Practical work shop hand book

WORKBOOK RBI MODULE

WORKSHOP

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Tanggal :

PRACTICAL WORK BOOK

Wajib dikerjakan
Sebagai syarat mengikuti Kualifikasi RBI
Engineer

Property of
Dr.Ir.M.Yudi.MS,MSc,MBA

Property of M Yudi MS 2010 Page 1 of 7

Practical work shop hand book

Work Book Module Hand book.

This section contains reference material for the RBI Practical Session Part 1.

The following documents are included:

1. P&I Diagram copy

2. RBI Procedure

3. Process Stream Definition Procedure

These should be used in conjunction with the work shop Module section of the RBI
Manual.

Property of M Yudi MS 2010 Page 2 of 7

Practical work shop hand book

Doc. No:RBI ENGINEERING-01-

Doc Title: RBI Rules And Instructions

Doc Category:- Work Instruction

Client:- N/A
Project:- N/A Project No:- N/A
Distributed Information:-

Other Information:
Originator:- Dr Ir M.Yudi MS ,MSc,MBA
Authoriser:- ditto

422 1.2 07/00 Sentence removed from IXM

3.5
417 1.1 05/00 Issued for Comment IXM RBI RBI
392 1.0 3/00 Original Issue IXM RBI
Issue No Rev. Date Description of Revision Originated Authorised Issued By
By By

Property of M Yudi MS 2010 Page 3 of 7

RBI PRACTICAL RBI HANBOOK

This document is the property of M Yudi MS

CONFIDENTIAL
DO NOT COPY

CONTENTS

1. PURPOSE 5

2. RELATED DOCUMENTS 5

3. METHOD 5

Modul 7. Workbook RBI .doc Page 4 of 22

RBI PRACTICAL RBI HANBOOK

PURPOSE

This work instruction defines the RBI Rules. This database is keyed on unit code and system
number. This instruction defines the way RBI in a way that works most effectively with the
Software

RELATED DOCUMENTS

RBI RBI Procedure 001-Corrosion Inspection-API 570-RP574-RP 580

METHOD

1.1. Stream Definition.

The contained fluid and its description shall be the basis for definition of streams.
Streams shall be identified by 3 character numeric codes according to the broad ranges described
in table 3.8 and shall have a contained fluid description which matches common plant usage such
as ‘reactor feed’. If the client has a stream numbering system in place, clients numbering system
may be used.

1.2. Stream Boundaries

The extent of any stream shall be governed by chemical changes in the contained fluid.
Where such changes occur, a new stream shall be introduced in order that the Real fluid description may
properly reflect these chemical changes.
Changes typically occur in process vessels heat exchangers and furnaces, but may occur in Corrosion
where two or more streams join together or where a process chemical such as corrosion inhibitor is
injected into a process fluid.

1.3. System Definitions

A system is part of a stream at similar pressure and temperature. Within any stream there may be changes
in pressure and/or temperature of the contained fluid. Where such changes are likely to give rise to
different corrosion regimes or to a different fluid state, systems shall be introduced. Pressure may be
decreased at a pressure control valve or increased by a pump or compressor. Temperature is normally
changed at a heat exchanger.
A System is identified by a suffix to the parent Stream identification i.e. 109-1; 109-2 etc..
Where parallel systems exist these may be identified by the addition of an alpha character i.e. 109-1A;
109-1B etc.. Parallel systems, whilst containing a common fluid, may have widely differing flow rates
and possibly different failure consequences from that of the parent stream. (see figure 1). It is up to the
judgement of the engineer whether to separately identify parallel streams.
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RBI PRACTICAL RBI HANBOOK

1.4. System Attributes

The attributes of a system are as follows:
• Common contained fluid;
• common operating pressures/temperatures;
• common fluid state;
• common Standby, Financial and Location Consequences.

