a PIPING AND VALVES World-class pipe-spool fabrication Ise these guidelines and checklist to valuate a fabricator’s ability to deliver he specified product on time .M. Billings, ARCO Exploration 1nd Production, Plano, Texas, D.M. verrer, ARCO Alaska, Inc., Prud- 0 Bay, Alasisa, and J.H. McHaney nd R.W. Wilson, Metallurgical onsultants, Ine., Houston, Texas. §l and gas production facil ties, refineries, petrochemi cal plants and power gener- ion stations are being installed in merging economies with limited apability for and experience in fab- ‘cating state-of the-art heavy indus- rial equipment. Key components or infrastructuro development will kely be purchased in more devel- ped economies with world-class acilities to produce prime movers, ressure vessels, piping systems, te, Carbon and low-alloy steel pipe pools are key components that can, designed and packaged for con- enient and economical transport to rorldwide installation sites. Conse- uently, pipe spools can be pur- hased wherever the necessary qual- ty can be obtained with reliable elivery schedules at reasonable otal cost. Over a decade of downsizing in be oil and gas industry coupled with mphasis on cost reduction appear © have convinced some regional \ipe-spool fabricators that becoming ho lowest-cost producer is more important to their survival than pro- tucing world-class products. How- -ver, selecting the lowest available nitial bid price for major compo- xents does not necessarily result in he lowest installed cost or on-sched- ule startup of a facility that operates properly. Improperly configured and fabricated pipe spools and/or late deliveries can have enormous nega- tive impacts on major projects. The authors are aware of multiple exam- ples. For instance, on one project, major weld-quality deficiencies in a ‘$5-million pipe-spool order resulted ‘in $15 to $20 million in total correc- tive and impact costs, including a delayed startup. The prospect of startup delay, initially predicted to ‘be one year, led to around-the-clock rework and inspection for several months. Also, there were multiple unplanned restarts. Several sections of the ASME BS1 Piping Code (Section 3 for plants and refineries, Section 4 for Jiquid hydrocarbon transportation and Section 8 for gas piping) do not incorporate requirements for formal quality plans and authorized inspec- tors of the type required by the ASME Boiler and Pressure Vessel Code. Without quality systems pre- scribed by industry standards, sys- tematically evaluating the potential reliability of candidate pipe-spool fabricators is a challenge. Also, sys- tematic comparisons between shops in different geographic areas is an even greater challenge. ‘Schedule constraints and limited project staff usually prohibit coma- prehensive audits of all candidate fabricators. Project management teams (PMTs) can use the following recommended protocol for abbrevi- ated technical audits to evaluate car- bon steel pipe-spool fabricators. Such, audits can identify those world-class fabricators that are most likely to deliver the specified product.on the required schedule. ‘Right fundamental characteris tics of world-class carbon steel pipe- spool fabricators are identified. A checklist including a scoring system for benchmarking pipe-spool fabri- cators compared to other candidates is recommended. An abbreviated technical audit of the recommended characteristics using the checklist requires at least four hours in a shop in addition to the time required at the site for introductions and other discussions. A team of two persons, preferably an experienced engineer and a shop inspector, is recom- mended for executing these abbre- viated technical audits. Widespread application of this abbreviated tech- nical audit protocol would result in more reliable pipe spools that meet the specification requirements and are delivered on schedule. Applicability. The recommended protocol was developed for screen- ing candidate pipe-spool fabricators for inclusion on approved supplier lists when insufficient recent expe- rience with the fabricator was avail- able to make that determination. An abbreviated technical audit will not provide all the information that can be collected during a comprehensive audit by an experienced audit team. However, the recommended proto- col can reliably distinguish between those shops that should be included on approved supplier lists and those swith serious deficiencies in their fab- rication and inspection practices. ‘When the economic stakes for a pro- {ject justify more comprehensive ‘audits to supplement those abbrevi-Eee cds os; Fo) Gtaseteice hoe s900 i incon ent eerteation of ag coamdateelle” welders. equipment limited gation taining: “4 indore aval ‘Some ivelding Lisl vetting Welding consumables a eonsumables availabe. ae ‘feiss, ‘and “Aéséptable NDE ‘seuipiriont and Mike to fay biaiclon a feregerent re. _wilten and traceete. ic) Insert fo nupiienete ‘in right column. (6): Ar Coos or ona nn 3 2 nla bs wekress 2 and goat, potent wate Goto) regona Ota Most inspection reilis: ¢om ie easy evalable bias esa 7 Al o68s vice BEES cquiprient and"! pereonnel ¢ funetio reports to topmanagerrent ated technical audits, comprehen- sive audits can be reserved for a shortlist of previously approved sup- pliers offering the best price and delivery. ‘The recommended protocol is ‘most appropriate for job shops that ‘employ ten or more welders to fabri cate multiple orders and the piping divisions of larger, full-scope fabri- cators. Smaller shops may not have the technical resources to support the characteristics identified as nee- essary for world-class performance. Regional fabricators typically have limited opportunity to bench- mark their practices against other fabricators, especially against those fabricators outside their immediate area. Consequently, a similar proto- ol was proposed to pipe-spoo! fabri- cators for benchmarking their pe formance against world-class ‘competition.? Regional fabricators may increase their access to large international projects by tailoring their fabrication and inspection prac- tices to increase their scores during benchmarking