RBI Initiative
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RBI Initiative

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An old RBI Initiative from my side.

An old RBI Initiative from my side.

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RBI Initiative RBI Initiative Document Transcript

  • RBI Initiative 1
  • Table of Contents PART 1: GENERAL INFORMATION 3 PART 2: THREATS AND RISKS: 5 PART 3: FACTS NOT FICTION 6 PART 4: SUSCEPTABILITIES TO FAILURE 7 PART 5: CONSEQUENCE OF FAILURE 11 PART 6: CRITICALITY 14 PART 7: REMNANT LIFE CALCULATIONS 17 PART 8: INSPECTION PLAN 22 2
  • MODULE 31 V-3010 VT-30002-9341X 4-VF-42057-1341X 4-VF-42057-9341X 10-VF-42056-1341X 10-PG-30002-AA02 6" 4" 10" HIGH High Level Trip 10-PO-30018-9145X 10" 24" 1743 mm 1660 mm Low Low Level Trip 558 mm 3" 3" 3" 3" 8" 3-OW-40013-9143X 3-OW-40013-9341X 6-PO-30019-9341X 6-PO-30019-3145X 6-CD-40007-9341X PART 1: GENERAL INFORMATION Unit Name: High Pressure Oil Production Separator Unit Description: Horizontal cigar shape gravity separator, with one bottom weir. Process Description: 3 phase (oil, gas, water) mix from high pressure oil producing wells enters the vessel via 10” inlet nozzle, inside the vessel the product separates with the assistance of the spreader, gas occupies the upper half of the vessel while oil and water goes to the lower half of the vessel while oil and water goes to the lower half behind the weir. By gravity (density difference). Oil passes over the weir when reaches the desired level to the front compartment. Unit Design Parameters: Design Pressure 100 BARG Design Temperature 90/-50 DEGC 3
  • Unit Operating Parameters: Maximum Operating Pressure 89 BARG Maximum Operating Temperature 78 DEGC Unit Construction Parameters: Volume: 53m3 Material: Carbon Steel Shell Thickness: 71mm Head Thickness: 38 mm Corrosion Allowance: 6 mm Inner Surface Area: 135 m2 Inner Surface Coating: Amine Adduct Crude Epoxy 75 mic, + 300 Glass flake Epoxy 300 mic Outer Surface Area: 150 m2 Outer Surface Coating: Zinc Silicate 100 mic. Year Built: 1989 Attached Piping: 10-PO-30018-9145X 3 PHAZE PRODUCT INLET LINE 10-PG-30002-AA02 GAS TO GAS TRAINS 4-VF-42057-9341X GAS TO FLARE HEADER 4-VF-42058-1341X GAS TO FLARE HEADER 10-VF-42056-1341X GAS TO FLARE HEADER 6-CD-40007-9341X WATER TO CLOSED DRAIN 3-OW-40013-9341X WATER TO OILY WATER NET 3-OW-40013-9143X WATER TO OILY WATER NET 6-PO-30019-3145X OIL TO V-3020 6-PO-30019-9341X OIL TO V-3020 4
  • PART 2: THREATS AND RISKS: Vessel Threats: External Corrosion: External corrosion is caused by surrounding environment impact on the vessel material. External corrosion forms as general, pitting and crevice corrosion. Internal Corrosion: Internal corrosion is caused by processed product impact on the vessel material, exacerbated by elevated pressure and temperature. Internal corrosion forms as general, pitting, galvanic, crevice and stress corrosion. Associated Piping Threats: External Corrosion: External corrosion is caused by surrounding environment impact on the piping material. External corrosion forms as general, pitting and crevice corrosion. Internal Corrosion: Internal corrosion is caused by processed product impact on the vessel material, exacerbated by elevated pressure and temperature. Internal corrosion forms as general, pitting, galvanic, erosion, crevice and stress corrosion. Saddles, Supports, Walkways and Concrete Foundation Threats: Saddles, supports and concrete foundation reinforcing steel suffer from general and crevice corrosion. Walkways, platforms and ladders are more susceptible to mechanical damage and bolting looseness. 5
