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TWI 20160103 RPT 001 01 Risk Based Inspection Implementation10
TWI 20160103 RPT 001 01 Risk Based Inspection Implementation10
TWI 20160103 RPT 001 01 Risk Based Inspection Implementation10
Job Title:
Report Title:
Document No:
«TWI-20160103-RPT-001-01»
Issue Date:
«15-07-2018»
For:
TWI Endorsement
This report has been reviewed in accordance with TWI Persia’s Procedures.
Table of Contents
1 Executive summary ..................................................................................................................... 4
1.1 Background ............................................................................................................................. 4
1.2 Objective ................................................................................................................................. 4
1.3 Work carried out ...................................................................................................................... 4
1.4 Conclusion............................................................................................................................... 4
1.4.1 Refining unit .................................................................................................................... 4
1.4.2 Boiler unit ........................................................................................................................ 5
1.4.3 Distilled water .................................................................................................................. 5
1.4.4 Flare unit ......................................................................................................................... 5
1.4.5 Hadikhani plant................................................................................................................ 5
1.4.6 Power house ................................................................................................................... 5
2 Recommendations ...................................................................................................................... 6
3 Introduction.................................................................................................................................. 7
3.1 Description of the gas refining units and utilities ..................................................................... 7
3.2 Description of utilities system .................................................................................................. 7
4 Objectives .................................................................................................................................... 8
5 Approach ..................................................................................................................................... 8
5.1 Data Flowchart ........................................................................................................................ 8
5.2 RBI project team ..................................................................................................................... 8
5.3 Information used in the RBI assessment and assumptions .................................................... 9
6 Damage mechanism review ...................................................................................................... 10
6.1 Gas refinery ........................................................................................................................... 10
6.2 Boiler unit .............................................................................................................................. 10
6.3 Distilled water ........................................................................................................................ 10
6.4 Flare unit ............................................................................................................................... 10
6.5 Hadikhani .............................................................................................................................. 11
6.6 Power house ......................................................................................................................... 11
7 Risk assessment ....................................................................................................................... 12
7.1 Assessment of failure probability and likelihood ................................................................... 12
7.2 Assessment of failure consequence ..................................................................................... 12
8 Inspection history ...................................................................................................................... 13
9 Remaining life assessment and mitigation planning ................................................................. 13
10 System and Corrosion loops definition ..................................................................................... 14
11 Overview of the Results ............................................................................................................ 19
12 References ................................................................................................................................ 22
Appendix A - RISKWISE RLI results gas refining unit ............................................................. 23
Appendix B - RISKWISE RLI results boiler unit ....................................................................... 69
Appendix C - RISKWISE results PSV's ................................................................................... 73
Appendix D - RISKWISE RLI results distilled water ................................................................. 81
Appendix E - RISKWISE RLI results flare unit ......................................................................... 84
Table of figures
1 Executive summary
1.1 Background
As a part of Bid Boland Gas Refining Co. integrity management plan, the refinery aimed to
optimise their integrity management system through a risk based inspection (RBI) approach
To facilitate this requirement, TWI Risk Based Inspection (RBI) software, RiskWISE version 6
for process equipment, pressure relief device and storage tanks, was used to establish a
risk-based inspection plan to formalize and optimize in-service inspection and maintenance
plans and schedules for various pressure equipment within the refining unit, utilities and
Hadikhani plant.
1.2 Objective
Develop an integrity management plan via a risk-based inspection (RBI) approach using the
existing inspection information provided by B.G.R.C in order to various pressure equipment
within the refining unit, utilities and Hadikhani plant. To ensure appropriate future operation of
the asset; certificate are developed to document and present the results.
1.3 Work carried out
The results from all available previous inspections, maintenances and integrity assessments
were reviewed. The probability and consequence of failure were determined with respect to the
component damage found and the effectiveness of the inspection. TWI’s in-house RBI software
RiskWISE™ is used to capture plant information, and define safe inspection intervals
international standard best practice and methodology.
1.4 Conclusion
A RBI assessment has been conducted on Bid Boland Gas Refining Co, four refining units,
related boiler unit, distilled water, flare unit and power house and Hadikhani plant.
1.4.1 Refining unit
At gas refining unit on each unit on the 102 equipment RBI assessment carried out.
The results indicate that the following pipes need to be change.
