COURSE DURATION: 2 weeks

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LEVEL: Advanced

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Main objectives

• To focus on the real work of Corrosion and Inspection Engineers – Boots on the ground.

• To minimize breaches that might adversely impact the integrity of the Pressure Equipment

       i.e. Furnaces, Boilers, Vessels, Heat Exchangers, Storage Tanks, Piping Systems, Pipelines and Relief Systems.

• To highlight cases that at times may be unnoticed till some unexpected thing happen.

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Training Module Details

• The Module is planned for 2 weeks duration.

• Delivery is through lecturer, presentations, practical examples, delegates interactions, open discussions and workshops.

 

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Real-World Inspection Planning and Integrity Management (Module 1 – 5 Days)​

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1- From Time-Based to Risk-Based Strategy​

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Oil and Gas Pressure Equipment inspection strategy changes understanding:

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• Time-Based Inspection: every 2, 3, 5, 10 Years: Codes, Laws or Site Practices.

• Condition-Based Inspection: Expected Degradation, Degradation Forms, Locations and Rates.

• Risk Based Inspection: Methodology that directs Inspection, Testing and Maintenance efforts to focus mainly  on the Higher Risk Pressure Equipment and Piping systems.

 

The Corrosion Loop concept represents a Loop where Equipment and Piping Systems are subject to identical operational process, corrosion environment, materials of construction that may be susceptible to similar Degradation Mechanisms 

 

Risk Assessment

• The Pressure Equipment contains Oil, Gas and Toxic materials: Hazardous Inventory

• Losses of Containment (LOC): Undesirable Event

• Fire, Explosion, Toxicity: Consequences

• Proactive Barriers/ Controls to prevent the Event: EPC (highest failure prevention stage), RBI, QA/QC, Procedures, PMs, Monitoring, Staff Competences.

• Reactive Barriers/ Recovery Measures: Emergency Response, Shutdown, Repair, Re- Design, Replacement, Staff Competences.

 

 

Risk-Based Strategy

• Strike the right balance between risk and effort

• Concentrate efforts in Most Critical Systems (High/ Medium Risk)

• Reduce efforts in Less-Critical systems (Low Risk)

• Time-Based/ Run-to-Fail modes may be applicable to Negligible Risk Systems

 

 

2- Inspection Plan Preparation

Computerized Maintenance Management System (Maximo/ Oracle)

• Review of Inspection Policy and Procedures

• RBI Review

• Monitoring of Process Parameters

• On-Stream Inspection (Policy; every year, every 2 years??)

• Work Orders for Repairs, Replacements and minor Projects

• Management of Change

  • Plant Changes/ Modifications

  • Temporary Repairs/ Technical Concessions

• Ordering, Inspection and Acceptance of Materials

• Inspection and Testing of Valves (Manual and Control Valves)

• Inhibitor Survey

• Cathodic Protection Survey

• Lifting Equipment Inspection and Certification (Country Law)

• Painting, insulation and wrapping inspection works

• Unplanned Work; Expect the Unexpected - Surprises are normally bad news.

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Risk Based Inspection and Inspection Data Management System

• Equipment

• Pipelines and Piping Systems

• Inspection and Testing of Pressure Relief Valves and Non-Return Valves

 

On-Stream Inspection and Off-Stream (Shutdown) Inspection Plans Preparation: it is important to maintain an updated inspection record keeping system for Searching and Retrieval of a variety of Inspection Reports and Data to be successful in Planning.

 

Unplanned Work – Expect the Unexpected (Surprises):

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In case a Degradation Mechanism is found (Metal Loss, Cracking or Blistering) during On- Stream Inspection or Shutdown a corrective action is required. Unanticipated repairs can be costly and may require a Shutdown or an increase of the Shutdown time. Unplanned events are bad news.

Often, Inspection Engineers are asked to determine if repairs can be minimized or delayed altogether. This is where Fitness for Service (FFS) evaluation can be utilized.

 

With the RBI, FFS studies and Composite Repairs (ISO/TS 24817 or ASME PCC-2) we should be able to keep pace with ever-increasing demands

 

Seek for a Specialist input if required like:

• Metallurgical Investigation

• Failure Analysis/ Root Cause Analysis

• Advanced NDT techniques and Destructive Tests

• Remaining Strength of damaged piping systems (FFS for Level 2 & 3)

• Pipework Composite Repairs (ISO/TS 24817 or ASME PCC-2)

• Piping and Equipment Stress Analysis and Rerating.