  • PART 3: FACTS NOT FICTION Date Ref Description 26.09.94 94-398 • Coating problems exist since the beginning of the vessel • Coating failure reported since September 1992 14.03.95 POC/0282/95 • Recommendations for wall thickness survey on water outlet line after the level control valve on 3-OW-40013-9341X line. 23.03.95 TI95-111 • Wall thickness survey carried out, no thickness degradation revealed. 21.01.95 TI95-024 • External wall thickness survey on the vessel showed no thickness degradation. 24.02.96 TI96-024 • External wall thickness survey on the vessel and attached piping showed no thickness degradation. 15.07.96 TI96-117 • Internal visual inspection reported internal coating deterioration, and 2mm pitting corrosion distributed allover the vessel surface. 27.02.98 TI98-047 • External wall thickness survey showed no significant degradation • Low readings obtained on 10-VF-42056-1341X. 13.08.2K TI2K-196 • Clusters of sound blistered areas along the vessel coating with no corrosion or rusting beneath. • Cracks in the internal paint reported. • Paint flecking in the nozzles reported. • Internal painting condition considered acceptable until the next recoating activity on July 2002. 26.05.2K TI2K-126 • External wall thickness survey showed no significant degradation. 22.04.02 TI02-120 • External wall thickness survey showed no significant degradation. 29.08.03 Painting Report • Vessel internally painted with 75 mic TankGuard primer and 300 mic Marathon top coat system. 6
  • PART 4: SUSCEPTABILITIES TO FAILURE Extreme High Medium Low Negligible 5 4 3 2 1 Vessel Failure Failure due to External General corrosion: External general corrosion is eliminated by the external coating, in addition, the absence of severe environmental conditions due to the lack of pollution and desert dry weather eliminates the probability of general external corrosion to occur or propagate rapidly. Rating 1 Failure due to External Pitting corrosion: External pitting corrosion is associated with insulation that can be damped with water. It is unlikely to be found within the vessel as it is not insulated by any means. Rating 1 Failure due to External Crevice corrosion: External crevice corrosion is formed due to moisture and dirt coalition at dead points within the unit construction, especially platform supports and attached nameplates. The cylindrical shape of the vessel is eliminating the existence of the dead points, as well as the nameplate is not directly attached to the vessel body but to a special holder. The attached platforms supporting may be collecting dirt and moisture, the moisture is not likely found for long times in desert environment, but there is a low possibility of generating corrosion cells there. Rating 2 Failure due to Internal General corrosion: Internal general corrosion is being controlled and eliminated by internal coating system applied. 6 mm corrosion allowance is also added to the designed wall thickness. Taking into consideration the design lifetime of 25 years, this gives 0.24 mm for lose per year. Internal coating has been re-applied in several occasions according to painting material manufacturer’s recommendations. During that, internal visual inspections had been carried out revealed with a confidence that no general corrosion mechanism is taking place. 7
  • There is always a possibility of changing the operation conditions what may lead to the appearance of general corrosion, although it is very rare. Rating 2 Failure due to Internal Pitting corrosion: Internal pitting corrosion is also controlled by the internal painting; the corrosion spices may consume the corrosion allowance throughout the lifetime. It had been recorded the occurrence of spreaded pitting with a depth of 2 mm but no propagation was reported afterwards. Partial deterioration of internal coating has been reported, what may increase the possibility of pitting occurrence Rating 3 Failure due to Internal Galvanic corrosion: Galvanic corrosion may occur between the vessel stainless steel internals and the carbon steel vessel, but the internal coating and the insulation installed between them make it unlikely to be found. Rating 1 Failure due to Internal Crevice corrosion: Crevice corrosion is most likely to happen in the vertical attached nozzles and their flanges. Adequate painting is being applied internally what may reduce the