12"AM-1201-203A, Rich amine from E5-B to T-2 at the unit 200,300,400 & 500
12"AM-1202-203A ,Lean amine from T-2 to E5-B at the unit 200,300,400 & 500
12"AM-1211-203A, Lean amine from T-2 to E4-B at the unit 200, 400 & 500
18"P-1205-203A, Acid gas from E-3A/F to D-2 at the unit 200,300,400 & 500
12"AM-1203-203A, Lean amine from E5-A to surge tank at the unit 200,300,400 & 500
14"AM-1301-203A, Lean amine from surge tank to MEA pumps at the unit 300, 400 & 500
12"AM-1302-203A, Lean amine from MEA pumps to lean MEA aerial cooler at the unit
400 & 500
4"AM-1303-203A, Lean amine from MEA pumps to filter-2 at the unit 200,300,400 & 500
4"AM-1304-203A, Lean amine from filter-2 to surge tank at the unit 200,300,400 & 500
6"P-1206-203A, Acid sour water from D-2 to reflux pumps at the unit 200,300,400 & 500
3"P-1207-203A, Acid sour water from reflux pumps to T-2 at the unit 200,300,400 & 500
30"P-1204-203A, Acid gas from T-2 to E-3A/F at the unit 200,300,400 & 500
3"P-1207-203A, Acid sour water from reflux pumps to T-2 at the unit 200,300,400 & 500
10"AM-1209-203A, Lean amine from E4-A to T-2 at the unit 200, 300 & 500
2 Recommendations
To mitigate the current low RLI and high risk predictions for components within Bid Boland gas
refinery, TWI recommended the following actions:
This assessment is based on the current feed gas composition. The plant operator stated
this will change in near future and therefore the impact of any changes needs to be
assessed.
A failure investigation is recommended to be conducted to identify the root cause of
cracking experienced in Rich and Lean Amine piping.
The above provides the main recommendations addressing critical issues within Bid
Boland gas refinery. In this project also provides the future inspection plan for all item of
equipment addressing all inspection issues.
The results of this study, highly depends on the data provided from plant operator,
previous inspection data, process information, etc. Therefore it is crucial for the user of this
RBI study to be aware of the criticality of data input.
In cases of there was no measurement thickness results for equipment, API 581 was used
to estimate the corrosion rate.
In the case of piping, the risks are the overall risk of each iso number. In order to obtain
the risk of piping in minor cases (example: reducer, elbow, tee, weld, different pipe size…),
first, CML's should be identified in the piping.
It is necessary to determine the CML's of having as built iso metric. To product iso
drawing, the entire site should be laser scan.
3 Introduction
Bid Boland gas refinery in the south west of Iran was commissioned in 1969 to refine the sour
gas collected from that area of the country to export and also feed the country’s main fuel
pipeline network. As a part of Bid Boland Gas Refining Co. integrity management plan, the
refinery aimed to optimize their integrity management system through a risk based inspection
(RBI) approach by implementing TWI RBI software, RISKWISE. TWI Persia, as a subsidiary for
TWI UK, carried out the implementation work with consultancy support from TWI UK. The RBI
study was conducted on four refining units, boiler unit, and distilled water, and flare unit,
Hadikhani & power house.
3.1 Description of the gas refining units and utilities
Bid Boland gas refinery has four amine treating units. The refinery was commissioned in
February 1965; however several changes have been made, so far, during the war. The sour
gas enters the refinery by a 40 inches transmission pipeline.
At each unit, there is a contact tower (T1) which removes H2S and CO2 using diethanolamine
(DEA) in units 200&300&400, methyldiethanolamine (MDEA) in unit 500. The refined gas,
known as sweet gas, exits from the top of the tower and is de-moisturized in the desalination
tower (T3) by using Silica Gel. The dry, sweet gas is then passed into the national gas pipeline
network through the Bid Boland gas pressurizing unit. The mixture of removed H2S and CO2
together with DEA & MDEA, known as Rich Amine, exit from the bottom of the contact tower.
The majority of H2S and CO2 are separated in the flash drum with inject lean amine at column
and sent to Fuel gas system and the lean amine going to the regenerator tower (T2) for
purification DEA & MDEA for the next cycle.
3.2 Description of utilities system
At the distilled water, soft water it is entered from Hadikhani facility and then storage to clarify
tank. Soft water supply to the distilled water unit after passing through pressure filter, base
exchanger and soft water storage tank, Enter the distilled water stage. Soft water in This stage
after passing through preheater, evaporator's 1&2, vapour separator's 1&2, distillate tank and
condenser's A&B be changed to distilled water and storage to distilled water tank.
