L&T Hydrocarbon Engineering - CEAI | Engineering · PDF fileL&T Hydrocarbon Engineering ......

L&T Hydrocarbon Engineering

Engineering Services - LTHE © 2017 : LTHE. All Rights Reserved 1


Engineering Services - LTHE © 2017 : LTHE. All Rights Reserved

Asset Integrity Management (AIM) : Basics▪ Hydrocarbon Sector – Key Challenges

▪ Three Elements : A, I & M

▪ Evolution of Maintenance Philosophy

AIM : Tools & Techniques▪ Simulation Techniques

▪ Fitness For Service (FFS)

▪ Risk Based Inspection (RBI)

▪ Corrosion Management Plan (CMP)

▪ Reliability Studies

▪ Root Cause Analysis (RCA)

▪ Remaining Life Assessment (RLA)

▪ Pipeline AIM

AIM in Practice : Examples

▪ Multi-disciplinary Solutions

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Talking Points




Offshore OnshoreConstruction

ServicesModular

FabricationEngineering

Services

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- Offshore Platforms- Modules & Pre-

assembled Units- Drilling Rigs & Floaters- Redevelopment /

Upgradation Projects- Subsea Pipelines- Subsea Systems

- Petroleum Refining- Gas Processing- Fertilizer- Petrochemicals- Cross-country Pipelines &

Terminals- Cryogenic Storage Systems

- Site Development & Pile Foundation

- Complete Civil & structural Work

- Plant & Non-plant Buildings

- Piping & Mechanical Erection

- Electrical & Instrumentation

- Tankages- Laying of Cross-country &

In-field Pipelines

- Offshore Structures & Modules

- Onshore Structures & Modules

- Modular Process Plants- Modular Reformer

Packages- Refinery &

Petrochemical Plant Equipment Skids

- Pipe Spools fabrication

- Concept Studies- Front End Engineering

Design (FEED)- Detailed Engineering- Engineering for Thermal

systems & Modular Plants

- Advanced Engineering- Special Studies- EPCM/PMC/E&P

services- Trouble-shooting & de-

bottlenecking



Asset Integrity Management : Basics

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▪ Strategic and geo-political significance of Projects : Very High

▪ Stringent operating conditions (pressure, temperature, flowrates, mechanical / thermal loading………)

▪ Aggressive fluids (hazardous, toxic, flammable, corrosive, abrasive…....)

▪ Adverse environmental conditions (deserts, deep sea, near-arctic locations with extremes of temperature, humidity, wind / wave loading)

▪ Safety-critical Installations (Accidents can be catastrophic)

▪ Prohibitive costs of shutdown (in case of unforeseen plant outages)

▪ Reliability of operation (must be ensured over entire design life of 25 – 30 years)

Hydrocarbon Sector : Key Challenges

The Industry is constantly searching for better design, engineering and technological solutions to mitigate the huge risks



▪ Assetso Plant and Machinery: Static Equipment, Rotating / Reciprocating Equipment

o Offshore Assets: Jackets, Decks, Pipelines, Flowlines

o Onshore Piping & Pipelines : Above-ground / Under-ground, Pipe Racks

o Civil Infrastructure: Buildings, Industrial Structures, Bridges, Flyovers, Highways, Ports, Airports

o Transportation Assets: aircraft, ships, tankers, railway rolling stock, automobiles

o Power Sector Assets : Generation, Transmission & Distribution Equipment

o Telecommunication Assets ………….

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The Three Elements : A, I & M

▪ Integrity o Ability of the “Assets” to safely perform their intended functions under prescribed conditions over a

specific period of time

o Integrity is compromised due to degraded performance / safety / quality parameters; obsolescence; unforeseen damage, breakdown or failure

▪ Management o To ensure, through proactive planning and actions, that the integrity of the Assets is not compromised

o To implement prompt remedial measures wherever lack of integrity of Assets is envisaged



Break-down Maintenance

Time -

scheduled

(Preventive)

Maintenance

Condition-

based

(Predictive)

Maintenance

Diagnostic

(Proactive) Maintenance

Maintenance Philosophy - Evolution

“If it isn’t broken, don’t fix it!”

