Virtual Conference on Risk-Based Inspection & Preventive Maintenance

1. Practical experience of RBI implementation challenges in a large UK refinery Keith Walton Business Development Manager, LifeTech Engineering Kerstin Ballantyne RBI Team Lead, Petroineos Manufacturing Scotland

2. Speakers Profile Years of Experience: 30 Educational Background: BA (Hons) Business Studies MSc Computing Science Brief Job Profile: Business Development Manager, LifeTech Engineering. Providing Asset Integrity Management software for RBI, NII, FFS and Asset Life Extension, associated support services and training. Professional Expertise: 30 years business experience (general management, operations management and business development) across several industry sectors, the last 20 years involved with the Aberdeen Oil & Gas industry in a number of AIM related roles. Speakers Photograph Keith Walton LifeTech Engineering

3. LifeTech Engineering Practical Experience of RBI Implementation Challenges in a Large UK Refinery

4. LifeTech Engineering About LifeTech Engineering LifeTech Engineering Ltd is a leading oil and gas Asset Integrity Management (AIM) consultancy, operating out of Aberdeen, UK. We provide specialist software, engineering services and training throughout the entire asset lifecycle to manage risk, reduce costs and improve Plant safety, efficiency, and productivity.

5. LifeTech Engineering • Project Background • Crude oil refinery commissioned in 1924 • Current daily refining capacity is 210,000 barrels • Historically contracted out several RBI projects using third party assessment and software • Recognised the need to take ownership and control of their RBI programme, therefore, decided to purchase RBI software and training, and to set up a joint team of Refinery personnel and RBI consultants

6. LifeTech Engineering What the Refinery Did • Purchased RBLX-RBI software • Received RBI training • Set up joint team of Refinery and LifeTech specialists (corrosion, process, inspection…) • Planned Scope of Work (SOW) • Kick off meeting and initial workshop • Project commenced

7. LifeTech Engineering RBI process flowchart

8. LifeTech Engineering • Challenges • Data Availability and Quality • Identification of Damage Mechanisms • Non-Intrusive Inspection Assessment • Dead Legs and Nozzles Assessments • Proposed Inspection Date

9. LifeTech Engineering • Challenge - Data Availability and Quality • Data quality has a direct relation to the relative accuracy of the RBI analysis. Data inputs and assumptions should be validated by qualified personnel (Process Engineer/Operator) to review operating parameters used • The current operator of the refinery has tried hard to convert inherited hard copies of drawings, reports, etc to electronic format, however, there have been some issues with availability and quality of data due to the age and changing ownership since 1924. • Solution • Gap Analysis between Line List and P&IDs • Quality assessment of Line List, P&IDs, GADs, Material Specs, Inspection Reports, Remedial Actions, etc.

10. LifeTech Engineering • Challenge - Identification of Damage Mechanisms • Identification of the credible damage mechanisms and failure modes for equipment included in a risk analysis is essential to the quality and the effectiveness of the risk analysis. • API 581 RBI guidelines do not address all the applicable damage mechanisms present in the refinery. For example, creep as an important DM in a refinery, is not covered. • Solution • Additional documents were referenced and the RBI software enhanced to cover all Damage Mechanisms covered in API 571 in addition to API 581. • A special module, covering Creep damage mechanism was developed and added to RBLX software.

11. LifeTech Engineering • Challenge – NII instead of IVI • Traditionally the Refinery conducted internal visual inspection (IVI) involving shutdown and entry into vessels and tanks with associated risks, loss of production and expense. • API 581 does not cover detailed calculations for Non-Intrusive Inspection (NII), therefore, a detailed methodology was needed to cover NII on specific equipment. • Solution • A module for NII (Non-Intrusive Inspection) was developed within the RBLX software to avoid IVI and the need for vessel isolation, confined space entry and decontamination. • A robust NII Module provides assurance that risk levels are not adversely affected by replacing IVI with NII.

12. LifeTech Engineering • Challenge - Dead Legs and Nozzles Assessment • Dead Legs can be areas of increased corrosion requiring special attention, due to concentration of corrosive species, especially those that are part of primary piping systems. There are also many nozzles connected to vessels that are sometimes critical requiring separate assessment. • API 581 does not address assessment of Dead Legs and nozzles in sufficient detail. These components are potentially high-risk areas, therefore, separate procedures were required for their assessment • Solution • Due to a large number of Dead Legs and Nozzles, it is difficult to assess all individually, therefore, a screening process was developed to filter the most critical items for detailed assessment. • Selected items were assessed in RBLX and specific inspection plans were developed.

13. LifeTech Engineering • Challenge – Proposed Inspection Date • Based on API 581, inspection date is defined based on the predicted risk, however, the Refinery wanted to add a Minimum Thickness Alert to this criterion. Also, the Refinery internal guidelines had to be incorporated into RBLX procedures when defining inspection plans and dates. • Solution • The RBLX software predicts risks and normally calculates inspection dates based on a Risk Target, however, the software was amended to include the Refinery defined maximum inspection interval of 12 years and to consider the Minimum Thickness Alert.

14. LifeTech Engineering • Conclusion • This project was a great success due to the following: • The teamwork and commitment demonstrated by both the Refinery personnel and Consultancy team was outstanding • Open communication (daily talks, weekly review meetings and monthly RBI steering team meetings) to address issues arising and willingness to propose solutions • Support from the Refinery senior management • Lessons Learned workshops throughout the project (not just at the end) • Speedy customisation of RBLX software based on Refinery/Consultant Review Meetings

15. LifeTech Engineering • Challenges revisited • Data Availability and Quality • Identification of Damage Mechanisms • Non-Intrusive Inspection Assessment • Dead Legs and Nozzles Assessments • Proposed Inspection Date

16. LifeTech Engineering THANK YOU & STAY SAFE

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