1.5. Rules for Systemisation

• Corrosion Tag assignment shall be based on the principle that a Tag belongs to the system which
provides the source of the contained fluid.
• Where equipment (columns, knock out drums etc.) is connected to more than one system, then the
equipment component (top, middle, bottom etc.) shall belong to the stream which most accurately
reflects the fluid contained by that component.
• Relief Valves shall belong to the protected item system not the relief system.

1.6. Application of RBI of API 570

1.7. The RBI system is designed to copy data down from stream to system to tag level.
After the streams and systems are defined on paper, the sequence of data entry
should be:
Enter all stream (fluid) identities. Process fluid composition details may be added later.
Enter all system data. Contents data will be selected from a pick list that refers to stream data.
Enter line or equipment data. The data entry form includes a system pick list. Selecting system
will add, contents, operating temperature and pressure and standby, financial and location
values to the line or equipment record.

1.8. RBI Records

It is often easiest to carry out the initial systemisation on a process flow diagram that gives an overall
view of the plant. The systems may then be transferred to the P&I D’s. The systems shall be identified
on the P&ID’s using a colour coding system. Each drawing will have a legend identifying the systems
present on that drawing by their number and description against the applicable colour coding. Note that
the purpose of the colour coding is to denote the system boundaries. Therefore, it is possible to have the
same colour representing several different systems providing the same colour is not used to identify
different systems on the same drawing. In some instances it may be necessary to use dotted or hatched
lines to identify the system changes where the number systems on a drawing exceeds the number of
colours available.

Modul 7. Workbook RBI .doc Page 6 of 22

RBI PRACTICAL RBI HANBOOK

Heat System
Exchanger 23-109-3A
Tag
Temperature
Change
requires
subdivision System
23-109-3

System System
23-109-1 23-109-2

Line diameter Control

change does NOT System
Valve
require 23-109-3B
TAG
subdivision!! Pressure change requires
subdivision

Stream 23-109
The FLUID is common, but pressures and
temperatures change

Figure 1. RBI

Modul 7. Workbook RBI .doc Page 7 of 22

RBI PRACTICAL RBI HANBOOK

Doc. No: 01-RBI-pcpt-010

Doc Title: Process Fluid (Process Stream)RBI Definition

Doc Category:- Work Instruction

Client:- N/A
Project:- N/A Project No:- N/A
Distributed Information:- Engineers

Other Information:
Originator:- Authoriser:- M Yudi MS

424 1.0 24/5/0 Original Issue

10
Issue No Rev. Date Description of Revision Originated Authorised Issued By
By By

Modul 7. Workbook RBI .doc Page 8 of 22

 MRI Practical Session Work Book
This document is the property of M Yudi MS
CONFIDENTIAL
DO NOT COPY

CONTENTS

1. PURPOSE 10

2. RELATED DOCUMENTS 10

3. METHOD 10

3.1 Stream Number 10

3.2 Stream Boundaries 10

3.3 Fluid Name 10

3.4 Real Fluid 10

3.5 Contaminants 11

3.6 Primary System Number Table. 12

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 MRI Practical Session Work Book

PURPOSE Formatted: Bullets and Numbering

This work instruction is a guide to defining the process fluids in RBI . Fluid definition is very
important for the final results of the RBI risk assessment. The consequences of failure and several
of the degradation models are driven by the fluid table. Deleted:

RELATED DOCUMENTS Formatted: Bullets and Numbering

Module 1,2,3,4,5,6 of RBI licensee RBI

METHOD Formatted: Bullets and Numbering

1.9. Stream Number Deleted: .

The contained fluid and its description shall be the basis for definition of streams.
Streams shall be identified by 3 character numeric codes according to the broad ranges described
in Table 3.6.
If the client has a stream numbering system on their process flow diagrams, the clients numbering Deleted:
system may be used. Deleted: in place

1.10. Stream Boundaries Formatted: Bullets and Numbering

The extent of any stream shall be governed by chemical changes in the contained fluid.
Where such changes occur, a new stream shall be introduced in order that the Real fluid description may
properly reflect these chemical changes.
Changes typically occur in process vessels, but may occur in Corrosion where two or more streams join
together or where a process chemical such as corrosion inhibitor is injected into a process fluid.