Produced distilled water in this stage to be transferred boiler unit. At the boiler unit distilled
water is changed into LP steam & HP steam, to use in refinery gas unit.
4 Objectives
Implement a RBI program using the Oil and Gas version of TWI RBI software,
RISKWIS6 on the refining units and related utilities.
5 Approach
5.1 Data Flowchart
Figure 1 shows a flowchart that summarizes the steps towards creating criticality ranking in
RiskWISE®.
This is an equipment module where the user can view a summary of risk on an equipment level
(showing aggregate risk), and on a component level (separate risk per each component). The
risk is calculated for three Assessment Periods (AP1, AP2 and AP3), as per API 581
procedures corresponding to the chosen risk assessment methodology.
Thermal fatigue
Thinning; due to internal and external corrosion.
Caustic corrosion
Corrosion under insulation
Oxidation
Caustic stress corrosion cracking
Corrosion fatigue
Other mechanical or metallurgical
6.5 Hadikhani
To estimate the remaining life (RL) of each item due to corrosion (or corrosion/erosion), the
minimum required thickness (MRT) was supposed to be provided by original designer of the
equipment. A thickness limit equal to 2.54 mm was considered as minimum practical thickness
(MPT) where the calculations resulted in small values of thicknesses.
7 Risk assessment
TWI specialists were joined to the site team to carry out the assessment work. The task was to
facilitate a remaining life and risk assessment considering likelihood and consequence of failure
and finally propose risk mitigating actions (optimising and producing inspection/maintenance
plans). Risk is the product of probability or likelihood of failure and consequence of failure.
8 Inspection history
Inspection history for each component it’s provided in according to the employer's certificates
and part 2, annex 2.C API 581(2016).
9 Remaining life assessment and mitigation planning
To reduce the risk to an acceptable level and increase the RLI (Run Length Indicator) of the
plant to an optimum duration, a risk mitigation strategy is carried out after the assessment work.
The RLI stands for Run Length Indicator, and is a representation of remaining life. The risk
based remaining life of the component here is considered the time that risk will reach an
acceptable level (risk target). Figure 2 illustrates this concept with associated mitigation action.
Figure 9 Distribution risk matrix for the three assessment periods at unit 200
Figure 10 Distribution risk matrix for the three assessment periods at unit 300
Figure 11 Distribution risk matrix for the three assessment periods at unit 400
Figure 12 Distribution risk matrix for the three assessment periods at unit 500
Figure 13 Distribution risk matrix for the three assessment periods at boiler unit
Figure 14 Distribution risk matrix for the three assessment periods at distilled water
Figure 15 Distribution risk matrix for the three assessment periods at Hadikhani
Figure 16 Distribution risk matrix for the three assessment periods at power house
Figure 17 Distribution risk matrix for the three assessment periods at flare unit
12 References
1 API RP 581, 2016: ‘Risk-based inspection base resource document’, American Petroleum
Institute, April.
2 API RP 580, 2009: ‘Risk-based inspection’, American Petroleum Institute, September.
3 API RP 570, 2002: ‘Piping inspection code’, American Petroleum Institute, December.
4 API RP 571, 2011: ‘Damage mechanisms affecting fixed equipment in the refining industry’,
American Petroleum Institute, April.
5 API RP 945, 1997: ‘Avoiding environmental cracking in amine unit’, American Petroleum
Institute, October.
6 ASME B31.3, 2014: ‘Process piping’, The American society of Mechanical Engineering.
7 ASME Section II, Part D, 2007 ‘Properties (metric) Materials’ ,The American society of
Mechanical Engineering.
8 BS 1501: Part 1, 1980 ‘Steel for fired and unfired pressure vessels: plate’, British Standard
Institution.
Appendix A
RISKWISE RLI results gas refining unit
At gas refining unit on each unit on the 102 equipment (308 components) RBI assessment
carried out. Date of over haul of gas refining units is 36 months; Risk Analysis Period for the
each component is 36 months. According to the results for all gas refining units, the equipment
is Classification as follows.
Category 1: The equipment in assessment period 1& 2 at the risk matrix in area 1A, 2A, 3A,
1B, 2B, 3B, 1C & 2C can be extend Risk Analysis Period from 36 months to 48.
