Presented by Mahendra , Hall of Fame Global Speaker & AIM Expert in 3rd Asean Refining & Petrochemical Forum 3017 Conference on " How MIQA can ensure the process safety of ageing petroleum industries which requires top driven proactive reliability culture , in-house technical expertise & operational discipline"

2. MIQA, An Ultimate Element of PSM
Implementation
AIM of process Safety Management
PSM Objectives
What’s MIQA , An Ultimate Element of PSM
Why Reliability of Static Equipment Important ?
Real Root Causes of Poor Reliability of Static Equipment
Global Scenario of Static Equipment
:”Wake up Call” to Operators of Ageing Petroleum Industries
MIQA in Ageing Assets : A Global Challenging Problem
Way forward to MIQA in Ageing Plants
Why MIQA (AIM/RBI) fail and how to get success

3. AIM of Process Safety Management
Develop plant’s systems & procedures to
prevent unwanted releases of spills &
emissions, which may ignite and cause
disaster of toxic impacts, local fires, or
explosions in plants - affecting people,
nearby Communities , Environment &
Image of Company

4. Flixoborogh, 1 June 1974
Additional facility built in 1972 for the
production of Cyclohexanone
•Used to produce Caprolactum intermediate
for the manufacture of nylon
• Section 25A involved oxidation of
cyclohexane at 8.8 Barg / 155°C
• The reaction was carried out in six liquid
phase reactors
•Each reactor was set 14” lower than the
previous to allow the liquid to flow under
gravity through the reaction train.
• March 27th 1974, a crack developed in
reactor number 5. The maintenance engineer
recommended shutdown for 3 weeks for
repair
Flixoborogh, 1 June 1974

7.  Proactive identification, evaluation and
mitigation of chemical releases that could
occur as a result of failures of processes,
procedures or equipment.
 Proactive control of the consequences of
catastrophic releases of highly hazardous
chemicals from a process.
PSM Objectives :

8. Out of 14 PSM Elements, MIQA is Ultimate for Process Safety

10. MIQA shall ensures 360⁰ Integrity
of equipment starts from inception of
its Design , Construction, Startups,
Commissioning , Operation, Turnaround
till Decommissioning, to prevent out of
containment of hazardous liquid & gases
from its pressure boundary

11.  Pressure Vessels and Storage tanks
 Piping systems including all components
 Relief & Vent systems and associated devices
 Safety Instrumented Systems (SISs) and Emergency
Shutdown (ESD) systems - Process control systems -
Controls system including monitoring devices and
sensors, critical alarms and interlocks.
 Rotary equipment
 Electrical equipment
Equipment Under MIQA

12. Identification and documentation of PSM critical equipment
MIQA Implementer Team
PSM critical equipment review
Quality Assurance of New Equipment
Maintenance, Inspection And Testing of Equipment
Repairs and Changes
Maintenance Procedures /schedule
Maintenance training
Quality Control of Maintenance, Repair and Operation (MRO) Materials and Spares
Reliability Engineering
Predictive Maintenance Program
Documentation
MIQA PROCEDURE

14. Ageing is the main cause of poor reliability of Static Assets

16. MIQA
VISUALIZING
RISKS & OPPORTUNITIES
IN AGEING ASSETS

17. Why Do
Equipment Age & Fail
in Petroleum
Industries

18. What’s Ageing & What are Aged Equipment ?
 Ageing is not by no. of years equipment passed
but by its present condition
 Aged Asset that outlived its useful life and may
include the equipment still functional but
expensive to operate/maintain, still works but
breakdown frequently disrupting operation or
equipment that broken and it is too expensive to
repair
Ageing Assets, a serious concern in petroleum industries for its sustenance

19. Broadly due to
poor design/construction and
In-service corrosion/ metallurgical
degradation due to poor
maintenance / mal-operation
Leading to Over ageing & premature
failure in catastrophic manner

20. Causes of Design Deficiencies
 No consideration of Geographical features & types
of crude processing while setting up refinery
 Poor knowledge & experience of designer for
selecting material, its degradation & protection
 Poor knowledge of NDT technologies, its selection
and practicality
 Economical Metallurgy due to limited budget

21. Off Spec. Materials
Noncompliance in
 METALLURGY
 Heat Treatment Condition
 Forming Method
 Dimensions & geometry
 Poor packing & dispatch

22. Metallurgy Mismatch
 P9 material in place of P91 resulted catastrophe just
after commissioning
 Carbon steel in place of Alloy steels
 SS 304H in Place of SS 304L & vice versa
 SA 516 Gr70 in place of SA 516 Gr60 in NACE & Caustic
Service
 Ordinary Brass in place of Ar stabilized Admiralty Brass
 SS 304 piping in place of SS 321

23. Heat Treatment Condition
 No Stabilization Treatment of Stabilized Grade SS 347 &
321 after welding leading to Chloride & Polythionic SCC.
 No PWHT of CS equipment after welding in caustic,
Amine, LPG, sodium carbonate & hydrogen Service causing
catastrophe due to SCC
 Failure of Admiralty brass U tube bundle in lube oil cooler
due to no solution annealing of tubes after bending
Use of SA191 Grade B7 studs in place of Grade B7M in
NACE H2S service

