ABB Life Extension

Neil Henry, ABB Consulting, September 2011
CSC 2011
Life Extension for Ageing Equipment
ABB Group
February 20, 2012 | Slide 1
Life extension for ageing plant
ABB Group
Why is it necessary?
What is required for process equipment?
A different approach from existing codes and methods
Examples
Typical result from studies
Learning from the work carried out
Asset Life - issues faced by production operations

CHALLENGING WORLD
ECONOMIC CLIMATE!
CHANGING PRODUCTION
REQUIREMENTS
Different production methods,
constituents and profiles
Operate beyond original design life

Run for cash
New plant build scale rising
1970s
1990s
2010s
2030s
Investment Justification
AGEING EQUIPMENT
Pressure from Regulators
ABB Group
CHANGES to
Engineering Standards
2050s
Why is it necessary? Process safety in older plant

Why is age important what is an expected service life?
HSE concern resulted in Research Report (RR)509, 2006
Further work leading to RR823 published 2010, concluded
Ageing influenced over 30% of equipment failures
HSE have to consider Operators safety justification

for continued use of ageing plant
OSHA National Emphasis Programs in refinery and

chemical (for mechanical integrity)
It is far more than a compliance issue equipment reliability

is an essential business requirement: confidence in assets
ABB Group
Asset categories v UK legislation
Pressure Systems
Safety Regulations
(PSSR)
COMAH, IPPC, PUWER
Pressure
Energy
Business
Critical
Hazardous
Fluids
Non-critical equipment (remainder)

Corporate
Governance
ABB Group
OSHA CFR 1910.119 (Process Safety Management)
Quotes from standard
ABB Group
!!
effective process safety management program requires a

systematic approach to evaluating the whole process
!!
employers need to develop the necessary expertise,

experiences, judgment and proactive initiative within their
workforce to properly implement and maintain an effective
process safety management program
!!
that the design and construction along with the testing,

inspection and operation are still suitable for the intended
use. Where the process technology requires a design
which departs from the applicable codes and standards,
the employer must document that the design and
construction is suitable for the intended purpose.
Process
Safety
There are
many
common
aspects
Integrity
Management
Many benefits result from an Integrated

approach to Safety and Integrity
ABB Group
Why does equipment fail? Lab Data.

No of Failures
40
35
30
25
20
No of Failures
15
10
5
ABB Group
Wear
Over
Pressure
Overheating
Creep
Mechanical
Failure
Brittle
fracture
Erosion
Weld
Failure
Fatigue
SCC
Corrosion
Identifying root causes
80
70
60
50
40
30
20
Series1
10
0
Operation
ABB Group
Design flaw
Maintenance
Error
Fabrication
Defect
Failed repair
Other
Failure of process plant

!!
There are very few failures reported on pressure

equipment
!!
Statistics suggest failure rates of 1x103 to 1x104 yrs:

!!
!!
But what level of failure? (deterioration, leak, major

loss)
When could failure occur?

!!
This year, next!..in 5 years or more
!!
Most failure statistics exclude corrosion damage
Objective is Avoiding unplanned failure - production impact
ABB Group
Ageing plant - The ageing stage
Accumulated Damage
Approaching design limits

Evidence of significant accumulated damage
Changes in process use
Repairs, refits, modifications
Deficiencies in systems and skills
Time
Initial
Operation
Mature
Stage
Ageing
Stage
Terminal
Stage
Ref: HSE RR 509 Plant Ageing Management of equipment containing hazardous fluids or pressure
ABB Group
What affects asset life? Understanding the challenge
Design quality - Life-limiting factors assumed at design stage
Design
Quality of the original fabrication and installation
Construction
Obsolescence of equipment
Operating within original design limits
Suppliers
Operation
Inspection
Knowledge of equipment condition e.g.

Inspection of static equipment or condition
monitoring of rotating equipment
Maintenance
Maintaining equipment in fit for

service condition
Quality of spare parts and repairs
Modifications
Asset life factors across the life cycle

ABB Group
Change of equipment
or operations that
negates original
design
!!
!!
!!
!!
!!
Life extension - challenges

Application of life extension practices
change to equipment and operating regimes,
incremental over time
Not simply fatigue or creep life
operating cycles and / or time related factors not
in design (fatigue or thermal)
Progressive corrosion model for life & inspection
time of initiation of corrosion
operational change over time
Condition Monitoring systems
knowing what to monitor?
Primarily containment of high hazard substances not
pressure
ABB Group
Asset life extension
Remnant Life
How to understand
remaining Asset Life?
Asset Life
ABB Group
Process change examples
Peak load operating eg power plants
Product demand cycles

Overnight
shutdowns
Week-end
shutdowns
Product grade change
Feedstock change
Process optimisation temperature

changes
ABB Group
Ti centrifuge suffering wear
Wear & Corrosion of centrifuge

scrolls
New grades of product contained higher residual acid and increased abrasion
Spare scroll installed when required - repair was carried between shutdowns
Limited management of repair no evaluation of damage extent
Actions taken
Evaluation & application of surface coating to scroll tips to extend life
ABB Group
Life extension Management Cycle

