Strategies for infrastructure reliability Case studies assess the effects of civil infrastructure deterioration on a plant-wide basis or on a critical specific structural level, including the importance of employing an engineered approach to crumbling infrastructure challenges she petrochemical industrial | Infiastructuce in certain regions, such as North America, Is agelng at a rapid pace, while demand for the productsmanufacturedby thesefaclities is Increasing even more ‘apidly. AS an owner understanding theriskassociated, ‘with not conducting maintenance on civil infrastructure versus spending the funds on maintenance to keep the facilities operating can involve difficult decision-making “opportunities” ‘As with process equipment, the 1isks associated with potential” process interruption by failures of civil Infrastructure are weighed and decisions ‘made, These decisions are based on the factual historical information of similar process scenarios, the effect on adjacent process steams and the facility as a Whole. Being proactive versus reactive hhas been proven, via risk-based Inspection (RBI), to’ be the best path available to owners as a means of ‘maintaining an operating facility with ‘minimal interruptions. Addressing civil infrastructure assets As a derivative of RBI, a new tool has been developed that addresses the condition of civil infrastructure assets Ina similar way to those assets Girectly involved with the process stream, Plant Conéition Management System (PCMS) is a program developed to proactively address concitions prior to serious developments such as safety concems and diminished structural Integety The POMS fortis divided into three phases. Phases 1 and 2 are almed) at establishing the need for condition assessments in different infrastructure assets, evaluating the causes of current distees, providing coneepiual cepatr recommendations and defining repair prlorities with assoclated budgetary repair costs. Phases 1 and 2 can include the evaluation of reinforced concrete, structural steel, masonry and timber structures, as well as fireproofing and Thomas Kline and George Fischer Structural Preservation Systems “Being proactive in the understanding of your tefinery’s infrastructure condition may not make you money, but it definitely can improve safety and save you money” protective lining systems. Approprlate ‘uznkey repairs, based upon wiork repalr prlorties, ate executed during Phase 3 fo accommodate awner maintenance needs to optimise uninterrupted support secviee Phase I involves theinitia inspection and scope definition for a faclty, by fdentifying those assets that are believed to be in a state of apparent deterioration. Initially, Phase 1 consists of a cursory site reconnalssance ‘walkthrough, or inventory of existing structures, to define the scope of repair opportunities, identify arcas requiring more in-depth evaluation, and exclude structures performing satisfactorily and consistently with their intended service. Phase 2 provides a more In-depth picture of what will require repair, how much and when it needs to be done. Employing a combination of, walkthrough and tactile investigatory techniques, evaluators are able 10 discern with some accuracy the presence, extent and, through a risk matrix consistent with owner/operator criteria, the priority level at which the repairexists and ultimately is scheduled {for implementation, Establishing repair priorities within civil Infrastructure along PCMS fuldelines covers safety, structural integrity and durability. A isk assessment checklist is a fundamental facet of the program that considers two factors: safety and asset pesformance, The primary objective of the program is safety, which is the prime directive when conditions are encountered that represent hazards to personnel and, toa slightly lesser degree, equipment and process streams. Performance refers to the ability of san asset to serve its intended function. For example, cracking in fireproofing for exposed structural steel could be considered a loss of fireproofing continuity. Such characteristics would suggest reduced fireproofing protection, Itisimportanttonotethata performance risk could result from multiple combinations of different deterioration manifestations, Similarly, the risk assessment of an element could combine the safety and_ performance fisk, such as a combination of falling debris with reduced fire protection du to severe cracking. Case study 1 Refinery objective “The objective of PCMS was to assess the existing condition of accessible Srctural steel pipe supports in designated sets within the. refinery. Distress Features in the structural steel and fireproofing were identified, dlocamentedand quantifedas necessary, Phases 1 and 2 established pipe supports of concen. by