Category 2: The equipment in the assessment period 1 & 2 are not area 1A, 2A, 3A, 1B, 2B,
3B, 1C & 2C, but with non-intrusive inspection it can be extend Risk Analysis Period from 36
months to 48.
Category 3: The equipment in the assessment period 1 & 2 are not area 1A, 2A, 3A, 1B, 2B,
3B, 1C & 2C, but according to the results RBI, it is necessary to inspect the Risk Analysis
Period for 36 months.
Category 4: The equipment in the assessment period 1 & 2 are not area 1A, 2A, 3A, 1B, 2B,
3B, 1C & 2C, but considering the results of the RBI, also taking into account the reports of the
employer need to be change.
80-10"AM-2212-203A 2A 2A 3A - 192
80-12"AM-2302-203A 3A 3A 3A - 192
80-12"P-2103-206A 2B 2B 2B - 192
80-16"S-2604-212A 1A 1A 1A - 192
80-2458 1A 1A 1A - 192
80-6"BD-2706-203A 2A 2A 2A - 192
80-6"C-2214-212A 1A 1A 1A - 192
80-6"C-2217-212A 1A 1A 1A - 192
80-D-218 1A 1A 1A - 192
80-D-219 1A 1A 1A - 192
80-SN2113 1A 1A 1A - 192
80-SN2136 1A 1A 1A - 192
80-SN2154 1A 1A 1A - 192
80-SN2309 1A 1A 1A - 192
80-SN2458 1A 1A 1A - 192
80-SN2580 1A 1A 1A - 192
80-10"BD-2116-203A 4A 4A 4A - 192
80-10"BD-2220-203A 5A 5A 5A - 192
80-12"AM-2105-203A 4B 4B 4B - 192
80-12"AM-2109-206A 5A 5A 5A - 192
80-12"CW-2114-219 4A 4A 4A - 192
80-12"CW-2607-219 4A 4A 4A - 192
80-14"BD-2701-203A 5B 5B 5B - 192
80-2"BD-2119-203A 5B 5B 5B - 192
80-2"P-2106-203A 5B 5B 5B - 192
80-12"AM-2107-203A 4A 4A 4A - 192
80-12"AM-2208-203A 4A 4A 4A - 192
80-14"AM-2301-203A 4A 4A 4A - 192
80-3"BD-2407-203A 5B 5B 5B - 192
80-3"BD-2408-203A 5B 5B 5B - 108
80-3"BD-2409-203A 5B 5B 5B - 108
80-4"C-2219-212A 4A 4A 4A - 192
80-6"C-2215-212A 4A 4A 4A - 192
80-6"C-2218-212A 5A 5A 5A - 192
80-12"AM-2104-206A 5C 5C 5C - 0
80-12"P-2102-206A 5B 5B 5B - 0
80-12"P-2101-206A 5B 5B 5B - 0
80-2"W-2112-206A 5B 5B 5B - 0
80-10"AM-2209-203A 5A 5A 5A -
80-12"AM-2108-203A 4A 4A 4A -
80-12"AM-2201-203A 5B 5B 5B -
80-12"AM-2202-203A 4A 4A 4A -
80-12"AM-2203-203A 5A 5A 5A -
80-12"AM-2211-203A 4A 4A 4A -
80-30"P-2204-203A 5A 5A 5A -
80-4"AM-2303-203A 5A 5A 5A -
80-4"AM-2304-203A 5A 5A 5A -
80-6"P-2206-203A 5B 5B 5B -
80-12"AM-3208-203A 2A 2A 3A - 192
80-12"AM-3211-203A 2A 3A 3A - 192
80-12"AM-3302-203A 3A 3A 3A - 192
80-12"P-3103-206A 2B 2B 2B - 192
80-16"S-3604-212A 1A 1A 1A - 192
80-6"BD-3706-203A 1A 1A 1A - 192
80-6"C-3214-212A 1A 1A 1A - 192
80-6"C-3217-212A 1A 1A 1A - 192
80-SN2077 1A 1A 1A - 192
80-SN2117 1A 1A 1A - 192
80-SN2118 1A 1A 1A - 192
80-SN2133 1A 1A 1A - 192
80-SN2210 1A 1A 1A - 192
80-SN2274 1A 1A 1A - 192