24. Dimension & Geometry/ Slope
Thinning of Elbow at Crown portion
 Undersize fillet welding in place of
Full Penetration welds
Out of roundness & Verticality in
Storage tanks

25. Poor Workmanship During Construction
 Welding by helpers / unqualified personnel
 Short Bolting
 Reverse Slope of pipelines causing inefficient
drainage
 Gas Cutting in place of Drilling for holes
 Box up Equipment with foreign materials
 Gas / Grinding Cutting of SS in place of Plasma

26. Construction Lapses
Poor workmanship & Nonstandard procedures
 Mismatch in Filler Wire.
 Improper baking of electrode / no or improper purging
 Metallurgy mix up.
 Non compliance of welding Procedure & repetitive repairs
 Manipulation in NDT & PWHT.
 Box up of Equipment With Foreign Materials
 No Dewatering & Dry up after Hydro Testing
 Poor Insulation: Aluminium clad on high temperature ASS lines.
 Poor Refractory Application & Dry out

27. Construction Lapses
Poor workmanship & Nonstandard procedures
 Poor application of coating & lining
 No Passivation & long idling without Preservation
 Use of Poor Quality water in hydro testing
 No PWHT ( Stabilization) in SS 321/347
 No SR of CS equipment in Amine, Caustic, LPG, H₂ service
 No RT after PWHT
 RT interpretation noncompliance with design need
 PWHT cycle problem in P91 & P92 dissimilar material.
 Poor control of welding parameters in Duplex & P91/P92.
 Lack of experience /poor qualification of QA/QC inspectors

28. Poor Start-Up & Commissioning Damages
Maximum damage in the life of a plant occurs
at start up Due to over run of operating
parameter and the remnant effect of this
damage may affect the design life significantly.
A step by step procedure if followed strictly
can give a safe and risk free plant start up & in-
turn smooth operation , longer run-length &
expected safer design life in future.

29. Post Commissioning Mal-Operation- No IOW
 Poor Control of Operating Parameters
 Long idling without proper preservation
 Inefficacy of dosing system for corrosion control.
 Running equipment beyond design parameters: No IOW
 Processing High TAN crude with low metallurgy
 Processing High NAN Crude with inadequate Metallurgy
 Running the equipment in leaky condition

30. Frequent Steam & Power Failures
 Thermal fatigue, Thermal Shocks Causing metallurgical
degradation due to thermo-mechanical Stress in High
Temperature Equipment.
 Accelerate corrosion due to stoppage of pumps causing
condensation of acidic gases in overhead circuit leading
to dew point corrosion at each event.
 Starvation of water in PG boilers leading to creep
failure .

31. Capacity Utilization Beyond Design
 Refiners running the plant as high as 120% to 140%
of its design just for greed of getting production or
breaking the previous bench mark records of
production causing high velocities of streams & high
temperature leading to erosion corrosion, fatigue &
creep damages.
 Change of crude (Opportunity crude) without
metallurgy up-gradation due to international market
drive & availability leading to faster rate of corrosion.

32. Frequent change of Inspectors
 Poor inspection recommendation
 Poor documentation.
 Lack of proactive skill & confidence In
Decision Making
 All above lead to confusion & chaos in
turn poor reliability.

33. No Company Owned Standards & Practices
Nonstandard norms & practices of Inspection &
Maintenance result
Repetitive failure
More Maintenance & Inspection cost
Poor Reliability of Equipment
No in-house talent & expertise development
More dependency & panic at time of resigning
Confusion, chaos & delay in jobs

35. Impact of Ageing on MIQA
 Increased Unpredictable Failures & catastrophes
 More Unsafe situation & fatal
 Pressure from Regulators
 More repair & more maintenance cost
 Poor run length & On-stream Service factor
 Need more Inspection with Advance NDT & Heavy
Replacement for Life Extension.

36. As per the current industry climate, pipelines
may cost up to $ 3 million per km to replace
for prolonging the lifetime of infrastructure and
avoiding preventable damage is extremely
valuable to operators.
Ageing Pipelines & Replacement Cost
4 million KM Ageing Pipelines replacement in USA
shall cost $12000 billion which can break the
backbone of most developed economy of world

37. With the safety of personnel being a top
priority across the entire global industry,
operators must ensure they have robust
monitoring and inspection regimes, corrosion
monitoring techniques, risk assessments and
active maintenance programs in place to
safeguard against risk.
Life Extension of Ageing Assets

38. Continued operation of ageing assets,
through RLA & Life Extension Plans
Creating opportunities to lower costs and
increased profits for sustenance, but
need wisdom & expertize.
As the industry seeks to increase the economic life
of assets, many will remain in operation longer
than anticipated. Some oil and gas assets have

39.  Current condition assessment
 Life extension evaluation and GAP analysis
 Technical qualification for life extension
 Obsolescence preparedness
 Life extension costs and plans
Five-step approach for Life Extension

40.  Assess history & present status
 Detect symptoms of ageing
 Examine options: e.g. continued service, re-rating, repair, scrapping
 Use risk-based approach to identify critical systems and equipment
 Life extension evaluation and GAP analysis
 Determine modifications required
 Perform technical qualification to operate structures & equipment
beyond original design life
 Obsolescence preparedness
 Elongated term cost prediction
What we do in Life Extension?