highlighting. safety, Stauctural and durability Issues, Causes Of steel) and fireproofing dlstess vere assessed. Ifeeadily apparent, repair work Porites were established, conceptual Fepair recommendations provided and budgetary costs assembled, The scope ‘as a follows Reviewed available project documents relative tothe evaluated pipe supports — "Reviewed concrete foundation bases, steel base plats, structural elements (le, columns, beams, bracing and connections) and fireproofing “Nemployed nondestructive testing (NDT), including crack comparators and mechanical hammer sounding techniques over representative pipe support elements in an effort to detectSd coke ced a | Larox Solid-Liquid | Separation Solutions We have the Products Larox Pressure Fiters Pannevis Vacuum Belt Fillers Hoesch Membrane Presses Scheibler Polishing Fiters We know your Process Catalyst removal & recovery Sulphur recovery BisPhenobA separation & washing | Trephinate Ac processing High purty polishing fitrtion ‘And much more We have the Answers \With over 2500 successful process soluions operating in every area of the CPl wo kriow we can solve your sold liquid separation problem. | Visit us at www larox comcpi to find out how we can provide the optimum solid-iquid separation solution = LAROX abnormal acoustic emissions that could suggest hidden dishes characteristics, ~ Obtained high-resolution digital photographs, authorised by the client, of representative pipe Suppor Astess occurences within the evaluated areas — Collet representative conercte power samples from Seeproofing materials using rotary hattamordllextettion techniques. Collected samples weresutmite for laboratory analysis — laboatory analysis include testing the powder samples for chlosue on (C1) content of hated connate | — Fstablshied repair prone Iased on salty, structural and_ducbilty. guidelines consistent with ihe PCMS rogram’ objectives — Performed a review of avallable repair and maintenance alternatives, and evaluated cot, eect of working space sad lustallation eng proces operations = Assembled ant submitted a waiten report detaling findings, analysis and conceptual repair recommendations Buayetaty repair costs were submited unde: separate coves 1s important to note chat the information prevented in the report did not inchide a sttutural analyse of the designate pipe support sets cause that leet eva ‘as outs the scope of CMS ‘he backbone of PEMS is the use of data fous, which ate employed inthe fed and implemented in the archival effort. For the refine’ pipe support project nine dats Fras ‘wece created and coded using the feirery plant and Pipe support nme. The forms are composed of ees ed {ext fees to expetite daa-collection effns. The fon Iheade inckides the general form name, the seiner pl the pipe soppon set umber an the form ete. Data fons were used only when applicable. For example a pipe Support et with no fireproofing on any of it elements would not requle the Use of forms designed tte fireproofing information, Background ‘The evaluated pipe supports were constructed in the 1940s, Pipe supports from that era were generally consticted of rill pipe. The pipe sections varied between din and 6in ‘ominal diameter forthe columns, and in nominal diameter fot the beams and bracing. All sections were welded to form small rig frames as patt of the support system, The use of fireproofing varied, depending on the specific plant unit and where in the plant the pipe rack was located. Approximately half of the pipe racks during this PCMS investigation did not have Breproofing, Project The project started with PCMS Phase 1, in which client representatives from each of the plant units met with representatives from Structural Preservation Systems (STS) to determine the scope of the task. A look at the areas of ‘once in each of the units was conducted. Tihs inital Visit provided information to determine the final scope of the Phase 2 work, Phase 2 involved a team of seven investigative specialist, including two engineers, two technicians and. three labourers for support, from SPS, The wock was coordinated tiurough refinery client management from each unit to {acilitate the process of obtaining permits, access to work areas, and to monitor and coordinate safety. The onsite work was accomplished in nine days, The SPS personnel were divided into two teams for elfciency of observations and recording purposes. The use of data forms was implemented extensively to record the gree of deterioration and cortasion, if any, that was observed ly the investigative fens. Also, photo logs were Incorporated into the forms to visually document the www.larox.com is pee earAt pipe racks with Sreprooting, excavations were made at predetermined locations tn assess concrete properties, and to observe