80-SN2281 1A 1A 1A - 192
80-SN2288 1A 1A 1A - 192
80-SN2583 1A 1A 1A - 192
80-10"BD-3116-203A 4A 4A 4A - 192
80-12"AM-3105-203A 4B 5B 5B - 192
80-12"AM-3107-203A 4A 4A 4A - 192
80-12"CW-3114-219 4A 4A 4A - 192
80-12"CW-3607-219 4A 4A 4A - 192
80-14"BD-3701-203A 5B 5B 5B - 192
80-2"BD-3119-203A 5B 5B 5B - 192
80-2"P-3106-203A 5B 5B 5B - 192
80-3"BD-3407-203A 5B 5B 5B - 192
80-3"BD-3408-203A 5B 5B 5B - 122
80-3"BD-3409-203A 5B 5B 5B - 122
80-4"C-3219-212A 4A 4A 4A - 192
80-6"C-3215-212A 4A 4A 4A - 192
80-6"C-3218-212A 4A 4A 4A - 192
80-12"AM-3104-206A 5C 5C 5C - 0
80-12"P-3101-206A 5B 5B 5B - 0
80-12"P-3102-206A 5B 5B 5B - 0
80-2"W-3112-206A 5B 5B 5B - 0
80-3"W-3110-206A 5B 5B 5B - 0
80-10"AM-3209-203A 5A 5A 5A -
80-10"AM-3212-203A 4A 4A 4A -
80-12"AM-3108-203A 4A 4A 4A -
80-12"AM-3201-203A 4B 5B 5B -
80-12"AM-3202-203A 5A 5A 5A -
80-12"AM-3203-203A 5A 5A 5A -
80-14"AM-3301-203A 5A 5A 5A -
80-18"P-3205-203A 5A 5A 5A -
80-30"P-3204-203A 5A 5A 5A -
80-4"AM-3303-203A 5A 5A 5A -
80-4"AM-3304-203A 5A 5A 5A -
80-6"P-3206-203A 5B 5B 5B -
80-10"AM-4209-203A 2A 2A 3A - 192
80-12"AM-4208-203A 2A 2A 3A - 192
80-12"P-4103-206A 2B 2B 2B - 192
80-16"S-4604-212A 1A 1A 1A - 192
80-6"BD-4706-203A 1A 1A 2A - 192
80-6"C-4214-212A 1A 1A 1A - 192
80-6"C-4217-212A 1A 1A 1A -
80-SN2114 1A 1A 1A - 192
80-SN2189 1A 1A 1A - 192
80-SN2202 1A 1A 1A - 192
80-SN2253 1A 1A 1A - 192
80-SN2295 1A 1A 1A - 192
80-SN2304 1A 1A 1A - 192
80-SN2322 1A 1A 1A - 192
80-SN2445 1A 1A 1A - 192
80-SN2581 1A 1A 1A - 192
80-10"BD-4116-203A 4A 4A 4A - 192
80-12"AM-4105-203A 4B 5B 5B - 192
80-12"AM-4107-203A 4A 4A 4A - 192
80-12"CW-4114-219 4A 4A 4A - 192
80-12"CW-4607-219 4A 4A 4A - 192
80-14"BD-4701-203A 5B 5B 5B - 192
80-2"BD-4119-203A 5B 5B 5B - 192
80-2"P-4106-203A 5B 5B 5B - 192
80-3"BD-4407-203A 5B 5B 5B - 192
80-3"BD-4408-203A 5B 5B 5B - 138
80-3"BD-4409-203A 5B 5B 5B - 138
80-4"C-4219-212A 4A 4A 4A - 192
80-6"C-4215-212A 4A 4A 4A - 192
80-6"C-4218-212A 4A 4A 4A - 192
80-12"AM-4104-206A 5C 5C 5C - 0
80-12"P-4101-206A 5B 5B 5B - 0
80-12"P-4102-206A 5B 5B 5B - 0
80-2"W-4112-206A 5B 5B 5B - 0
80-3"W-4110-206A 5B 5B 5B - 0
80-10"AM-4212-203A 4A 4A 4A -
80-12"AM-4108-203A 4A 4A 4A -
80-12"AM-4201-203A 5B 5B 5B -
80-12"AM-4202-203A 5A 5A 5A -
80-12"AM-4203-203A 5A 5A 5A -
80-12"AM-4211-203A 4A 4A 4A -
80-12"AM-4302-203A 5A 5A 5A -
80-14"AM-4301-203A 5A 5A 5A -
80-30"P-4204-203A 5A 5A 5A -
80-4"AM-4303-203A 5A 5A 5A -
80-4"AM-4304-203A 5A 5A 5A -
80-6"P-4206-203A 5B 5B 5B -
80-12"AM-5208-203A 2A 2A 3A - 192