probability of the occurrence, but previous experience with painting deterioration inside the attached nozzles increases the possibility of such mechanism to take place. Rating 3 Failure due to Internal Stress corrosion: Stress corrosion cracking occurs mainly within the welds heat affected zones, but the possibility of happening within the main vessel body exists. The vessel is mainly designed to withstand the stresses caused by the internal pressure, although the overpressurising conditions may occur from time to time. The existence of internal coating reduces the possibility of such mechanism, in addition it has not been reported before within the area. Rating 2 8
  • Associated Piping Failure: Failure due to External General corrosion: External general corrosion on associated piping is controlled by the application of protective painting system, the absence of severe environment conditions and pollution eliminates the possibilities of occurrence or propagation. Rating 1 Failure due to External Pitting corrosion: External pitting corrosion is associated with insulation existence, and the existence of chlorides for stainless steel piping. Associated piping of the vessel is not insulated, and the stainless steel piping is painted, in addition to lack of chlorides existence. Rating 1 Failure due to External Crevice corrosion: External crevice corrosion for piping occurs mainly at supporting points and within the external side of flange connections due to moisture and dirt trap. There is a fair chance to occur although the general environment conditions are not so helpful. Rating 2 Failure due to Internal General corrosion: Internal general corrosion is a result of the flowing media reaction with the pipe metal. It is most likely to happen within the carbon steel portions rather than the stainless steel. The routine wall thickness survey carried out on the attached piping throughout the last few years did not show any significant wall thickness loss. Rating 1 Failure due to Internal Pitting corrosion: Internal pitting corrosion is mainly happening due to the presence of particular agents, like chlorides and sulfides. No history of such failure within the vessel piping, but threat exists. Rating 2 Failure due to Internal Galvanic corrosion: Internal galvanic corrosion occurs between dissimilar metal connections with the existence of suitable electrolyte. There are causes of galvanic corrosion between carbon 9
  • steel and stainless steel connections within BED area, but none of them within the vessel skid. Rating 1 Failure due to Internal Erosion corrosion: Internal erosion corrosion occurs at or after flow restrictions and direction changes. In general it shows up within carbon steel piping, with a possibility of occurrence within stainless steel piping. Rating 2 Failure due to Internal Crevice corrosion: Internal crevice corrosion is more combined with slow flow piping. It is unlikely to happen within the vessel piping due to high pressure and flow rate. Rating 1 Failure due to Internal Stress corrosion: Internal stress corrosion within piping system is usually combined with excess vibration rather than over pressurizing. Rating 2 10
  • PART 5: CONSEQUENCE OF FAILURE Extreme High Medium Low Negligible 5 4 3 2 1 Vessel Failure Consequence: Consequence of failure due to External General corrosion: External general corrosion leads to general wall thickness loss exposing the vessel to be a subject to collapse or fracture under internal pressure, what will lead to a large amount of oil and gas release, massive production loss and cost of new vessel. Rating 5 Consequence of failure due to External Pitting corrosion: External pitting corrosion leads to low amount of oil or gas release, low production loss and low cost of vessel repair. Rating 2 Consequence of failure due to External Crevice corrosion: External crevice corrosion leads to low amount of oil or gas release, low production loss and low cost of vessel repair. Rating 2 Consequence of failure due to Internal General corrosion: Internal general corrosion leads to general wall thickness loss exposing the vessel to be a subject to collapse or fracture under internal pressure, what will lead to a large amount of oil and gas release, massive production loss and cost of new vessel. Rating 5 Consequence of failure due to Internal Pitting corrosion: Internal pitting corrosion leads to low amount of oil or gas release, low production loss and low cost of vessel repair. Rating 2 11
