Interested to learn how Inspecta can help you? We invited customers and partners to a presentation of Certification. Topics in the attached Slideshare is: - Inspecta Overview - Integrity Engineering - Definition and lifecycle perspective - Design verification and optimization - Revisions, Fitness-for-service evaluation, Inspection planning - Non-Intrusive Inspection (NII) - Examples of Assignments and Projects

1. Inspecta – Overview of Integrity Engineering Services
OTD 2014, October 15, Bergen
1 16/10/2014

2. Contents
• Inspecta Overview
• Integrity Engineering
− Definition and lifecycle perspective
• Design verification and optimization
• Revisions, Fitness-for-service evaluation, Inspection planning
• Non-Intrusive Inspection (NII)
• Examples of Assignments and Projects
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3. Inspecta Integrity Engineering
Fast facts
Competence
• 80 highly skilled and experienced engineers
• Design optimization and design verification
• In-depth damage assessments and inspection planning,
risk assessments
• Structural integrity, fitness-for-service, life time extension
• Welding technology
• Quality assurance
Experience
• Over 30 years of experience from providing independent
assessments and consultancy in the industry
• Nuclear Power, Conventional Power, Pulp & Paper, Rail,
Mining, Oil & Gas and Aerospace
• Contracted for method development and research
performed by experts with international leading
competence
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4. 2014-10-16
Integrity Engineering

5. Integrity Engineering is design, assurance, and verification
to ensure that a component, process or system, meets its
intended function and requirements over the lifecycle
Should minimize costs together with technical and legal risks
2014-10-16
Integrity Engineering

6. Integrity Engineering
New trends in a lifecycle perspective
Integrity Philosophy
HSE & Risk Engineering
Integrity processes
Fit for service
Integrity plans
Integrity analyses
Continuous improvement
Verification and audits
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FEASIBILITY CONSEPT EXECUTION OPERATION

7. Integrity Engineering
New trends in a lifecycle perspective
Integrity Philosophy
HSE & Risk Engineering
Integrity processes
Fit for service
Integrity plans
Integrity analyses
Continuous improvement
Verification and audits
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FEASIBILITY CONSEPT EXECUTION OPERATION

8. 2014-10-16
Design and
modification

9. Design optimization and verification
Optimization and Qualification of Strength and Reliability
• Qualification and optimization of strength and reliability of
mechanical components with respect to degradation
‒ Pressure vessels, piping systems, welded joints, bolts, steel structures,
lifting equipment, gear boxes, shafts, polymer piping, concrete structures
• Stress analysis and assessment of failure modes
‒ Plastic collapse, ratcheting, fracture, fatigue, creep, SCC, HIC,
corrosion, seismic assessments,...
‒ Design by formula and advanced FEM
• Specification of applicable load cases
‒ Identification of loads (normal operation, upset, exceptional),
assessment of applicable load levels and load combination
• Design verification according to international codes
‒ EN13445, EN13480, ASME VIII Div 2 and Div 3, ASME III, …
‒ NORSOK, DNV RPs, ISO, Eurocode, …
‒ ProSACC, FITNET/R6, BS7910, ASME XI, API 579/ASME FFS, …
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10. Design optimization and verification
Optimization and Qualification of Strength and Reliability
• Residual stress analysis and optimization
‒ Weld residual stress analysis
‒ Optimization of welds and surface treatments
for Residual Stress Design
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Stainless
Inside back weld
Path
Inconel 82 weld steel weld

11. Design optimization and verification
Manufacturing quality verification and documentation
• Required defect limits in manufacturing inspection
‒ Use of detailed requirements for NDT in specific applications
‒ Reduction of repairs - Which defects/indications require repair?
• To avoid unnecessary repairs that influence material properties,
and to reach relevant costs in manufacturing inspection
• ASME III Code Case N-818 approved (nuclear components)
• JIP by DNV ongoing for similar guideline for Oil & Gas
• Acceptable defect size in different components / regions
‒ Identification of possible defect types and causes during manufacturing
‒ Definition of application specific loads, including fatigue loads
and residual stresses
‒ Specific material properties may be applied
‒ Damage tolerance assessment of components and structures with safety
margins according to standards as API 579, ASME XI or ProSACC
‒ Optimization of welding / manufacturing with respect to defects & NDT
• Quality assurance
‒ Establishment of inspection and testing plans (ITP)
‒ Risk methods for decreased quality deficiencies in manufacturing
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12. Design optimization and verification
Particular knowledge and experience valuable for Oil & Gas
• New standards in Oil & Gas increase the need for deep knowledge in fracture
mechanics, weld residual stress analysis and fatigue
• This is our core competence!
‒ We have engineers with long experience from work in the safety critical nuclear industry, within
these areas Design optimization and verification, Adapted inspection plans and Lifetime extension
‒ Good track record in contract method development, with capacity to realize useful solutions.
• Design Optimization and Verification – new guidelines including fracture mechanics
‒ ASME VIII, Div 3 for high pressure vessels (>10 ksi / 70 MPa) and new guideline API 17TR8
‒ DNV RP-F112 – Hydrogen Induced Stress Cracking (HISC) in super duplex steel with cathodes
• FFS and Life Time Extension – guidelines from API, DNV, NORSOK, OLF, …
‒ Our experience in fatigue assessments and development of adapted inspection plans
12 October 16, 2014