80-12"P-5103-206A 2B 2B 2B - 192
80-16"S-5604-212A 1A 1A 1A - 192
80-6"BD-5706-203A 1A 1A 1A - 192
80-6"C-5214-212A 1A 1A 1A - 192
80-6"C-5217-212A 1A 1A 1A - 192
80-SN2128 1A 1A 1A - 192
80-SN2131 1A 1A 1A - 192
80-SN2278 1A 1A 1A - 192
80-SN2313 1A 1A 1A - 192
80-SN2579 1A 1A 1A - 192
80-SN5924 1A 1A 1A - 192
80-SN6478 1A 1A 1A - 192
80-SN6513 1A 1A 1A - 192
80-SN9254 1A 1A 1A - 192
80-10"BD-5116-203A 4A 4A 4A - 192
80-12"AM-5105-203A 4B 5B 5B - 192
80-12"AM-5107-203A 4A 4A 4A - 192
80-12"CW-5114-219 4A 4A 4A - 192
80-12"CW-5607-219 4A 4A 4A - 192
80-14"BD-5701-203A 5B 5B 5B - 192
80-2"BD-5119-203A 5B 5B 5B - 192
80-2"P-5106-203A 5B 5B 5B - 192
80-3"BD-5407-203A 5B 5B 5B - 192
80-3"BD-5408-203A 5B 5B 5B - 107
80-3"BD-5409-203A 5B 5B 5B - 107
80-4"C-5219-212A 4A 4A 4A - 192
80-6"C-5215-212A 4A 4A 4A 192
80-6"C-5218-212A 4A 4A 4A 192
80-12"AM-5104-206A 5C 5C 5C - 0
80-12"P-5101-206A 5B 5B 5B - 0
80-12"P-5102-206A 5B 5B 5B - 0
80-2"W-5112-206A 5B 5B 5B - 0
80-3"W-5110-206A 5B 5B 5B - 0
2.Temperature limitation
80-10"AM-5209-203A 5A 5A 5A -
80-10"AM-5212-203A 4A 4A 4A -
80-12"AM-5108-203A 4A 4A 4A -
80-12"AM-5201-203A 5B 5B 5B -
80-12"AM-5202-203A 4A 4A 4A -
80-12"AM-5203-203A 4A 4A 5A -
80-12"AM-5211-203A 4A 4A 4A -
80-12"AM-5302-203A 5A 5A 5A -
80-14"AM-5301-203A 5A 5A 5A -
80-30"P-5204-203A 5A 5A 5A -
80-4"AM-5303-203A 5A 5A 5A -
80-4"AM-5304-203A 5A 5A 5A -
80-6"P-5206-203A 5B 5B 5B -
Figure 1 through 4 The Classification of each unit is based shown on the different categories.
After reviewing Figures 1 through 4, it is seen that in each unit 12% of the equipment is in
category 3. If, during a over haul period each unit, we inspect equipment’s in category 3, can be
extend Risk Analysis Period from 36 months to 48.
12%
35%
12% Category 1
Category 2
Category 3
Category 4
41%
13%
36% Category 1
12%
Category 2
Category 3
Category 4
39%
14%
30%
Category 1
12%
Category 2
Category 3
Category 4
44%
15%
34%
Category 1
12%
Category 2
Category 3
Category 4
39%
Appendix B
RISKWISE RLI results boiler unit
In this appendix, the risk distribution is presented for the various damage mechanisms of the
boiler unit. This unit consists of four boilers. Figures 1 and 2 show Pie chart the distribution of
risk for the different damage mechanism steam and water drum, date of over haul of boilers is
24 months. As can be seen that in the water and steam drum we are in the assessment period
1 and 2 at category 1, So can be extend Risk Analysis Period for boilers from 24 months to 36.