and abbreviated tech- nical audits. ISO 9000 certification. Certifica- tion to one of the ISO 9000 series quality standards may be a useful indicator of the potential reliability of a pipe-spool fabricator. However, ISO certification is provided by a varicty of different organizations and the actual requirements to obtain certi- fication can vary from one certifying authority to another and from region-to-region for a single certifYy- ing authority. The authors have encountered fabricators with ISO 9000 quality certification that did not possess the characteristics of world-class fabricators. Conse- quently, even certified ISO 9000 pipe-spool fabrieators should be reviewed to determine if their quality and delivery are likely to be satis- factory for a particular application Fundamental characteristics. Eight fundamental characteristics of world-class carbon steel pipe-spool fabricators can be investigated dur- ing an abbreviated technical audit. ‘The findings ean be recorded on a copy of the checklist. These eight characteristics are not the only ones 118 HYDROCARBON PROCESSING / OCTOBER 1995 of concern, but the authors have observed ‘a strong correlation between these and the performance of pipe-spool fabricators. When the febricator’s management has not rec- ognized these eight characteristics as crucial and has not put them into day-to-day practice within the orga- nization, there is reason for serious concern about the ability of that shop to perform reliably. Written instructions to pro- duction and quality personnel. Pipe-spool fabrication for interna- tional projects typically involves specification requirements in addi- tion to the basic requirements of ‘industry piping codes such as ASME 818, B31.4 or B31.8. Furthermore, cach order a fabricator executes may have specification requirements dif- ferent from all other orders being processed at the same time. Com- munication of all the requirements to appropriate shop employees and inspectors is crucial to the success- ful on-schedule completion of a pipe- spool order. Relying on oral communication of specification requirements is genor-ally undependable and consequently undesirable. Providing a copy of the customer's specification to each employee with the expectation that they will analyze the requirements for themselves is clearly impractical. Consequently, managers of world- class pipe-spool fabricators develop systems that reliably extract all nec- essary specification requirements and communicate that information to shop supervisors, workers and inspectors, Drawings and the order routing system should supply the informa- tion that shop employees need to exe- cute an order in written form with- ‘out routine supplemental oral instructions. The written instruc- ions to shop workers and inspectors should include: a) a detailed bill of material (BOM); b) all dimensional requirements; ¢) applicable welding procedure specifications (WPSs); and ¢)all inspection requirements. Some routing systoms require workers and inspectors to sign and date the order traveler as each task is completed. Auditors should request a brief ing on the system for extracting and distributing specification require- ments prior to entering a shop. Audi- tors must concentrate on under- standing the communication system that is reported to be in-place and then verifying that the system actu- ally functions during the audit. A useful tactic is to ask selected employees questions, such as: a) “What are you doing for this order you are processing” b) “How do you ‘know that is what the customer ‘wants you to do?” and ¢) “Can you show me how to verify that what you have told mo is indeed correct?” Be concerned if details of the customer's, specification requirements have been incorreetly communicated or misunderstood. Evaluating the abil- ity of the communication system to function reliably for the order under consideration is more important, than evaluating the significance of details that have been improperly ‘communicated. 2. Material control and trace- ability. An audit team must ovala- ate the ability of the material control system to track the material for the pending order. World-class pipe-spool fabricators have systems in place to maintain positive material identifi- cation on all material in their pos- session from the time of receipt of pipe, fittings and flanges through to shipment of eompleted pipe spools, Dedicated areas should exist by pro- ject or customer for materials stor- ‘age. ‘The fabricator should follow an established procedure to issue mato- rials to the production function, Free- issue materials must be identified and controlled per the customer's requirements. In a world-class pipe-spool shop, every length of pipe, including those tobe used for structural welding, has some form of positive identification permanently applied using paint or die stamps. This is applied at the time the length is cut from the source material and indicates the source and usage of that pipe. Color codes in the form of paint stripes applied in the pipe storage area can be used to indicate grades and may be satis- factory when specifications do not require traceability to specific heats of steel. A world-class identification system must contain provisions for identifying specific heats by trans- fer of heat numbers, either to the component or to the order traveler. The absence of identification applied by the fabricator is not acceptable for world-class fabrica- tion, even when the component is for structural use. The presence of unidentified material anywhere in a shop increases the probability that, improperly identified material will he installed and shipped to a cus- tomer. Conversion of an unmarked component, requires only one mis- ‘take; conversion of a component with prior permanently marked identifi- cation requires two consecutive mis- takes, Be concerned if you find pipe without identification markings any where other than the receiving area, serap bins or quarantine for noncon- forming material. ‘Anditors should request a brief ing on the system for material iden- tification before entering a shop and then be alert for components with no identification or identification that does not conform to the system. ‘When components that appear to be inadequately identified are observed, the auditors should imme- diately question workers in the area about the identification. Auditors should also select several compo- nents at random in various stages of production and ask employees about the idontification of the com- ponent. Appropriate questions TVA RC ORS) Using Coalescers LOSING PROFITS Using Gravity Separation? 