Business strategy
Project
Delivery
Corporate
production
planning
Project
Scoping
Project
priority
evaluation
ABB Group
Prioritisation
of assets
Data
gathering
Asset Life Actions

Asset Sustenance plan
Condition &
life
assessment
Typical results of Ageing Plant Study

Items need to be replaced
within next 20 years
ALS Category
Items need major repairs

within next 20 years
Items need further

evaluation
8%
7%
1%
11%
A
Items need minor repairs

B next 20 years
within
C
D
E
73%
Items can continue to be operated

for the next 20 years
ABB Group
Interpreting the results financially

Deterioration Mechanism
(s)
Over required lifetime
Not significant
No routine
maintenance
operate to failure
ABB Group
Major
Minor
Routine
maintenance
Minor repair
Significant
Replacement
repair
Typical study output. Spend map is predicted

Estimated Investment per Year (overall)
Total
Sum of Cost
60000000
50000000
40000000
30000000
20000000
Total
10000000
0
06
20 2007 008
09
2
20 2010 11
20 2012 13
20 2014 15
20 2016 17
18
20
19
20
20
20
20
ABB Group
Year Required
21
20
22
20
23
20
24
20
Total
25
20
26
20
Asset life extension part of an integrated study

Asset Life Studies
Criticality and
Management of Risk
Process
Hazard
Review
Training,
Coaching
and People
Development
SIL
ABB Group
Total Plant
Reliability
RBI+ and RCM
Effective
Turnaround
Management
Specialist
Technical
Consultancy
Rotating &
Machines
Electrical
Control
Instrumentation
Civil & Structural
Vessels
Piping
Fired Equipment
Materials
Process
Example of top down asset life assessments

Heat Exchanger
Original Design
Standards
Normal Design
Life
Process Pump
40 years
plus
30 to 40
years
Impact of
Deterioration
Mechanisms
Service &
process
Corrosion
fretting
Corrosion
or Erosion
Assessed
Asset Life
20 years or
less
10 years or
less
Best Practice
Maintenance
Practices
Inspection Methods
& History
Operating Practices
Environmental
Conditions
ABB Group
Asset life extension
Effective & efficient application:
ABB Group
Criticality or vulnerability study
Identified investment required
Actions necessary to maintain integrity
Achieving Safety Standards
Sustain or achieve operating performance
Meet future production requirements
In the short term (typically up to 5 years)
In the longer term (typically 10 to 20 years)
Conclusion life extension to avoid this!
Piper Alpha 1988
Humber Refinery 2001
ABB Group
Pembroke Refinery 1994
Texas City 2005
ABB Group

ABB Life Extension

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Neil Henry, ABB Consulting, September 2011

Life extension for ageing plant

What is required for process equipment?

A different approach from existing codes and methods

Typical result from studies

Learning from the work carried out

Asset Life - issues faced by production operations

Operate beyond original design life

New plant build scale rising

Why is it necessary? Process safety in older plant

HSE concern resulted in Research Report (RR)509, 2006

Further work leading to RR823 published 2010, concluded

Ageing influenced over 30% of equipment failures

HSE have to consider Operators safety justification

OSHA National Emphasis Programs in refinery and

It is far more than a compliance issue equipment reliability

Asset categories v UK legislation

COMAH, IPPC, PUWER

Non-critical equipment (remainder)

OSHA CFR 1910.119 (Process Safety Management)

Quotes from standard

effective process safety management program requires a

employers need to develop the necessary expertise,

that the design and construction along with the testing,

Many benefits result from an Integrated

Why does equipment fail? Lab Data.

Identifying root causes

Failure of process plant

There are very few failures reported on pressure

Statistics suggest failure rates of 1x103 to 1x104 yrs:

But what level of failure? (deterioration, leak, major

When could failure occur?

This year, next!..in 5 years or more

Most failure statistics exclude corrosion damage

Objective is Avoiding unplanned failure - production impact

Ageing plant - The ageing stage

Approaching design limits

What affects asset life? Understanding the challenge

Design quality - Life-limiting factors assumed at design stage

Quality of the original fabrication and installation

Knowledge of equipment condition e.g.

Maintaining equipment in fit for

Asset life factors across the life cycle

Life extension - challenges

Asset life extension

Process change examples

Peak load operating eg power plants

Product demand cycles

Product grade change

Process optimisation temperature

Ti centrifuge suffering wear

Wear & Corrosion of centrifuge

Limited management of repair no evaluation of damage extent

Evaluation & application of surface coating to scroll tips to extend life

Life extension Management Cycle

Asset Life Actions

Typical results of Ageing Plant Study

Items need major repairs

Items need further

Items need minor repairs

Items can continue to be operated

Interpreting the results financially

Typical study output. Spend map is predicted

Asset life extension part of an integrated study