Regular intervention to avoid unplanned

shutdown

Trend Analysis of parameters to detect

abnormality

Expert Assessment and remedial intervention

Power Plant / Process Plants (continuous

operation)

Only for non-critical systems and redundancies

Periodic trend analysis on condition of

plant assets

Pre-emptive measures for critical systems –

needs diagnostic expertise



The Bathtub Curve

58



Design / Engineering

Manufacturing / Assembly / Installation

Pre-commissioning / Commissioning /

Performance Tests

Operation & Maintenance

Shutdown & De-Commissioning

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Key Stages in Asset Lifecycle

▪ Management of Asset Integrity starts right from the Design stage of the Assets and continues through the operating life of the Assets

▪ Therefore, a holistic approach is needed, involving all Stakeholders, to ensure proper Asset Integrity over the entire lifecycle of the Asset



AIM : Tools & Techniques

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Design & Engineering Operation & Maintenance

AIM : Tools & Techniques

▪ Simulation techniques

o Chemical Process (Static / Dynamic)

o Mechanical (FEA based stress analysis)

o Thermal-Fluid Systems (CFD Studies)

▪ Design Verification

o Scale-up Studies

o Prototype Testing

o Pilot Plant trials

o Experimental stress analysis

▪ Reliability Assessment

o RAM Study

▪ Corrosion Assessment

o Risk Based Inspection (RBI) Report

o Corrosion Management Plan (CMP)

▪ Periodic Monitoring techniques

o Vibration & Noise

o Wear Debris Analysis

o Thermography

o Process parameters trending

▪ Non-destructive Testing

o UT, DPT, MPT, RT, PAUT

▪ Remote Monitoring / Diagnostics

▪ In-service inspections (on-line)

▪ Shutdown inspections

▪ Activities under RCM program

▪ Fitness For Service (FFS) Study

▪ Residual Life Assessment (RLA)

▪ Root Cause Analysis (RCA)



Simulation Techniques in Design / Engineering

▪ Chemical Process Simulation (Steady-State, Dynamic and Multi-phase systems)

▪ Mechanical Simulation (FEA based Stress Analysis solutions involving Static, Dynamic, Elasto-Plastic, non-Linear and multi-Physics environments)

▪ Thermal-Fluid System Simulation (CFD techniques applied to thermal and fluid systems; Combined FEA + CFD Studies)

▪ Materials Simulation (Corrosion Rate, Crack Propagation, Material Characterization)

▪ Structural Simulation (specialized studies for offshore structures, platforms, jackets and sub-sea pipelines)

▪ Power Plant Simulation (Dynamic Simulation of Steam and Electrical systems and development of Operator Training Simulators)

▪ Interaction Modelling (Fluid – Structure / Soil – Structure / Wind & Wave Loading)

▪ Multi-D Modelling (4-Dimensional, with Time aspect included)



Fitness For Service (FFS)

▪ Fitness For Service (FFS) Assessment is a quantitative engineering evaluation to demonstrate the structural integrity of new and in-service components / equipment and the safe and reliable operation for desired future period.

▪ It is based on a multi-disciplinary engineering analysis approach and also known as Engineering Critical Analysis (ECA)

▪ FFS philosophy requires the specific “damage mechanism” to be identified, which then leads to further assessment and decision-making.



▪ API RP 579 /ASME FFS-1-2007 : Fitness For Service Assessment methodology (11 Modules / 3 Levels) : For equipment designed as per ASME B&PV Code / ASME B 31.1 / ASME 31.3 / API 620 & API 650

▪ BS 7910-2005 : Guide To Methods For Assessing The Acceptability of Flaws in Metallic Structures (3 Modules / 3 Parent Levels) : For all metallic components

▪ British Energy Standard R5: Assessment of Structural Integrity at High Temperature

▪ British Energy Standard R6: Assessment of Integrity of Structures Containing Defects

FFS : Major Approaches



Risk Based Inspection (RBI)

OBJECTIVES

o Identify Operational Risks

o Specify approach for Inspection based on the Risks

o Safeguard Safety of Personnel, Assets and Environment

o Increase Plant Availability by avoiding Unplanned Outages

o Gain Monetary Benefits

▪ Risk Based Inspection (RBI) is a structured process that Identifies, Assesses and Maps RISKS (mainly due to corrosion) and recommends the optimum Inspection Philosophy for Assets.

▪ Typical methodologies adopted are API / DNV, or Company-specific (e.g., Shell, Petronas)

▪ Severity of Risk is determined by the Probability and the Consequences

Typical Risk Matrix



Corrosion Management Plan (CMP)

▪ Corrosion Management Plan (CMP) provides comprehensive recommendations,

developed during design / engineering phase, to the Asset Owner / Operator for

mitigating corrosion-related Risks. This is based on appropriate selection of materials

and optimum inspection philosophy.