Internal thinning 1B 3B 3B - 60
Thermal fatigue 1C 1C 3C - 67
Caustic corrosion 1B 1B 3B - 80
External corrosion 1B 3B 3B - 60
Oxidation 1B 1B 3B - 80
Corrosion fatigue 1C 1C 3C - 67
Internal thinning 1B 3B 3B - 60
Thermal fatigue 1B 1B 3B - 80
External corrosion 1B 3B 3B - 60
Oxidation 1B 1B 3B - 80
Corrosion fatigue 1B 1B 3B - 80
Deaerator
RLI
Equipment Number AP1 AP2 AP3 Finding
(months)
Figure 1 Pie chart, distribution of risk for different damage mechanism steam drum
Figure 2 Pie chart, distribution of risk for different damage mechanism water drum
Appendix C
RISKWISE results PSV's
Given that a shop bench pre-pop test is performed, the resulting pass data is given the highest
degree of confidence and the highest inspection effectiveness. as shown in the table below, for
the total PSV's distribution of risk, is the category 1. Therefore, it's possible to change the date
of the testing of the PSV's in accordance with the employer opinion.
Due to the fact that the safety valves installed in 20-SL-3312-212K (EXHAUST STEAM) have
not been tested since 2006, then, according to a technical inspection plan in 2018, to be test.
PSV
Component Finding
Equipment Number Description damage Risk
Number (PRD)
PSV-0401A Leakage 1A
80-12"P-2101-206A -
PSV-0501B Fire 1B
PSV-0301A Leakage 1A -
80-12"P-3101-206A
PSV-0301B Fire 1B
PSV-0201B Leakage 1A -
80-12"P-4101-206A
PSV-0401B Fire 1B
A58442 Leakage 1A -
80-12"P-5101-206A
A58443 Fire 1B
Leakage -
1A
80-P-204A PSV-217 Blocked discharge with
1B
administrative controls in place
Leakage -
1A
80-P-204B PSV-0416 Blocked discharge with
1B
administrative controls in place
Leakage -
1A
80-P-304A 10414307 Blocked discharge with
1B
administrative controls in place
Leakage -
1A
80-P-304 PSV-0215 Blocked discharge with
1B
administrative controls in place
Leakage -
1A
80-P-404A 476009-9-KE Blocked discharge with
1B
administrative controls in place
Leakage -
1A
80-P-404B 476009-7-KE Blocked discharge with
1B
administrative controls in place
PSV
Component Finding
Equipment Number Description damage Risk
Number (PRD)
Leakage -
1A
80-P-504A PSV-0316 Blocked discharge with
1B
administrative controls in place
Leakage -
1A
80-P-504B 96110-FA Blocked discharge with
1B
administrative controls in place
Leakage -
1C
80-D-206 PSV-211 Tower P/A or reflux pump
1C
failures
Leakage -
1C
80-D-306 10414317 Tower P/A or reflux pump
1C
failures
Leakage -
1C
80-D-406 476009-8-KE Tower P/A or reflux pump
1C
failures
Leakage -
1C
80-D-506 PSV-0214 Tower P/A or reflux pump
1C
failures
Leakage -
1A
80-T-203A PSV-0410A Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-203B PSV-0410B Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-203C PSV-0310B Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-303A PSV-0210A Tower P/A or reflux pump
1B
failures
PSV
Component Finding
Equipment Number Description damage Risk
Number (PRD)
Tower P/A or reflux pump 1B
failures
Leakage -
1A
80-T-303C PSV-0210C Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-403A PSV-0110A Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-403B PSV-0410C Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-403C PSV-0310C Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-503A (103A) PSV-0310A Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-503B PSV-0210B Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-503C 10414305 Tower P/A or reflux pump
1B
failures
Leakage 1C -
80-FIL-201 PSV-214
Fire 1B
Leakage 1C -
80-FIL-301 10414308
Fire 1B
Leakage 1C -
80-FIL-401 PSV-0114
Fire 1B
PSV
Component Finding
Equipment Number Description damage Risk
Number (PRD)
Fire 1B
Leakage -
1A
80-H-201 PSV-215 Tower P/A or reflux pump
1B
failures
Leakage -
1C
80-H-301 10414316 Tower P/A or reflux pump
1B
failures
Leakage -
1C
80-H-401 476009-4-KE Tower P/A or reflux pump
1B
failures
Leakage -
1C
80-H-501 PSV-0511 Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-201 PSV-0202 Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-301 PSV-0510B Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-401 KGC 871550 Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-T-501 PSV-0402 Tower P/A or reflux pump