1.11. Fluid Name Formatted: Bullets and Numbering

The common name for the fluid that the plant personnel will recognise. Examples include Reactor Feed,
Depropanizer Overheads, C-202 Residue, Cooling Water, HP Steam, etc. This fluid name will be
reported as the contents of equipment and Corrosion.

1.12. Real Fluid Formatted: Bullets and Numbering

The main constituents of the fluid should be listed in this field. Every individual fluid named will
contribute their properties for the determination of fluid hazard. As a guide, any component that makes
up more than 20 percent should be listed.
Components that make up less than 20 percent should only be listed if they have some significant
property such as toxicity that should drive consequences of failure. For example, a fluid
containing a small percentage of hydrogen sulfide would be considered as toxic. The plant
process engineer should determine the lower limit, but for general guidance, toxic components

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 MRI Practical Session Work Book
such as hydrogen sulfide should generally be listed as a constituent at the 1 percent level but not
below. Deleted: ... [1]

1.13. Contaminants Formatted: Bullets and Numbering

The fluid data table contains the following numeric fields

Vapour/Liquid Ratio This field is used in the API RP 14E erosion

calculation for two phase streams. In oil and gas production the units are
SCF/BBL. In refining and chemicals the units are volume percent vapour.
This field should be left at zero for single phase streams.

Water (%) A non-zero value in this field sends the

program to the NACE wet corrosion table. A zero value sends the program
to the NACE dry corrosion table. Only leave zero in this field when there is
knowledge that water is definitely not in the stream.

Water pH This field is for information only and has no

effect onRBI results

Hydrogen Sulfide (ppm) This field is used in the Couper-Gorman high

temperature refinery corrosion model. It also determines partial pressure
for the wet H2S cracking model. If accurate numbers are not known, it is
acceptable to use orders of magnitude such as 10, 100, 1,000, 10,000, etc.

Carbon Dioxide (%) This drives the carbon dioxide corrosion

model for oil and gas production and refinery. It has no effect in chemicals
configuration.

Hydrogen (%) This drives the high temperature attack model

in refinery and chemicals. In absence of accurate plant data estimates to the
nearest 10% will be adequate.

Sulfur (%) This field is used in the modified McConomy

high temperature refinery corrosion model. The upper limit of sulfur
content for crudes normally processed should be used.

Total Acid Number This field is used in the naphthenic acid high
temperature refinery corrosion model. The upper limit of TAN for crudes
normally processed should be used.

Chloride (ppm) This field is used in the internal stress

corrosion cracking model. If this value is not known exactly, it is
acceptable to use order of magnitude values, such as 1, 10, 100, 1000, etc.

Oxygen (ppb) This field is for information only.

Fluoride (ppm) This field is for information only.

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 MRI Practical Session Work Book
Cyanide (ppm) This field is for information only.

Sulfur Dioxide This field is for information only.

Dew Point This field is for information only.

Inhibitor Efficiency This field is for information only.

Primary System Number Table. Deleted: ... [2]

Formatted: Bullets and Numbering
Streams should be numbered according to the clients process flow diagram numbering or any other
numbering system agreed by the client.
If numbers must be created an example of a stream numbering system is shown below:
Stream General Fluid Characteristics
Group
100 ->199 Utility Streams; Steam; Air; Water; Nitrogen
200 ->299 Crudes; HGO; Residues; Coke; Lub oils; Waxes; Asphalt
300 ->399 Distillates; Jet Fuels; Diesel; LCO; Kerosene
400 ->499 Naphtha; Alkylates;
500 ->599 C5 and lighter; Light Ends
600 ->699 Hydrogen; CO2; Oxygen
700 ->799 Chemical Injections; DEA; Corrosion Inhibitors
800 ->899 Not allocated
900 ->999 Waste Streams

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 MRI Practical Session Work Book

Work Book Section 2 – Module 2.