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3- On-Stream Inspection

Good communication, in particularly Operations staff and Process Engineers plays an important role in the overall On-Stream Inspection process, always remember; Best results in professional communication are achieved with short and simple words and practical examples

Aid improvement within the organization through teaching value-added Visual Inspection to others by Look, Listen & Feel methodology; in service inspection for Leaks, Corrosion, Cracking, Mechanical faults, Vibrations, Supports, Valves performance, insulation conditions, etc, Visual Inspection Check List Samples for On-Stream Inspection by Corrosion Loops

Promote Non-Intrusive Inspection as per RBI Study; Conventional (VT, DPT, MPI, RT, UT) and Advanced NDT techniques in Process Piping. Refer to Critical Piping UT Scanning-

Collect periodic Laboratory Analysis in Process Water (Cl-, PH, H2S & CO2) and Feed Gas (H2S and CO2). Time to time, O2 tests in water is advised. In case, sample show O2 more than 10ppb or PH less than 4, these figures shall be entered in the next RBI review study and the Corrosion Technical support shall be requested.

Shutdown Preparation; Collect data to prepare the Shutdown Scope of Work, firm the Plan and prepare required Resources.

 

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Pre-Shutdown Activities;

• Review the history of each Pressure Equipment and Piping System, evaluate the Reason for Shutdown Inspection and prepare relevant documentation to be used during Shutdown.

• Prepare the necessary PTW (Permit to Work) and ARA (Activity Risk Assessment) required.

• Preparation of Inspection and Test Plans (ITP) for; Repairs, Replacements, Modifications and Projects (new materials, pre-fabrication, testing, painting, etc)

• Scaffolding erection, Removal of Insulation and Cladding, Hot Bolting, etc.

 

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Post Shutdown Activities;​

• Fixing insulation Cladding, Scaffolding removal, Housekeeping, Close the PTW,

• Preparation of Inspection Reports, update Record Keeping Systems

 

Other Common Planned Inspection Tasks: CUI, CUS, UGC, Painting, Ordering and Acceptance of Materials, Pre-Fabrication and Welding, Internal Inspection of Non-Shutdown Equipment, Pipeline Pig Survey, Lifting Equipment, Inhibitor Survey, Flexible Hoses, RBI data collection for next reviews, update Inspection Procedures, Specification and Best Practices.

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Inspection Monthly Report Preparation: This Report shall include the Inspection Highlights of the Month, Areas of Concern (Overdues, Deviations, temporary repairs, Technical Concessions), 5 Years Business Plan, the Year Plan status and the Laboratory Analysis

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4- Off-Stream Inspection – Shutdown Planned Activities

Fulfill the ARA-Activity Risk Assessment requirements and activate the Inspection PTW-Permit to Work as Planned

Equipment internal inspection stages: Review last Inspection Reports, validation of PTW, Preliminary Inspection prior to cleaning, Perform detailed Inspection complemented with NDT’s, follow-up any recommended work and perform the Final inspection with Operations and Mechanical to issue the Equipment Box-up Certificate.

Non-Intrusive Inspection (NDT) in Piping Systems operating in Cold and Hot Services.

Follow-up Projects, Modifications, Replacements and Repairs as per Inspection and Test Plan to ensure conformity of Specifications, Design, Materials, Welding, Construction, NDT’s, Pressure Tests, Painting/Coatings, Insulation, etc.

Provide assistance in Valve Servicing Inspection and Pressure Testing applicable to Manual, Control, NRV-Non-Return or Check Valves and PSV’s/TSV’s

Concentrate efforts to resolve all Technical Concessions issued from Temporary Repairs, Deviations from Design or Specifications and any overdues or pending work.

Unplanned Shutdown Works: Discuss unexpected inspection findings and resolve new Shutdown generated activities.

If Degradation Mechanism is found (Metal Loss, Cracking or Blistering) during Shutdown, the Inspection Engineers are asked to determine if repairs can be minimized or delayed (FFS) or Temporary Pipework Composite Repair as per ISO/TS 24817 or ASME PCC-2 can be also performed as the unplanned Standard repairs can be costly and may implies an increase of the Shutdown time.