the amount of steel pipe corosion and potential section loss. Theseobsorvations ‘were recorded on the data forms, t0 be later analysed and inchaded in the final report, Pipe racks without freproofin ‘were observed for corrosion and distress and duly noted oa the data forms, 0 be analysed later the office. Approximate quantities for ie various repair or member replacement sections were tabulated and incorporated into the final submitted ork product, ‘The Phase 2 field investigation Information was then analysed. with aw data from the feld data forms, consolidated and prioritised 10 determine the extent of potential repairs. The repair recommendations, polorities and approximate orderof- magnitude costs were included in report for each unit in the refinery. As a result of Phase 2 activities, the operator ‘yas able co determine internal repale Tocation priorities and the budgets requlied to perform the sepaiss in the varlous units, For the clients refinery, t was decided to complete the priority No I and No 2 items in a single anit, starting with the coker unit. Repair programme ‘The PCMS Phase 3 activities included ‘the actual work to perform the needed repalts, starting with the coker unit. SPS provided engineering and construction ‘management for the cient designated contractors to perform lead abatement, shoring and structural steel reinforcing fo replacement. The contractors were under direct contract with the client. “This phase did not have conerete repair, ‘which SPS would have performed itself Future work for 2008 will include engineering and construction ‘management in another refinery unit. The work wil be similar to the work in the coker unit. SPS will provide engineering and construction ‘management for the stel pipe rack repair activites. The repairs will include both priority No 1 and No 2 work, as noted on the PCMS data forms and report. Case study 2 Coker support structures Concerns with the coke drum support structures ata California refinery stemmed from visually obvious concrete distress in the form of cracks, delaminations, open spalls, exposed conoding reinforcing steel bats and falled existing concrete patch repals In these critical support structures. TRE objective was to assess the existing condition of two reinforced concrete coke drum support stuctures by ‘employing a focused tactile condition “The backbone of PCMS is the use of data forms, which are employed in the field and implemented in the archival effort. The forms are composed of checklists and text fields to expedite data-collection efforts” survey following a seven-step evaluation process — Characterise trends of existing coriginal construction details, if available — Document indicators of apparent structural integrity concerns Identity apparent root causes of deterioration = Quantify extent of concrete distress — Formulate conceptual turkey concrete repair solutions = Tstimate orderof-magnitude costs for established concrete repair solutions, Background The two structures, each supporting two large coke drum vessels, had been originally designed and constructed in. ‘the mid-1950s. They are massive table top, conventionally reinforced concrete frame structuces with — clecular penetrations extending through the full Si thickness of the switch deck slab to accommodate the feustum-cone bottom of the coke drum, Over its setvice life a serles of seismic upgrades hhad been installed in the form of Bre reinforce polymer (FRP) wraps applied to beam and column surfaces to stiffen the frame structure, Additionally, a series of poorly planned and executed, patch repaiss had been attempted in egions of conciete _clacking, delamination and open spalls on both steuctures, These only exacerbated the deteriorated conditions. Project, ‘The scope of work was as follows — Reviewed available project documents relative to the evaluated ‘coke druen support structures — Performed 2 visual inspection of accessible concrete surfaces, noting areas of cracking, spalling, staining and other significant features such as mapping — Using site-assembled access scaffolding, an acoustic impact survey ‘was performed in representative areas lover accessible concrete member surfaces in an effort to detect sub- surface voids and delaminations (e, internal separations) — Performed a pachometer suevey to determine the presence and orientation Of embudded relnforcing steel details, Reinforcing steel configurationsdetected, during the survey were compared to asdesigned ceinforcing details —rerformed non-destructive ultrasonic pulse velocity (UPV) and rebound hammer testing, ASTM C597 and ASTM C-805, respectively. These techniques were employed at rupresentative locations to ascertain consistency and quality ofthe conerete, in-situ, for correlation with the sample recovery