RBI Configuration Data

Action : Enter the Configuration Data

Company : PT. x
New Unit to be set up :
Plant Code : PT x
Plant Name : RBI Unit
Plant Description : RBI and Test Data only.
Plant Start Up Date :
Unit Revision Number : P1

Configuration Details for new unit:

Units of Measurement
Pressure – bar gauge
Temperature – degrees Celsius
Pipe Diameter – inches
Wall Thickness – mm
Corrosion Rates – mm/year
Volume – cubic metres

Consequence Rule Set – World Rules

Probability Model Set – Oil & Gas
Use Pipe Specification in B31.3 Calc. – YES

Remaining Life Bands – 4 years & 8 years

Pressure Bands – 7 barg & 30 barg

The new Unit must be set ACTIVE and LOCKED.

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 MRI Practical Session Work Book

Corrosion Specification Data

Action : CreateRBI Corrosion Specifications for the pipework contained on P&IDiagram Number
PPA-12-E3-050-C

Data :
The necessary information is shown below:
Pipe Material Size ranges Schedule Wall Design Design C.A.
Spec. Thickness Pressure Tenmp.
mm
B03 API 5L Grade A 2" ! 8" 40 14 barg 200 degC 1.5 mm
B23 ASTM A333-GR6 0.5"! 1.5" 160 13.96 barg 200 degC 1.5 mm
ASTM A333-GR6 2" 80
ÁSTM A333-GR6 3"! 6" 40
ASTM A333-GR6 8"! 10" 20
ASTM A333-GR6 12" 30
ASTM A333-GR6 14"! 24" 20
ASTM A333-GR6 26"! 32" STD
ASTM A333-GR6 34"! 36" 20
F03 API5L-GRB 0.5"! 2" 160 82.8 barg 200 degC 1.5 mm
API5L-GRB 3"! 24" 80
API5L-GRB 26" - 24mm
28" - 25.6mm
30" - 27.2mm
32" - 28.8mm
34" - 30.4mm
36" - 32mm
38" - 33.6mm
40" - 35.2mm
42" - 36.8mm
44" - 38.4mm
46" - 40mm

TIP:
When creating the Pipe Spec F03 for sizes which have no defined Schedule, enter the smallest and largest
diameters and the material specification but leave the Schedule set to '-'.
Then complete the wall thickness values using the function EDIT>PIPE SPEC.

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 MRI Practical Session Work Book
PROCESS STREAMS

Action : Create the Fluid characteristics for the process streams on the P&I Diagram Number PPA-12-
E3-050-C

The streams I want you to deal with are –

1. The Rich Glycol from the Separators to the Glycol Flash Drum
2. The Glycol from the Flash Drum to the Still Column
3. The Lean Glycol from the Reboiler to the Surge Drum

Find these on the P&I Diagram.

Tell me if you believe they all contain the same fluid.

We will assign a Stream Number of 211 to the Rich Glycol;

A Stream Number of 213 to the Glycol leaving the Flash Drum and
A Stream Number of 215 to the Glycol from the Reboiler.