13. 2014-10-16
Fitness-for-service
evaluation
Revision and inspection
planning - ProSACC

14. Fitness-For-Service assessment
FFS assessments are used for evaluation of the safety margins when
operating components contain flaws or damage
– General / Local / Pitting Corrosion
– Hydrogen Damage
– Brittle Fracture
– Crack-Like Flaws
– Creep Damage
– Fire Damage
– Dents / Gouges
– Weld Misalignment / Shell Distortion
– Laminations
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15. Fitness-For-Service assessment
• Flaws and damage are found at revisions.
• FFS assessments for decision if continue operate,
provided that a suitable inspection and monitoring programs
• Continued operation is very valuable to secure a well prepared repair or exchange
• FFS also in processes for establishing intervals for revision/inspection,
by results established for assumed defects
• Inspecta has developed a procedure and software for engineering assessment of
components with defects.
o The procedure is mandatory for the Swedish nuclear industry
o Has been developed an maintained by Inspecta since 1991.
o Software for assessment following procedures ProSACC, R6, ASME XI and API 579/ASME-FFS.
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16. Procedure and software for FFS evaluation -- ProSACC
• ProSACC modules for integrity assessment of defects
‒ Handbook SSM 2008:01
‒ Stress intensity factor solutions and limit load solutions are
provided for a wide range of geometries, crack shapes and loads
‒ FAD procedure for evaluation of brittle fracture, elastic-plastic
fracture and plastic collapse
‒ According to ProSACC/R6/BS7910/FITNET and ASME XI
‒ Crack growth analysis modules for fatigue and stress corrosion
• Recently developed new functions
‒ Will be included in a new revision of handbook & software, August 2014
‒ Safety evaluation system for secondary stresses at ductile failure
‒ Solutions for new geometries and crack shapes (continuously added)
‒ Estimate of fracture toughness by use of the Master curve method
‒ Updated recommendations for weld residual stress profiles
‒ Evaluation of ductile tearing (J-R-evaluation)
‒ Probabilistic evaluation of defects (using Monte Carlo and FORM)
‒ Module for evaluation of crack opening areas and leak rates
for LBB evaluation
‒ Module for management of piping or multiple components under development;
improves piping data transfer, common data and updates
‒ Use of CTOD as complement to fracture toughness (measured - for API5 79)
• Training
‒ We give training courses in FFS analyses for the Swedish process
industry (usually ProSACC but also API 579-1/ASME FFS-1)
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17. Data needed for a FFS assessment
Information needed for a comprehensive FFS calculation
of a component/equipment is summarized below.
• Geometry and supports
• Material specification
• Loading conditions and process environment
• Inspection and NDT data
• Damage mechanism identification
• Safety margin requirements
(Conservative data can be estimated by Inspecta when data is lacking)
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Phased Array UT

18. Inspection Planning in the Nuclear Power Industry
Experiences and lessons from development during 1994 - 2014
1994:
• New regulation that require establishment of adapted plans for
recurrent In-Service Inspection.
o Previously prescribed fix inspection intervals
o New regulation due to unexpected failures and damages
• Basic classification methodology developed (qualitative RBI)
considering:
o Damage mechanism susceptibility assessment
o Simplified consequence assessment
o Simplified FFS analyses
• Defects found during revisions needed more detailed FFS
assessments. This frequently caused extended outages.
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19. Inspection Planning in the Nuclear Power Industry
Experiences and lessons from development during 1994 - 2014
2004:
• Two different methodologies for quantitative RBI applied (and developed)
o Extensive work load to implement these detailed methods
• Decision to start work for having complete FFS analyses for all critical
equipment, finalized before the revision
o Previously a history of many extended revisions due to the need for detailed
analysis of defects after they were found
• …
2014:
• Approved FFS analyses in advance to revisions for all critical equipment
o for decision if can wait to repair; for better preparation, and at best opportunity
• Conclusion that semi-quantitative RBI methodology may be most efficient
o Supporting documents developed by probabilistic analyses
o Systematic assessment of the effect of different POD for NDT
• …
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20. Processes and guidelines for recertification, revisions and life time extension
-- fundamental steps
Example - Recertification process for used equipment in DNV RP E101:
Acceptance criteria
- cover both fabrication defects and operational related defects
- the basis for acceptance criteria shall be documented
- acceptance criteria for highly stressed areas and less severe areas ¨
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21. 2014-10-16
Development
• Implementation of
Non-Intrusive
Inspection (NII)