program, — Collected concrete cores using wet rotary diamond core drilling technigues ‘and concrete powder samples using rotary hammer dill — Submitted collected coreand powder samples for laboratory analysis, which included: = Depth of carbonation testing: Carbonation depths were determined using a modified phenolphthalein pH Indicator solution sprayed onto freshly fractured concretesurtaces. Observations ff the resultant spray surface colour tints indicated the existing concrete environment and susceptibility to cottosion activity Chloride ion content of hardened concrete tests: Chemical extraction test results determined the chloride ion level within the coneret. the detected level is an indicator of the potential electrochemical process of embedded metal corrosion within the conerete mass = Compressive strength testing of concrete core specimens (ASTM C-42): ‘Test results provided strength values and were an indicator as to the relative ‘quality of the concrete — Performed a review of available epair alternatives for the structures to provide the best long-term serviceability — Prepared a turnkey proposal that addressed the requited repairs and met the operator's anticipated repair Repair programme Upon the review of various repair options, the effect on workspace and evaluating onine/off-line concrete repait scenarios, the resultant repair strategy was selected: = Worked in association with the refinery at preplanning on-line and off- line ‘conerete repair operations, providing process access and shielding to critical process assets = Installed working platforms 10 provide access to elevated arcas — Excavated and removed deteriorated“Critical thinking comes into play when the information and data are presented in a thoughtful format, and enlightened decisions can be formulated on how best to approach crumbling infrastructure” concrete materials within perimeter saweuts and prepared concrete surfaces in accordance with International Concrete Repair Institute (ICRI) and American Concrete Institute (ACI) guidelines. Repairs were performed in an engineered staged sequence pattern — ‘Cleaned and protected exposed reinforcing steel bars accompanied by rebar augmentation or replacement, as needed — Applied corrosion-inhibiting technology within repair product matrices. The application of corrosion inhibitors Within repair concrete mix designs will mitigate further deterioration into the original sound concrete substrate and reduce the potential of premature repair failure along the repair bond line — Installed a passive cathodic protection system ‘employing corrosion mitigating anode technology within repair cavities to arrest potential halo corrosion effects — Enginceced and built unique circular concrete formsrork with stee! and wood components — Assembled mortar-tight concrete forrawork at concrete repair locations — Reestablished structural section in repair areas by placing rapid setting, high-quality, dense cementitious ropair materials within formed cavity areas using form and pour techniques. However, consistent material ‘characteristics and properties were necessary. As such, pre- bagged repair concrete materials from reputable manufacturers were used in the repair programme — Removed mortar-tight formwork after an extended wet ‘outing period and dressed repair areas to match adjacent parent concrete surface contours. Critical thinking As came scen from these casestudies, when understanding such as when trying to grasp the effects of deterioration fon a plant-wide basis, or on a critical specific structural level — it is important to employ an engincered approach and critical thinking, Critical thinking comes Into play when the information and data are presented in a thoughtful format, and enlightened decisions can be formulated on how best to approach crumbling Infrastructure. Ths atic Is base ona paper (RMC-08-3) presented atthe NPRA ‘aiasy and Msintenance Conference im San Antonio, Tes, ‘May 2008 Thomas Kine is Division Manager, Engineering Services, Structural Preservation Systems in Dear Park, Tees, Email tine@structuraLnet George Fischer is Chie Structural Engineer, Structural Preservation Systems in Green Bay, Wisconsin Email: gfscher@structural.net SAMSON Think big! 1 Our Series 250 votes koop everything ‘under con! thanks fe thei modular design wit sizes up o DN. 500, presure-bolanced, rmuli-saged plugs and noise-educing ims. The wide range of valve materials mean even corrsive ond erosive mei canbe cored sofely ond riya high pressure drops cand extrome operting temperatures Dimensions nd flanges conform to the most important indusalstanderds such as ANS, DIN, JS, olowing SAMSON'S contre vives to be used in applications worldwide. SAMSON AG. 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