The Fluid characteristics for each stream are as follows:

Rich Glycol
Water 60%
Carbon Dioxide 0.217
Tri Ethylene Glycol
C1
C2
C3
C3
C4
Glycol from Flash Water 60%
Drum
Tri Ethylene Glycol
Lean Glycol from Water 5%
Reboiler
Tri Ethylene Glycol

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 MRI Practical Session Work Book
Action : CreateRBI Asset records for Static Equipment.
Static Items Technical Details

Glycol Flash Drum

TAG No. 1-V-520A
Working Pressure 4.9 barg
Design Pressure 10 barg
Working Temperature 50 C
Design Temperature 70 C
Material of Construction ASTM A516-GR70
Nom. Wall Thickness 13.5 mm
Corrosion Allowance 3 mm
Capacity 7.8 cubic metres

Cartridge Filters
TAG No. 1-F-520B A/B
Working Pressure 4.9 barg
Design Pressure 10 barg
Working Temperature 50 C
Design Temperature 70 C
Material of Construction ASTM A516-GR70
Nom. Wall Thickness 7 mm
Corrosion Allowance 3 mm
Capacity 0.2 cubic metres

Active Carbon Filter

TAG No. 1-F-520D
Working Pressure 4.9 barg
Design Pressure 10 barg
Working Temperature 50 C
Design Temperature 70 C
Material of Construction ASTM A516-GR70
Nom. Wall Thickness 7 mm
Corrosion Allowance 3 mm
Capacity 1.2 cubic metres

Rich/Lean Glycol Exchanger

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 MRI Practical Session Work Book
TAG No. 1-E-520E
HOT Pass COLD Pass
Working Pressure 0.3 barg 5 barg
Design Pressure 10 barg 10 barg
Working Temperature IN 93 C OUT 50 C IN 12.8 C OUT 50 C
Design Temperature 150 C 150 C
Material of Construction ASTM A312-TP316L
Corrosion Allowance 0
Nominal Wall 1 mm

TAG No. 1-E-520F

HOT Pass COLD Pass
Working Pressure 0.3 barg 4.9 barg
Design Pressure 10 barg 10 barg
Working Temperature IN 132 C OUT 92 C IN 50 C OUT 87 C
Design Temperature 150 C 150 C
Material of Construction ASTM A312-TP316L
Corrosion Allowance 0
Nominal Wall 1 mm

Pipework Details

ACTION: Complete the attached line schedule data from information on the P&I Diagram.

We will then discuss and assign the Standby, Financial and Location Consequence Factors.

You will then enter the data intoRBI.

Use ASSETS>ADD>LINE LIST

TIP:
The Line Numbering Convention is as follows:

Diameter + Service + Spec + Number

The Insulation Code is obtained by observation and will be either '-' for not insulated or 'H' for Heat
Insulation.

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 MRI Practical Session Work Book
Dia. Service Spec Numbe Insulation From To System Press Temp Phase S F L
r Des/opt Des/opt
3” Glicol F03 52520 - Separator1-v 42601- HE 1-520E 101 liquid 2 1 1
APL 5L

42” GL bBBB HE 1- - 52520 52521 101 liquid 2 2 1

B 520E

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 MRI Practical Session Work Book
Ext Exten
Inn Con Ins Method
corrosi fatiq scc crack POF COF Crit of remaks
Corr index Interv of Insp
on insp
1 2 3 3 3 1 1

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 MRI Practical Session Work Book

Plant Integrity Review

ACTION: Carry out a Plant Integrity Review on ONE Corrosion system, ONE Line

REVIEW DATA: The data you will use for this exercise is listed below.

PIR SYSTEM. – 211-2

The System was last inspected on 10/10/98.

The Internal Corrosion Rate was measured and found to be 0.197 mm/year for all lines in the system
EXCEPT 2"-GL-B03-52BA20.
This line is to be treated as an exception.

The External Corrosion Rate is confirmed as 0.1 mm/year

The Process Operation has been stable and will be stable for the next 5 years.

No unpredicted failure mechanisms have been detected.

Assign a Confidence Factor of 1

PIR LINE: 2"-GL-B03-52BA20.

The Internal Corrosion Rate was found to be 0.788 mm/year.

Otherwise the line is the same as the rest of the system.

A Condition Code of M should be assigned.
Assign a Confidence Factor of 0 (zero)

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MRI Practical Session Work Book
Your Justifications
On MAWP

Data Wall thickness measurement

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3.7