1B
failures
Leakage -
1A
80-FIL-202 PSV-0209 Liquid overfitting with
1B
administrative controls in place
Leakage -
1A
80-FIL-302 10414309 Liquid overfitting with
1B
administrative controls in place
PSV
Component Finding
Equipment Number Description damage Risk
Number (PRD)
Leakage -
1A
80-FIL-402 PSV-0513 Liquid overfitting with
1B
administrative controls in place
Leakage -
1A
80-FIL-502 JMB-C Liquid overfitting with
1B
administrative controls in place
Leakage -
1C
80-D-207 PSV-0206 Liquid overfitting with
1B
administrative controls in place
Leakage -
1C
80-D-208 PSV-0407 Liquid overfitting with
1B
administrative controls in place
Leakage -
1C
80-D-307 10414310 Liquid overfitting with
1B
administrative controls in place
Leakage -
1C
80-D-308 PSV-00506 Liquid overfitting with
1B
administrative controls in place
Leakage -
1C
80-D-407 PSV-0406 Liquid overfitting with
1B
administrative controls in place
Leakage -
1C
80-D-408 PSV-0207 Liquid overfitting with
1B
administrative controls in place
Leakage -
1C
80-D-507 PSV-0506 Liquid overfitting with
1B
administrative controls in place
Leakage -
1C
80-D-508 PSV-0507 Liquid overfitting with
1B
administrative controls in place
PSV
Component Finding
Equipment Number Description damage Risk
Number (PRD)
Electrical power supply failure 1B
Leakage 1A -
80-D-301-COLUMN KGC 87151
Electrical power supply failure 1B
Leakage 1A -
80-D-401-COLUMN PSV-0303A
Electrical power supply failure 1B
Leakage 1A -
80-D-501-COLUMN PSV-0103
Electrical power supply failure 1B
Leakage -
1B
80-T-202 PSV-0204 Tower P/A or reflux pump
1B
failures
Leakage -
1B
80-T-302 PSV-0108 Tower P/A or reflux pump
1B
failures
Leakage -
1B
80-T-402 PSV-0104 Tower P/A or reflux pump
1B
failures
Leakage -
1B
80-T-502 PSV-0105 Tower P/A or reflux pump
1B
failures
Leakage -
1B
80-D-202 PSV-0405 Tower P/A or reflux pump
1B
failures
Leakage -
1B
80-D-302 PSV-0505 Tower P/A or reflux pump
1B
failures
Leakage -
1B
80-D-402 PSV-0208 Tower P/A or reflux pump
1B
failures
Leakage 1B
80-D-502 PSV-0304 -
Tower P/A or reflux pump 1B
PSV
Component Finding
Equipment Number Description damage Risk
Number (PRD)
failures
Leakage
78H-001C (STEAM 51944 1C
Blocked discharge without -
DRUM) 51943 1B
administrative controls
Leakage
78H-001C (SUPER 1C
54666 Blocked discharge without -
HEAT STEAM) 1B
administrative controls
Leakage
78H-001D (STEAM 53477 1C
Blocked discharge without -
DRUM) 54716 1B
administrative controls
Leakage
78H-001D (SUPER 1C
54715 Blocked discharge without -
HEAT STEAM) 1B
administrative controls
Leakage
78H-001E (STEAM 54674 1C
Blocked discharge without -
DRUM) 51938 1B
administrative controls
Leakage
78H-001E (SUPER 1C
51945 Blocked discharge without -
HEAT STEAM) 1B
administrative controls
Leakage
TYPE:SC-300 S 54693 1C
Blocked discharge without -
(STEAM DRUM) 54691 1B
administrative controls
TYPE:SC-300 S Leakage
1C
(SUPER HEAT 54692 Blocked discharge without -
STEAM) 1B
administrative controls
54696 Leakage
20-SL-3312-212K 1C
54695 Blocked discharge with -
(EXHAUST STEAM) 1B
54694 administrative controls in place
Appendix D
RISKWISE RLI results distilled water
In the table below, the risk distribution for the various equipment’s of the distilled water unit is
specified. Comments are provided for each equipment in the finding section.
Distilled water
Equipment
AP1 AP2 AP3 Finding RLI
Number
Distilled water
Equipment
AP1 AP2 AP3 Finding RLI
Number
the inspection mitigation planning.
Appendix E
RISKWISE RLI results flare unit
In the table below, the risk distribution for the various equipment’s of the flare unit is specified.
Comments are provided for each equipment in the finding section.
Presence of chlorine ion in injected water in the non-acid flare causes severe pitting corrosion
in the cladding stainless steel. Observe the following are required for these equipment’s:
1 Control the amount of chlorine ion in injected water to the equipment
2 It's also necessary will be inspected of the equipment in according with the inspection
planning.
3 Replacement of the internal cladding in the non-acid flare.
Flare
Flare