 

The following specialized contractors shall be made available on call basis for Shutdown:

• Remaining Strength of damaged piping systems (FFS for Level 2 & 3)

• Pipework Composite Repairs - ISO/TS 24817 or ASME PCC-2

• Metallurgical Replicas and Destructive Testing

• Advanced NDT techniques

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Collect all Non-Resolved Shutdown generated activities and add to the Shutdown Prioritized Punch List. All Temporary Repairs, Deviations from Standard, Planned activities not performed or any other Areas of Concern shall be subject to Technical Concession assessment process in line with the Management of Change (MOC) process.

Issue the draft Shutdown report and prepare for the Executive and Detailed Inspection Reports. Segregate/collect the important data found to add to the next RBI Review.

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Real-world Inspection Planning and Integrity Management (Module 2 – 5 Days)​

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5- Critical Process Piping and Common Failure Modes

Interpretation of Plant Construction Piping Specifications

• Service Class/ Commodity/ Temperature Range/ Flange Rating/ Nominal Corrosion Allowance (mm) and Pipe Material

• Materials and Fabrication to conform ASME B31.3

• Each Piping Class shall be used within its Pressure and Temperature range.

• Piping System components: Pipes, Fittings, Valves, Flanges, Gaskets and Bolting

 

Process Piping is of utmost importance as the Oil and Gas Industry continues to have more incidents due to breaches of containment related to Process Piping than all Pressure Equipment combined, therefore ensure:

 

• No Improper piping degradation mechanisms evaluation and classification (RBI).

• Critical corrosion monitoring locations are properly identified and recorded.

• Confirm no excursion to Brittle Fracture regime at Depressurizing Systems

 

Process Piping Systems shall be subject to inspection programs as robust as the Static Pressure Equipment such that no severe internal or external corrosion, cracking or any other type of failures would cause unexpected Plant upsets or Plant Shutdown that implies production losses, unsafe situations, environmental adverse impact, costly and time consuming repairs.

 

 

Focus on RBI Critical Process Piping with high focus on:

• Piping Dead legs i.e. no-flow, low-flow lines

• Dual Temperature Piping (Molecular Sieve Systems)

• Injection Points and Mixing Points

• Eliminate/ Minimize Threaded Connections

• Close Follow-up of Temporary Repairs

• Environmental assisted Chloride Stress Corrosion Cracking in Austenitic Stainless Steel Materials (under supports, pads, insulation and wrapping)

• Vibrations and fatigue failure, particularly in small bore piping

• Valves and flange joint gasket failures.

• Out of specification in piping components (counterfeit materials).

 

Out-of-sight, Out-of-mind

• Corrosion under insulation/ Fireproofing (CUI/CUF) mainly in small bore piping

• Corrosion Under Supports (CUS)

• Trunnion Supports/ Hidden Corrosion

• Under Ground Corrosion (UGC)

• Underside Tank Bottom Plate Soil Corrosion

• Under Water Corrosion

• Water Low/High Tide and Splash zones

• Remote Areas

 

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6- Quality Assurance and Quality Control - Inspection and Test Plan

Assist in understanding the Work Sequence Control Sheet function and the Inspection and Test Plan to confirm that all Quality Assurance criteria has not been overlooked and the Quality Control needs have been established prior to start any Minor Project, Modification, Replacement or Repair.

 

The ITP is a document/table prepared with sequence of important Tasks and Controls and defines Roles and Responsibilities negotiated and agreed among of all parties involved in a Structured and Systematic manner. ITP Table is “tailor made” to better serve the QA/QC objective of each case

 

The ITP - Inspection Test and Plan is about establishing negotiated Roles and Responsibilities of all parties involved to ensure that the required quality has been met but not limited to:

1. Specifications and Design

2. Welding - WPS/ PQS/ WQT

3. Materials, Fabrication, Assembly and Erection

4. Inspection, Examination and Testing

5. Painting, Coatings, Insulation and Wrapping

6. Documentation Review and ITP Certificate

 

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Pressure Testing and Leak Testing

Facilitate the Testing establishment for validating the integrity of Pressure Equipment and Piping Systems that has undergone repairs, modifications or maintenance activities. Provide insight to the various types of pressure and leak tests and safety hazards awareness.

