Operational Excellence at Ibis Hotel London IQPC MAHENDRA
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Equipment at an oil refinery was aging and not being properly maintained, resulting in a catastrophic accident that killed six people. The document discusses the need to improve reliability for aging industrial plants to prevent dangerous failures through proper maintenance and repairs. Attention must be paid to safety as equipment gets older.
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Operational Excellence at Ibis Hotel London IQPC MAHENDRA
- 4. Ageing equipment if not being taken care, either they will kill us or get killed themselves
- 13. High Temperature Sulfidation Ф8” 52” length piece u/s bend Low Silicon CS
- 14. Tesoro Refinery, 2 Apr 2010, six fatalities
- 17. What’s the road to reliability for ageing plant?
- 23. Thank you
Editor's Notes
- What’s ageing: Ageing is not about how old equipment is; it’s about the condition and how it’s changing over time. These ageing assets are running above it’s design capacity due to increased demand of gas and petroleum in every corner of the world and processing more corrosive cheaper crude to survive competition and sustenance. These ageing assets are in vicious circle. one side suffering from frequent outages/catastrophes and pressure from regulators and other side from competition, high maintenance cost and loss of production resulting poor margin. Sustenance is at stake in present low oil price regime. What’s the way out.........
- Ageing management is cradle to grave life cycle process in the entire journey of asset / facility from it’s design to decommissioning. A plant which is no longer considered fully fit for purpose due to age related deterioration in it’s integrity or functional performance called ageing plant. Some facility are born sick during it’s initial operation itself. Some facility failed before it’s design life due to abuse in design , construction, start up and operation stage called premature ageing. Some facility performs satisfactory till it’s design without fail called as normal ageing and may have further life after expiry. Ageing of the facility depends upon “how it is being designed, constructed , operated and maintained “
- For effective maintenance considering safety / Reliability , API RP 581, API RP 580, and API RP 579-1 are widely practiced for RBI & FFS along with API Std 570, 510 & 653 of piping, pressure vessel & storage tanks. API RP 580 details the “what to do at a minimum for a credible RBI analysis and program;” whereas API RP 581 is the “how to do it” document. However API RP 579-1 is practiced , when the equipment degraded beyond its design spec for continue service to sustain the operation in exigency. API 571, 583, 584 and 585 are practices for Damage mechanisms, CUI, IOW & Pressurized Equipment
- Learning from past failures, could be a great help for avoiding the catastrophes in ageing assets. These four incident are the wake up call to all operators & regulators of petroleum installations. In spite of full fledged AIM/RBI/PSM implementation and safety guards/alarms with team of experts above four mishaps & several others could not be prevented and put up the question mark on the safety & reliability of the ageing assets even in the organization which are world fame and pioneer in the field. These mishaps changed the entire scenario of petroleum installation and directed to use the inherently safer materials and robust design to avoid mishaps and catastrophes instead using economical design and controlling operating parameters in a tight range.
- On 06Aug2012, explosion & fire took place due to Ф8” just upstream of bend rupture in LGO side stream of crude distillation of Chevron Richmond refinery in USA. Analysis of ruptured component indicated low silicon carbon steel material and failed due to high temperature sulphur corrosion (erosion corrosion phenomenon) which is localised damage mostly prevalent in the location of turbulence and high velocity region causing uniform thinning over a large area. Silicon content is an important parameter to prevent HTSC in carbon steel since silicon content if lower than 0.1% corrosion rate soot up exponentially. HTSC failures tend to involve rupture resulting large leaks rather than pinhole leak. Historical data revealed no thickness data recorded on this component in their RBI plans . This component was never replaced since its commissioning in seventies when there was no control over silicon content in CS. After USTM & silicon many other components were found having the silicon content lesser than 0.1%. This incident due to several fatalities , production loss and damage to plant and image/reputation of company has given big jolt to chevron. After that Chevron has developed new construction guidelines stating piping installed in high temperature and high sulphur service shall be constructed with 9 chrome steel. This incident has brought the revolution in material selection world over to “ use inherently safer material and robust design instead economical” to avoid failures and catastrophes. Hence let’s say “ Reliable is safe ! Safe is profitable”
- On 2nd Apr 2010 six fatalities with explosion / fire due to catastrophic rupture of CS heat exchanger shell in NHT took place in Tesoro refinery. In the fire zone there are six exchanger in two rows of three exchanger each in series. (Naphtha+hydrogen) feed tube side enter into heater at 550 ᴼF & 630 Psig. After heating at 625ᴼF, this feed enter into reactor for removing impurities from naphtha. The O/L feed of reactor passes shell side of exchanger A & D for cooling at 630ᴼF- 710ᴼF at 590 psig. After A & B, the effluent passes into B & E and then A & F for further cooling and finally effluent come out at 270ᴼF from exchanger C & F . Shell longitudinal joint rupture took place in exchanger E and in exchanger B circumferential joint was found cracked. Cause of rupture is due to long term hydrogen exposure of CS shell beyond the HTHA limit of Nelson curve of CS due to chockage of tube preventing heat flow from shell to tube in exchanger E & B. Investigation revealed there was no TI points on these exchangers. This incident brought the revolution in selection of material for resistant to HTHA and modified the Nelson curve & API RP 941 mentioning CS in high temperature can be used if the temperature is lesser than 400ᴼF & hydrogen Pressure is lesser than 50 psig. API 571 damage mechanisms recommend to use inherently safer material as 300 series as well as 5 Cr, 9 Cr & 12 Cr alloys or stabilized grades special Cr-Ni steel as in reformer. This incidents has brought the revolution to use inherently safer material instead using economical carbon steel and given big impact world over to modify the existing plant. Again Let’s say “ Reliable is Safe ! Safe is profitable
- Reliability has to start from inception of thought to have facility. Reliability is important start from conceptual design (feed data), detailed engineering, procurement, construction and start up till commissioning at every step but design stage it is easier and without expense. Hence during design stage the reliability shall be given special emphasis. RBI shall not be done during operation & turn around but it must be done during design and construction stage otherwise it becomes unreliable. Material spec., quality lapses and degradation are to be monitored & controlled at every steps in the entire life cycle of assets from its design to final decommissioning . if not done will result into in born sick plant & AIM/ RBI becomes herculean task.
- If you are attending maximum emergency jobs and unscheduled jobs and least planned / scheduled & preventive jobs in proactive manner then you are in sick plant and progressing lot of unknown ageing. In this situation , if you implement RBI/AIM with the service provider then you are certainly going to fail and result shall be even worst than without RBI. It is happening and happened all over the world. AIM / RBI has failed. Why? Lack of leadership Lack of approach to FMEA & RCA Lack of knowledge/in-house expertise Total dependency on service provider which are interested in their business more and reliability of your system less. Lack of data hindrance to quantitative approach of RBI Lack of monitoring for condition assessment Uncertainty of machine, technician , site condition and situation due to lack of time and access Lack of interface for ensuring integrity Remember Robust health of equipment along with in-house expertise & reliability culture are must to make AIM/RBI successful. Hence first step for ageing asset integrity management is to strengthen the health of equipment through FMEA or RCA instead just maintaining the equipment by just quick fixing the symptoms.
- AIM / RBI is the combined responsibility of each and every department including HR, Finance, Commercial & Contractual manpower. Hence everyone shall be aware and trained about reliability and what is their role in that.