  • Consequence of failure due to Internal Galvanic corrosion: Internal galvanic corrosion leads to no oil or gas release, low production loss and low cost of vessel repair. Rating 1 Consequence of failure due to Internal Crevice corrosion: Internal crevice corrosion leads to low oil or gas release, medium production loss and medium cost of vessel repair. Rating 3 Consequence of failure due to Internal Stress corrosion: Internal stress corrosion cracking leads to high oil or gas release, high production loss and high cost of vessel repair. Rating 4 Associated Piping Failure Consequence: Consequence of failure due to External General corrosion: External general corrosion on associated piping leads to medium oil or gas release, medium production loss and low repair cost. Rating 3 Consequence of failure due to External Pitting corrosion: External pitting corrosion on associated piping leads to low oil or gas release, negligible production loss and low repair cost. Rating 2 Consequence of failure due to External Crevice corrosion: External crevice corrosion on associated piping leads to low oil or gas release, negligible production loss and low repair cost. Rating 2 Consequence of failure due to Internal General corrosion: External general corrosion on associated piping leads to medium oil or gas release, medium production loss and low repair cost. Rating 3 12
  • Consequence of failure due to Internal Pitting corrosion: Internal pitting corrosion on associated piping leads to low oil or gas release, negligible production loss and low repair cost. Rating 2 Consequence of failure due to Internal Galvanic corrosion: Internal galvanic corrosion leads to low oil or gas release, negligible production loss and low repair cost. Rating 2 Consequence of failure due to Internal Erosion corrosion: Internal erosion corrosion leads to low oil or gas release, negligible production loss and low repair cost. Rating 2 Consequence of failure due to internal Crevice corrosion: Internal crevice corrosion leads to negligible oil or gas release, negligible production loss and negligible repair cost. Rating 1 Consequence of failure due to Internal Stress corrosion: Internal stress corrosion leads to high oil or gas release, medium production loss and medium repair cost. Rating 4 13
  • PART 6: CRITICALITY Extreme High Medium Low Negligible 5 4 3 2 1 Vessel Failure Criticality Criticality of failure due to External General corrosion: Susceptibility Rating 1 Consequence Rating 5 Criticality Rating 4 Criticality of failure due to External Pitting corrosion: Susceptibility Rating 1 Consequence Rating 2 Criticality Rating 1 Criticality of failure due to External Crevice corrosion: Susceptibility Rating 2 Consequence Rating 2 Criticality Rating 2 Criticality of failure due to Internal General corrosion: Susceptibility Rating 2 Consequence Rating 5 Criticality Rating 5 14
  • Criticality of failure due to Internal Pitting corrosion: Susceptibility Rating 3 Consequence Rating 2 Criticality Rating 3 Criticality of failure due to Internal Galvanic corrosion: Susceptibility Rating 1 Consequence Rating 1 Criticality Rating 1 Criticality of failure due to Internal Crevice corrosion: Susceptibility Rating 3 Consequence Rating 3 Criticality Rating 4 Criticality of failure due to Internal Stress corrosion: Susceptibility Rating 2 Consequence Rating 4 Criticality Rating 4 Associated Piping Failure Criticality: Criticality of failure due to External General corrosion: Susceptibility Rating 1 Consequence Rating 3 Criticality Rating 2 Criticality of failure due to External Pitting corrosion: Susceptibility Rating 1 Consequence Rating 2 Criticality Rating 1 Criticality of failure due to External Crevice corrosion: Susceptibility Rating 2 Consequence Rating 2 Criticality Rating 2 Criticality of failure due to Internal General corrosion: Susceptibility Rating 1 Consequence Rating 3 Criticality Rating 2 15