DEFINE

MITIGATE

CONTROLASSESS

MANAGE

RISK

o DEFINE : Process & Environmental Threats

o MITIGATE : through right Material Selection

o CONTROL : through additional Barriers

o ASSESS : Criticality of Threats

o MANAGE : through appropriate Inspection



Reliability Studies

▪ Reliability is the ability of a system or component to function under definedconditions for a specified period of time.

▪ Reliability Engineering is a probabilistic methodology that deals with the estimation, prevention and management of high levels of "lifetime" engineering uncertainty and risk of failure.

▪ For operating process plants Reliability aspects are handled at two level:

o RAM (Reliability, Availability & Maintainability) Study - undertaken during Design / Engineering phase

o RCM (Reliability Centered Maintenance) Methodology - implemented during Operation and Maintenance phase



Risk vs Cost / Complexity Assessment

Typical Fault Tree Diagram

Reliability Test Plan of Equipment

Tools For Reliability Study

Cost



Root Cause Analysis (RCA)

▪ Root Cause Analysis (RCA) is a systematic, multi-disciplinary approach to determine the causes behind any failure.

▪ The primary objective of RCA Study is to understand the causes responsible for any failure, so that the findings can be utilized to:

o Prevent any future occurrence of such failureo Improve design of products / systems and o Revise operational guidelines for minimizing failures / plant outages

▪ Standard techniques for performing RCA:

o Fault Tree Analysis (FTA)o Failure Mode & Effect Analysis (FMEA)o Fishbone (Ishikawa) or Cause-&-Effect Diagramo Pareto Analysiso 5-Why Methodology

Governing Standard:

IEC 62740 : 2015



Remaining Life Assessment (RLA)

▪ Remaining Life Assessment (RLA) is a structured study that is performed to

establish the following:

o Appropriate inspection interval for equipment / pipingo An in-service monitoring plan for the plant and equipmento Need for remediation of any defect / damage to avoid failureo Decision about plant upgrade / revamp / decommissioning

▪ RLA is a multi-disciplinary approach (typically involving Materials & Corrosion, Mechanical and Process disciplines)

▪ RLA is typically undertaken for High Pressure / High Temperature equipment and Aged Assets

▪ RLA does not provide precise estimate of actual time to failure

▪ Remaining life estimates fall in either of the categories:

o Remaining life calculated with reasonable certainty

o Remaining life cannot be established with reasonable certainty

o There is little or no remaining life



Asset Integrity Solutions : Pipelines

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Asset Management : Pipelines

Pipeline Design /

Engineering

Flow Assurance

Studies

Material Selection & Corrosion Protection

Process Hazard

Analysis



• Audits of existing Cathodic Protection (CP) systems

• AC Interference Investigation (ACI)

• Close Interval Potential Survey (CIPS)

• Direct Current Voltage Gradient Survey (DCVGS)

• Pipeline Current Mapping Survey (PCMS)

• Soil Resistivity Check and Soil Analysis

• External Corrosion Direct Assessment (ECDA)

• Internal Corrosion Direct Assessment (ICDA)



AIM in Practice : Some Examples

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Example: Process Design / Simulation



Fig 2. Phase Envelope Curve

-80

-60

-40

-20

0

20

40

60

0 20000 40000 60000 80000 100000 120000 140000 160000 180000 200000

Onshore II Onshore III Trunkline II TrunkLine III

Fig 1. Pipeline Profile

Fig 3. Schematic Diagram of OLGA Network

- PipelineFig 4. Schematic Diagram of OLGA

Network - Well bore



Example : FEA / CFD / Noise Mapping



Example : Design Integrity - Offshore Assets



Example: Vibration-based Fault Diagnostics

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6.7 mm/sec @

18.75 Hz

3.53 mm/sec @ 18.75 Hz

25 Hz

1.55 mm/sec @ 18.75 Hz

Vibration Spectrum : Horizontal (X)

Vibration Spectrum : Horizontal (Y)

Vibration Spectrum : Vertical (Z)



Example : Monitoring by Thermography

Gearboxes Bearing Lubrication

Rolling Element BearingsRefractory Lining of Duct

Transformer Unit

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Example : Materials & Corrosion Studies



Example : Hazard Assessment Studies

▪ Stack Emission▪ Flare Radiation▪ Gas Dispersion▪ Hydrocarbon Leakage▪ Fire Incident▪ Explosion Modelling



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L&T Hydrocarbon Engineering - CEAI | Engineering · PDF fileL&T Hydrocarbon Engineering ......

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