Innovative approach of damage mechanism identification for energy equipment – A case study of oil refinery

ABSTRACT

The purpose of this paper is to show the results of Risk-Based Inspection (RBI) analysis conducted in a refinery plant in the Middle East by applying slightly modified methodology for an RBI. Due to the complexity of the refinery, a summary of identified damage mechanisms and discussion regarding barriers are shown in chosen representative units. Application of the Innovative approach in the implementation of RBI process will be presented by defining active and passive damage mechanisms, with the emphasis on damage mechanism identification for energy equipment. Finally, the main result of application of Innovative approach lies in the fact that one can setup the system that can be more useful than the traditional approach to an RBI analysis in a way that specific time frame for triggering an RBI review can be better defined. This approach was developed and successfully applied for an RBI study covering six units where over 1100 pieces of major equipment and more than 15000 pieces of piping systems were analyzed.

KEYWORDS:

• RBI
• energy equipment
• damage mechanisms
• active damage mechanisms
• passive damage mechanisms
• barriers

Abbreviations

RBI	=	Risk Based Inspection
ASME	=	American Society of Mechanical Engineers
PCC	=	Post Construction Committee
API	=	American Petroleum Institute
RP	=	Recommended Practice
IOW	=	Integrity Operating Window
CL	=	Corrosion Loop
CCD	=	Corrosion Control Document
CUI	=	Corrosion Under Insulation
PSV	=	Process Safety Valve
PWHT	=	Post Weld Heat Treatment
MDMT	=	Minimum Designed Metal Temperature
NDE	=	Nondestructive Examination

Additional information

Notes on contributors

Vladimir Pilić

Vladimir Pilić is a research associate at the Faculty of Technical Sciences in Novi Sad with research focus on energy efficiency, energy and process engineering, with emphasis on the Risk Based Inspection and damage mechanisms typical for energy, process and oil and gas industry. During the last 10 years, Vladimir participated in both research and industrial projects which lead him to specialize in RBI and ultimately obtain the API certificate for RBI. Vladimir’s current research topic is the implementation of RBI methodology and accompanying tools in other industries.

Daniel Baloš

Daniel Baloš holds MSc in mechanical engineer with the specialization in applicative IT and industrial management and a PhD in application of data mining techniques on material behavior modelling for high temperature components. Daniel has almost 20 years of experience in research and industrial projects, as well as training activities in risk-based inspections for power plants and refining industry. Participated in and lead RBI implementation projects for major oil and gas and/or companies in Serbia, Germany, South Africa, Qatar, China, Kuwait, Romania and many others. Since 2005, Daniel is teaching RBI techniques and holding courses in RBI for petrochemical and power industry with successful courses delivered in countries worldwide.

Aleksandar S. Anđelković

Aleksandar S. Anđelković is an Assistant Professor and Head of Thermal Engineering Chair and Laboratory at the Faculty of Technical Sciences in Novi Sad. Researcher and independent consultant focusing on: Indoor Environmental Quality - IEQ; HVAC systems; energy efficiency; building design, performance and operation; renewable energy; energy audits and management. Through current work at University and numerous consultancy projects Aleksandar developed excellent project management, leadership, interpretation and problem-solving skills allowing for a smooth transition to any engineering environment which resulted in broadening his expertise to an oil and gas industry.

Višnja Mihajlović

Višnja Mihajlović is an Assistant Professor at the “Mihajlo Pupin” Technical Faculty in Zrenjanin. Višnja is holding PhD in Environmental Engineering and has over a decade of teaching experience. Participated in both national and international industrial and research projects in the area of environmental engineering. Višnja’s field of interest are environmental engineering, environmental impact assessment and occupational safety.

Damir Đaković

Damir Đaković is an Associate Professor and Head of Process Engineering Chair at the Faculty of Technical Sciences in Novi Sad. Damir had started his research career in the field of oil and gas only to become interested in the process of drying shortly thereafter. Participated in both research and industrial projects as well as in projects concerning energy efficiency improvement and promotion. Damir’s fields of interest are possible application of newly found knowledge in the transfer phenomena (mass and heat) for energy efficiency improvement, various application aspects of renewable sources of energy, unit operations and equipment, drying.