  • Criticality of failure due to Internal Pitting corrosion: Susceptibility Rating 2 Consequence Rating 2 Criticality Rating 2 Criticality of failure due to Internal Galvanic corrosion: Susceptibility Rating 1 Consequence Rating 2 Criticality Rating 1 Criticality of failure due to Internal Erosion corrosion: Susceptibility Rating 2 Consequence Rating 2 Criticality Rating 2 Criticality of failure due to internal Crevice corrosion: Susceptibility Rating 1 Consequence Rating 1 Criticality Rating 1 Criticality of failure due to Internal Stress corrosion: Susceptibility Rating 2 Consequence Rating 4 Criticality Rating 4 16
  • PART 7: REMNANT LIFE CALCULATIONS Vessel Remnant Life Calculations: 1- Shell Remnant Life Calculation: Shell Thickness Degradation Chart Year Built: 1989 75 Year Start in Service: 1990 Thickness 70 Corrosion allowance: 6 mm 65 Original wall thickness: 71 mm 60 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 Minimum accepted wall Service Years thickness: 71 – 6 = 65 mm Min Design Actual Design Corrosion Rate: 6mm/25years = 0.24 mm/year Actual up to date Corrosion Rate (based on internal inspection reports): 2mm/15years = 0.133 mm/year 2- Heads Remnant Life Calculation: Heads Thickness Degradation Chart Year Built: 1989 40 Year Start in Service: 1990 Thickness 35 Corrosion allowance: 6 mm Original wall thickness: 38 mm 30 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 Minimum accepted wall Service Years thickness: 38 – 6 = 32 mm Min Design Actual Design Corrosion Rate: 6mm/25years = 0.24 mm/year Assumed up to date Corrosion Rate (no corrosion reported on heads): 2mm/15years = 0.1 mm/year 17
  • Piping Remnant Life Calculation: A- 10-PO-30018-9145X 10-PO-30018-9145X Year Start in Service: 1990 18.5 Corrosion allowance: 1 mm 18 Thickness 17.5 Original wall thickness: 18.24mm 17 16.5 Minimum accepted wall thickness: 16 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 17.24mm Years Min Design Design Corrosion Rate: 1mm/25years = 0.04 mm/year Assumed up to date Corrosion Rate (no corrosion reported on this piping): 0.04 mm/year B- 10-PG-30002-AA02 Year Start in Service: 1990 10-PG-30002-AA02 10 Corrosion allowance: 0 mm 8 Thickness 6 Original wall thickness: 9.27mm 4 2 Minimum accepted wall thickness: 0 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 9.27mm Years Min Design Design Corrosion Rate: 0 Assumed up to date Corrosion Rate (no corrosion reported on this piping): 0 C- 4-VF-42057-9341X Year Start in Service: 1990 4-VF-42057-9341X 9 Corrosion allowance: 0 mm 8 7 6 Thickness Original wall thickness: 8.56mm 5 4 3 2 Minimum accepted wall thickness: 1 0 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 8.56mm Years Min Design Design Corrosion Rate: 0mm/year Assumed up to date Corrosion Rate (no corrosion reported on this piping): 0 mm/year 18
  • D- 4-VF-42058-1341X Year Start in Service: 1990 4-VF-42058-1341X 3.5 Corrosion allowance: 0 mm 3 2.5 Thickness Original wall thickness: 3.05mm 1.5 2 1 Minimum accepted wall thickness: 0.5 0 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 3.05mm Years Design Corrosion Rate: 0mm/year Min Design Assumed up to date Corrosion Rate (no corrosion reported on this piping): 0mm/year E- 10-VF-42056-1341X Year Start in Service: 1990 10-VF-42056-1341X 4.5 Corrosion allowance: 0 mm 4 3.5 3 Thickness Original wall thickness: 4.19mm 2.5 2 1.5 1 Minimum accepted wall thickness: 0.5 0 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 4.19mm Years Design Corrosion Rate: 3mm/25years = Min Design 0.12 mm/year Assumed up to date Corrosion Rate (no corrosion reported on this piping): 0.12 mm/year F- 6-CD-40007-9341X Year Start in Service: 1990 6-CD-40007-9341X 12 Corrosion allowance: 0 mm 10 8 Thickness Original wall thickness: 10.79mm 6 4 2 Minimum accepted wall thickness: 0 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 10.79mm Years Min Design Design Corrosion Rate: 0mm/year Assumed up to date Corrosion Rate (no corrosion reported on this piping): 0mm/year 19
