Valero Benicia’s

Mechanical Integrity Program

Karen Muehlbauer
Mechanical Reliability Manager
Thursday, March 27, 2014

1
 Mechanical Integrity

The objective of the mechanical integrity (MI)

program is to prevent a “loss of containment.”
-A loss of containment can result in personnel exposure, fire,
equipment damage, or environmental impact.
-MI is a structured system for inspection, testing and preventative
maintenance (ITPM) of refinery facilities. This system is essential to
preserve the mechanical integrity of the equipment and provide an
operation which meets high standards of safety, health, and
environmental performance.
-MI applies to existing facilities, new construction, modifications to
existing facilities, and replacement-in-kind repairs.

2
 Mechanical Integrity

- The Mechanical Integrity program addresses

inspection, testing, and preventative maintenance
(ITPM) in the following areas:

Piping Fixed Equipment Relief Systems

Valves Rotating Equipment Vent Systems
Electrical Instrumentation Controls
Alarms Interlocks Monitoring Devices
Emergency Shutdown Systems

3
 History and Benefits of RBI

Benicia utilizes a Risk Based Inspection Program (RBI) in accordance with API RP 580/581
Program Development:
 Benicia has a strong RBI heritage (approved program since 2003)
 November 2011 initiated plant wide roll-out:
• 3rd Party asset management company (Pinnacle)
• Inspection Data Management System (PCMS)
• Consistent approach across the VLO circuit

4
 History and Benefits of RBI
Risk Based Inspection Program (RBI) (Cont.)

Benefits of a Comprehensive RBI Program:

 Insures that inspection resources are focused in the areas of highest risk:
• Defined Inspection Plans
• Damage Mechanism Specific
• Defined Inspection Effectiveness/Inspection Credit

Other benefits:
 Drives appropriate and timely equipment replacements and upgrades
 Drives the T/A Risk Based Work Selection process
 Generates Corrosion Model Diagram (CMD), Material Operating Envelope (MOE)
limits

5
 Mechanical Integrity

Stream Data – Process Eng • Crude Selection/

- AspenTech: Hysys Model Evaluation Guidelines
- Confirmed through sampling • Unit Health
Monitoring (UHM)
• Industry Knowledge

Field Inspection
- External Visual
Materials Review
- Ultrasonic Thickness
- Review of Damage Mechanism
- Cracking Inspection
- Establish Matl Operating Envelop
- Special Emphasis (
High Temp Sulfidation,
CUI, Nap Acid, Etc.)
Inspector Review
- Review Inspection History
- Develop Appropriate
Inspection Plan
6
 Process

Inspection

Planning &
Operations

Engineering

Optimization
Personnel

Environmental
Master Equip List

x
x
(MEL)

x
Process Info

Conseq of Failure

x
x
x (CoF)

x
x Unit Margins

PID
x

Review
x
x
x

System Review

Damage Mech
x
x
x

Review
Valero Support

x
x
x

Conseq Review
x
x
x
x
x

Validation Mtg

Inspection
x

Planning
 Mechanical Integrity

- A multidisciplined group is key to developing a

successful RBI program
- RBI is a focused inspection program reducing the risk
and improving mechanical integrity of fixed equipment
and piping across the refinery.