22. Development of process for implementation of NII
Development of work process for pre-analyses and performing NII
• Well connected process, from preparatory analyses, to
performing the NDT, to evaluation of the findings
• Sufficient safety margins according to standards and codes
Basis for developing the process for NII:
• DNV’s Recommended Practice G103 for NII, with modifications
for improvement:
o Increased use of quantitative values in parts of the process
o Integration with Fitness For Service analysis API 579/ProSACC
o In-depth corrosion and degradation assessment process
o Improved connection between the adjustment of intervals and
the nature of degradation mechanism and uncertainties
o Efforts for NDT performance demonstration and training in the
process
 Inspecta’s work with similar challenges in the nuclear industry
and the pulp industry
Degradation analysis
• General corrosion
• Pitting, Crevice corrosion
• CO2 and H2S corrosion
• Galvanic corrosion
• Bacterial corrosion
• Erosion corrosion
• Stress Corrosion Cracking
o Chloride
o Sulphide
o …
• Fatigue
• Creep
• …

23. Main steps in the process:
– Systematic and detailed assessment per region in vessels
– Corrosion and degradation assessment
 Identify damage mechanism based on materials, media, temperatures,…
 Growth rate assessment, from inspection history and findings for thinning, and
otherwise by expert assessments and monitoring of corrosion conditions
– Assessment of acceptable defect size
 Considering materials, defect type, pressure, temperature, load cycles, …
 FFS assessment with safety margins according to API 579 or proSACC
 Interval by growth assessment for corrosion and other degradation
– Assessment of NDT performance
 Selection of inspection method(s) and coverage related to defect type and size
 Technical motivation of detection capabilities and limitations (following ASME V
Article 14 and ENIQ QMD)
 Validation/test of NDT performance - connected to acceptable defect size
– NDT of vessel and assessment of results
• Standard NII plan, including
o degradation type, NDT method(s), detection limit, areas, etc.
o scaffolding, removal of insulation, opening, empting, cleaning, etc
• Evaluation of findings and feedback, documentation of inspection history
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R6
Critical region (failure)
Non-critical region (safe)
Development of process for implementation of NII

24. 2014-10-16
Examples of
• Assignments
• Projects

25. CASE: Fitness-For-Service assessment for oil & gas separator
• At the turnaround for a platform in 2012 defects
were detected in the first stage separator.
• Inspecta was commissioned to carry out
fitness-for-service evaluation to assess which
nozzles that needed to be repaired.
• 23 reportable indications were found in 8 out of
12 welds between nozzles and the vessel.
• Stress analyses were performed for the vessel
including detailed modelling of the 8 nozzles
and interacting equipment.
• The most probable root cause for the defects
was determined to be lack of fusion.
• Safety margins with respect to fracture and
plastic collapse were evaluated in accordance
to Level 3 in API 579-1 and ProSACC.
• The conclusion from the FFS analyses of the
23 defects was that only one nozzle needed to
be repaired.
• An extended outage was avoided.
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26. Challenges in Subsea Integrity Engineering
Causes for incidents in the North Sea
based on a survey performed by DNV and
reported in its Recommended Practice for Integrity
Management of Subsea Pipeline Systems. Equipment/Issue Threat
Threats to Subsea Production North Sea
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Rigid Risers Corrosion, Fatigue, Damage
Flexible Risers Water ingress/corrosion
End fitting failure
Carcass failure
Unpiggable Pipelines Corrosion
Moorings Fatigue / wear
Manifolds Fatigue , Damage
Wells / Xmas
trees/BOP
Seal, mechanical damage
Valves Mechanical failure
Maintain information
overview
Loss of containment due to
missed integrity issue
Align best practice for
Asset Integrity subsea
Loss of containment due to poor
integrity practice
Information gathered during meetings with BP and Shell. Loss of
hydro carbon containment is the key threat for all operators.
27%
5%
11%
18%
24%
5%
10%
Corrosion
Natuarl Hazard
Other
Anchor
Impact
structual
Material