41. AIMS outline the ability of an asset to perform its
required function effectively and efficiently
whilst protecting health, safety & environment
and the means of ensuring that the people,
systems, processes, and resources that deliver
integrity are in place, in use and will perform
when required over the whole lifecycle of the
asset
What’s AIM

42. An Integrity Management System should address the
quality at every stage of the asset life cycle, from the
design of new facilities to maintenance management to
decommissioning. Inspections, auditing/assurance and
overall quality processes are just some of the tools
designed to make an AIMS effective
The AIMS should also endeavor to maintain the asset in a
fit-for-service condition while extending its remaining life
in the most reliable, safe, and cost-effective manner. The
AIM programs (in the US) attempt to meet API-580, API-
581, and PAS 55 requirements, as applicable.

46. MIQA in Ageing Assets : A global Challenge
Ageing Assets : Predict, control , Monitor & Mitigate Complex Corrosion & Metallurgical Degradation

47. MIQA in Ageing Assets : A Global Challenge for PSM
Management of Ageing Assets: Need Top driven Reliability
Culture & In-house Team Expertise
Proactive Detection, Dynamic Risk Analysis and Timely Action for avoiding Catastrophes

48. Management of Ageing Assets: A Complex Problem

50. Corrosion is Cancerous disease to Industries
Specially Oil & Gas which can kill the total
economy of a company or country.
Are you aware of this fact ?
Replacement of Ageing Assets can break the
backbone of even most developed World
economy and life enhancement is the only
option to sustain.

52. MIQA in Ageing Assets & Cost Reduction
Arbitrary Cost Reduction : Increasing Risk of Replacing the Facility for sustenance

53. MIQA in Ageing Asset & Cost Reduction
Arbitrarily cutting skilled head counts
Increasing Risk to sustenance due to Poor Monitoring & Maintenance

54. MIQA in Ageing Assets :A Global Challenge for PSM
Way forward to Reliability of Ageing Assets

55. MIQA in Ageing Assets & Cost Reduction
Reducing Inspection Budget Arbitrarily : Increasing Risk to Sustenance

56. Risk Assessment Through RBI & FFS Technologies for
achieving Reliability of static assets, is the key to
survival for Ageing Petroleum Industries
Both Technologies are Complementary, Stands alone
separately but meet together in Crisis
MIQA & Management of Ageing Assets
World over, No break through yet for both RBI/FFS due to
lack of expertise , high complexity and poor culture

58. A New Way to Use RBI - The Long Play
While RBI will continue to be used in the short term to defer
inspections, its real power lies in its ability to create a long
term plan. Have you thought about using it for the long term?
the term "RBI it away" as in completing an RBI assessment to
make an overdue inspection disappear. These people are very
short sighted in their views of RBI's capabilities. RBI is a
powerful equipment life-cycle tool that can predict damage out
into the future, and the API codes allow you to take full
advantage of this technology.

61. Ageing Assets : A threat to sustenance , Environment & Human Life
MIQA in Ageing Assets : A Global Challenge for PSM

62. MIQA in Ageing Assets : A Global Challenge for PSM
Way Forward to Reliability: Life Time Integrated Integrity of Entire Plant

64. High Temperature Sulfidation
Ф8” 52” length piece u/s bend
Low Silicon CS

65. Tesoro Refinery, 2 Apr
2010, six fatalities

70. Thinning & Over pressurization

72. Importance of Reliability Culture

73. Importance of Reliability Culture
For long term survival, take significant management energy as well as strong commitment from all levels

74. Proactive Culture through MIQA, MOC & IOW Implementation

79. MIQA in Ageing Assets : A Global Challenge for
PSMGood Asset Integrity Management balances Design Integrity , Operating Integrity and Technical
Integrity in the most cost effective and productive way starting from plant design to end of life

90.  MIQA , most important Element of Process Safety Management and is ultimate to
prevent Out of containment of hydrocarbon or toxic liquid and gases avoiding fire ,
explosion and catastrophes by ensuring the mechanical integrity of assets at every
stage starting from inception of design to start up during construction and then
commissioning to and then during operation , break downs , turn around till
decommissioning.
 Global statistic of petroleum industries estimated 80 % static assets consisting mainly
pipelines, plant piping, pressure vessels and safety valves in refineries and
petrochemicals are aged either due to expiry or due to poor condition. These assets
are still productive but having lot of uncertainty for reliability and frequently failing
resulting catastrophes and explosion. Replacement of these assets is not feasible due
to high cost & time constraint. Life enhancement is the only option . MIQA needs top
driven proactive reliability culture , In-house technical expertize and operational
discipline along with time and funding.
Conclusion