induced cracking SPV355 Very Low Very Low
7 Shell plate bottom ⑦ Macrocell corrosion SPV355 Very Low Very Low
8 Shell plate bottom ⑧ Sulfide stress corrosion cracking SPV355 Very Low Very Low
9 Shell plate bottom ⑨ Deposition of scale SPV355 Moderate Medium
4 Internal piping SUS- 304
Evaluation(for
likelihood)
1Seal Components ofthe electricalequipment body
No. Components name Damage mechanisms Materials
Failure probability between the SDM- SDM
Quantitative, Qualitative
Worksheet for maintenance planning by RBI / RBM of the Desalter (2/2)
Remarks
a ; Maintenance grades defines a scope for opening of equipment.
b ; Maintenance period defines the period of the inspection equipment.
c ; Maintenance period defining the period for implementing the inspection.
Likelihoodof
Failure
Consequenceof
Failure
① Deterioration of O- RingDecreasedfunction
Moderate Ⅴ C Ⅴ- C Replaced Ⅰ C A TBM 4SDM/OSI
①- 1Local corrosion of theadapters
Decreasedfunction
Moderate Ⅴ C Ⅴ- C Replaced Ⅰ C A TBM 4SDM/OSI
①- 2Entrance bushing(Deterioration of Teflon)
Decreasedfunction
Moderate Ⅲ C Ⅲ- C Inspection Ⅱ C A TBM 4 SDM
② Deterioration of theelectrode plates
Decreasedfunction
Moderate Ⅳ C Ⅳ- C Replaced/Repaired Ⅱ C A TBM 4 SDM
②- 1Hanger support(Deterioration of Teflon)
Decreasedfunction
Moderate Ⅱ C Ⅱ- C VT Inspection Ⅱ C A TBM 4 SDM
③Local corrosion of theelectrode plate straps
Decreasedfunction
Moderate Ⅴ C Ⅴ- C Replaced Ⅰ C A TBM 4 SDM
3 Shell plate bottom ④ Macrocell corrosion Leakage significant Ⅰ E Ⅰ- E No actions Ⅰ E A TBM 4 SDM
4 Shell plate bottom ⑤ Hydrogen induced cracking Leakage significant Ⅰ E Ⅰ- E No actions Ⅰ E ACBM+TBM
4SDM/OSI
5 Shell plate bottom ⑥ Sulfide stress corrosion crackingLeakage significant Ⅰ E Ⅰ- E No actions Ⅰ E A TBM 4 SDM
⑦ Local corrosionDecreasedfunction
Moderate Ⅳ C Ⅳ- C NDI/Cleaning Ⅰ C A TBM 4 SDM
⑦- 1 FoulingDecreasedfunction
Insignificant Ⅰ A Ⅰ-A NDI Ⅰ A A TBM 4 SDM
8 Bolt & Nut ⑧ Fatigue failureDecreasedfunction
Insignificant Ⅰ A Ⅰ-A No actions Ⅰ A A TBM 4 SDM
9 Shell plate bottom ⑨ Deposition of scaleDecreasedfunction
Moderate Ⅲ C Ⅲ- C VT Inspection Ⅰ C A TBM 4 SDM
6 Internal piping
Primary riskrankings
Consequenceof
Failure
Seal Components of theelectrical equipment body
No. Components name
2 Electrode plate
1
Risk reduction measures
Countermeasures
Damage mechanisms Secondary risks rankingsa b
Likelihoodof
Failure
Consequence(Economic loss
assessment) SDM/OSI
Failuremode
c
Maintenance planning
Primary
Risk Ranking
Secondary
Risk Ranking
No.1 CD
No.2 CD
WN Water
BL
Unit A
Unit A
Ma
in d
istilla
tion
colu
mn
coating +neutralizer
coating
coating +neutralizer
NaOH
NaOH
2.MTBF primary Risks rank
1.MTBFTBM
3.MTBF 2nd Risks rank
Increasing of coking
Increasing of the Chemical Treatments
Increasing of soiled
Increasing of corrosion thinning
An unplanned shutdown
Increasing of catalyst poisoning
Degree of influence that are expected MTBF
(mean time between failures)
Downstream units(FCC)
Visualization Schematic diagram of a Degree of influence
The degree of influence dotted lines
MTBF; Mean Time Between Failures
Desalter
Furnace
Tray
Tubes Tubes
TBM=Time Based Maintenance
The Primary Risk Ranking
Legend
O-Rings
End adapters
Straps
Basic Risk Assessment Concepts
Ⅴ
Ⅳ
Ⅲ
Ⅱ
Ⅰ
A B C D E
Risk ranking of 48 months after the start of operation
Lik
elih
oo
d C
ate
go
ry
010
110
210
Conseqence Cat egor y
310
410
610
許容
保有分散
低減回避
除去
移転
O-Rings
End adapters
Straps
replace
Countermeasure
Ⅴ-C categories
As an action examples
Lik
elih
ood C
ate
gory
Conseqence Category
The Secondary Risk Ranking
The secondary risks rank
Ⅴ
Ⅳ
Ⅲ
Ⅱ 3
Ⅰ 10
A B C D E 13
Risk ranking of 48 months after the start ofoperation(The secondary risks rank)
Lik
elih
oo
d C
ateg
ory
010
110
210
Conseqence Cat egor y
310
410
610
Reduced lines
Schematic diagram of CSCC / ASCC inspection plan
by ultrasonic backscattering wave
LSg
loadL
strengthS ,
KIC: fracture toughness,
σ n: residual stress, D: diameter,
t: wall thickness, P: pressure,
a: crack depth, Y: Shape factor
Yat
PDg
nICK ・2
Limit state function
Ris
k
Str
eng
Time (years)
Threshold
Present state by ultrasonic backscattering wave
Expanded inspection level
Expected line of strength
reduction based on experience
It is absolute requirement that
corrosion protection material is
sound
Low
External corrosionInternal corrosion
Estimated line of linear regression
The next on stream inspection
will be after 4 years
Midium
Midium High
High(Damage)
corrosion allowance
0),( LSg