Pressure Test: The application of a Pressure above the Maximo Allowable Operating Pressure (MAOP) to demonstrate integrity of Design and Manufacture of new Piping/ Equipment, modifications or Repairs/ Replacements.

Leak Test: The application of a Pressure with Inert Gas, Process Fluid or Air not exceeding the MAOP, normally done by Operations to verify a Leak-Tightness system after re-jointing.

Hydrostatic Testing is the preferred method of Pressure Testing (1.5 the Design Pressure) if no overload or stress is caused on supporting structures or foundations.

Pneumatic Testing is potentially hazardous because the high energy released in case of failure. Therefore, this Pressure Test (1.1 the Design Pressure) shall be performed only when testing is essential and Hydrotest is not possible.

The test medium shall preferably be inert gas and the pressure shall be raised in small increments and followed by Inspection Leak Test after each increment.

 

Note: This is the last requirement of construction/fabrication and shall be performed in accordance with approved ITP i.e. after all Quality requirements are approved. Waived Pressure Testing cases covered by specific No-Destructive Testing.

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7- Effective inspection record keeping system

Provide insight into developing an adequate record keeping system.

After incidents, inspection records reveal often that more detailed inspections, repairs, replacements or other action should have been scheduled prior to the event.

 

Experience shows that:

• Pressure Equipment i.e. Columns, Vessels, Heat Exchangers, Air Coolers, Boilers, Fired Heaters, Tanks, etc, the Record Keeping System is in general in good order.

• Piping Systems, particularly for Small Bore Piping the record keeping has been proven not so effective (8.1).

• Regardless of the type and size of the Equipment and Piping Systems the effectiveness of the entire record keeping is of paramount importance for a robust and sound PEIM

 

Inspection Planning and Integrity Management of Static Equipment and Piping Systems cannot be obtained if the Record Keeping System is not able to provide searchable information related to Inspection plans, reports, repairs, modifications, material up-grades, temporary repairs/ technical concessions, degradation mechanisms, CUI reports, drawings, photographs, etc, enabling to answer questions related to equipment and piping history.

 

Effective Inspection Record keeping is a High Value Inspection Task and fundamental for a successful Pressure Equipment Integrity Management System.​​

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8-Pressure Equipment Integrity Managemant in our Digitalized World

This work focus in demonstrating how to ease and gain advantage of advanced digital technologies to add value to key subjects related to Mechanical Integrity of Pressure Equipment and Piping Systems in the Oil and Gas Plants, Refineries and Petrochemical industries while handling the following matters:

• Recording, Searching and Retrieval of a variety of Inspection Data, Asset History Verification, Reporting, Analysis, Tracking, Planning, preparation of Scope of Works and Budgets.

• Understanding of Design, Operational and Technical Integrity for Mechanical Integrity Risk Analysis, Risk Based Inspection (RBI) studies, identification and prioritization of different areas of concern requiring further attention and Engineering Support based on their criticality and classification.

• Enabling visualization in precise and detailed 3D representations for Searching and Grouping of Piping Systems by Material, Rate, Size, Degradation Mechanism, Repairs, Replacements, Upgrades, Insulated, non-Insulated, etc. the criteria is ours.

 

Adding a customized 3D software shall be able to strengthen and further improve the Integrity Management System for Static Pressure Equipment and Critical Piping Systems with focus on Small Bore Piping, to enrich Inspection Record Keeping Systems and therefore enhancing our ability to manage the overall Inspection and Corrosion Business Process.

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INSTRUCTOR

Francisco Costa - Brief Biography

Corrosion and Inspection Engineer Consultant with 42 years of experience in the Oil and Gas Industries and Oil Refineries. Academic background in Electromechanical Engineering.

Seconded by PARTEX Oil & Gas in 1982 to Abu Dhabi Gas Industries (GASCO) Ruwais NGL Fractionation Plant until 1992, then moved to Buhasa NGL Liquefaction Plant as Head of Inspection until 2017. Prior, he did work in two Oil Refineries, first in Mozambique and after in Portugal.

Francisco possesses extensive and solid field experience and is highly focused on Plant Asset Integrity Management Systems to enhance Process Safety and Economical Operation. Regularly attends, participates, and presents in Conferences, Workshops, and Congresses.

Francisco is experienced in training his area of expertise.