  • G- 3-OW-40013-9341X Year Start in Service: 1990 3-OW-40013-9341X 9 Corrosion allowance: 0 mm 8 7 6 Thickness Original wall thickness: 7.62mm 5 4 3 Minimum accepted wall thickness: 2 1 0 7.62mm 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 Years Design Corrosion Rate: 0mm/year Min Design Assumed up to date Corrosion Rate (no corrosion reported on this piping): 0mm/year H- 3-OW-40013-9143X Year Start in Service: 1990 3-OW-40013-9143X 9 Corrosion allowance: 1 mm 8 7 Original wall thickness: 7.62mm 6 Thickness 5 4 3 Minimum accepted wall thickness: 2 1 0 6.62mm 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 Years Design Corrosion Rate: Min Design 1mm/25years = 0.04 mm/year Assumed up to date Corrosion Rate (no corrosion reported on this piping): 0.04mm/year I- 6-PO-30019-3145X Year Start in Service: 1990 6-PO-30019-3145X 8 Corrosion allowance: 1 mm 7 6 Original wall thickness: 7.11mm Thickness 5 4 3 Minimum accepted wall thickness: 2 1 6.11mm 0 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 Design Corrosion Rate: Years Min Design 1mm/25years = 0.04 mm/year Assumed up to date Corrosion Rate (no corrosion reported on this piping): 0.04 mm/year 20
  • J- 6-PO-30019-9341X Year Start in Service: 1990 6-PO-30019-9341X 12 Corrosion allowance: 0 mm 10 8 Thickness Original wall thickness: 10.97mm 6 4 Minimum accepted wall thickness: 2 0 10.97mm 1990 1995 2000 2005 2010 2015 2020 2025 2030 2035 2040 Years Design Corrosion Rate: 0mm/year Min Design Assumed up to date Corrosion Rate (no corrosion reported on this piping): 0mm/year 21
  • PART 8: INSPECTION PLAN A- Vessel Inspection: 1- Internal Inspection: Vessel Highest Criticality rating: 5 (Extreme) Inspection Confidence Rating: High Inspection Interval Factor: 0.3 Maximum Internal Inspection Interval = Remnant Life X Inspection Interval Factor = 240 months X 0.3 = 72 months (6 years) (Last Internal Inspection was in 2002, next to be in 2008) 2- External Inspection: Technique Application Area Interval Failure to be monitored X-Ray Shooting Attached Horizontal nozzles and bottom Yearly Wall thinning vertical nozzles Ultrasonic Wall Bottom area of the vessel with height up 2 Yearly Wall thinning Thickness to 1660mm, covering the water phase Measurements area, with a 150mm grid Visual Inspection All flange connections Yearly Flange Leakage 22
  • B- Associated Piping Inspection: External Inspection: Piping Highest Criticality rating: 4 (High) Inspection Confidence Rating: High Inspection Interval Factor: 0.4 Maximum External Inspection Interval = Remnant Life X Inspection Interval Factor = 120 months X 0.4 = 48 months (2 years) (Last Inspection was in 2004, next to be in 2006) Application Area Material Corrosion Inspection Technique Interval Failure to be monitored Allowance 10-PO-30018-9145X Carbon Steel 1mm UT wall thickness measure 2 Yearly Wall thinning 10-PG-30002-AA02 Duplex Stainless Steel 0mm Visual Inspection Yearly Flange leakage 4-VF-42057-9341X 316L Stainless Steel 0mm Visual Inspection Yearly Flange Leakage 4-VF-42058-1341X 316L Stainless Steel 0mm Visual Inspection Yearly Flange Leakage 10-VF-42056-1341X 316L Stainless Steel 0mm Visual Inspection Yearly Flange Leakage 6-CD-40007-9341X 316L Stainless Steel 0mm Visual Inspection Yearly Flange Leakage 3-OW-40013-9341X 316L Stainless Steel 0mm Visual Inspection Yearly Flange Leakage 3-OW-40013-9143X Carbon Steel 1mm UT wall thickness measure 2 Yearly Wall thinning 6-PO-30019-3145X Carbon Steel 1mm UT wall thickness measure 2 Yearly Wall thinning 6-PO-30019-9341X 316L Stainless Steel 0mm Visual Inspection Yearly Flange Leakage 23