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High efficiency bi-component mesh Plato packs Uitra high efficiency cylincrical units Coalesoer vessels Custom made packs Pilot test unitsinclude: a) “What is the order number for this component?” ) "How can this component be linked to a drawing, bill of material or other identify. ing document?” and ©) “What information ean you tell me about the source and heat number of this component?” Be concerned if material iden- tification and traceability is inade- quate, especially when an order involves material othor than ASTM A458 or A 106 Grade B pipe. 8, Welding procedure specifi- cations accessible to welders. ASME B313, B31.4, B31.8 and other industry standards for pipe-spool fabrication require that welding be performed in accordance with writ- ten and properly qualified WPSs by properly qualified welders. The intent of these requirements is to ensure that all welders produce uni- form welds according to practices specified by shop management, rather than to each welder’s personal preference. World-class pipe-spool fabricators provide welders with readily acces- sible WPS documents in a format and language that the welders can apply. Welders at world-class shops are trained to translate the written, instructions into the specified weld- ing technique. Furthermore, welders at world-class shops acknowledge their obligation to weld according to the WPSs rather than their personal preferences. A file of WPS documents in an office remote to the shop floor does not provide the access that welders need. Shop managers who rely on supervisors to orally instruct welders from a binder of inaccessible WPSs ‘oo often abdicate their responsibility to control the welding performed in their shop. Welders are more likely to weld according to their personal preferences when WPSs are inac- cessible and instructions are oral. The evaluation audit-must deter- nine if WPSs are being properly exe- cuted by welders, Auditors should inquire about the system for distri- bution of WPS instructions to welders before entering a shop and then determine if the system fune- tions as described. Auditors should also ask a sample of welders the fol- lowing questions: a) “What WPS are you using for the weld you are cur- rently making?” b) “Would you please show me a copy of that WPS?” ¢) “How do you know that this is the correct WPS to use for this weld?” and d) “What test did you take to be qualified to make this weld?” If some welders are unable to answer these questions, be con- cerned. If none of the welders can answer these questions or if they ‘weld according to their personal pref- ‘erences, there is major doubt that, the shop can perform as specified on even moderately difficult orders 4. Calibrated welding machines and wire feeders. Welders must know the amperage and voltage that their welding power supply delivers to follow the speci fied ranges for electrical parameters in WPSs, World-class pipe-spool fab- rricators have systems in place to rou- tinely maintain and calibrate the electrical output from all welding power supplies. Power supplies for gas metal-are welding (GMAW), gas tungsten-are welding (GTAW) and submenged-are ‘welding (SAW) frequently have built- in voltage and amperage meters. Shielded metal-are welding (SMAW) power supplies typically do not. Built-in meters must be maintained and periodically calibrated to ensure that-a welder can properly adjust his or her power supply. Settings for adjusting SMAW power supplies ‘without built-in meters must be peri- odically calibrated using external ‘meters. Shunted meters inserted in ‘the welding circuit are reported to be more accurate than tong meters, that clamp around the welding leads. Auditors should ask a sample of welders the following questions: a) “What amperage, voltage and travel speed are you using for the weld you are currently making?” b) “How do you know that the way you have the power supply set delivers that amperage and voltage?” and c) “How often are the settings on your power supply verified and calibrated?” Welders in world-class fabrication shops should be able to answer all 120 HYDROCARBON PROCESSING /OCTORER 1998 these questions, In some shops, welders may neod to refer an auditor to their supervisor, plant maintenance or the inspection group for details of the calibration program. Observing meters with broken dials or other obvious signs that the meters do not work indicates that managers and supervisors do not recognize the sig nificance of properly calibrated meters and dials. 5. Central control of welding consumables. World-class pipe- spool fabricators recognize that weld- ing consumables should be controlled through central issue from a store- room rather than directly available to welders on the shop floor. Con- trolled, rather than free, issue of welding consumables | greatly improves the probability that each weld will be made with the specified consumable. Of course, verification hy a stockroom can only be done when the correct. consumable can be determined from written instruetions to the shop workers. Consequently, welders (or their helpers) should req- uisition consumables against a work order and a specified WPS. The improved reliability comes from two persons, the welder and the stock person, checking and then verifying the consumable requirement and identification. ‘Auditors should request informa tion relating to the system for con- trol and issuance of welding con- sumables before entering a shop and then visit consumable storage areas to observe several welders obtaining consumables from stock at different, times, if possible, Storage of con- sumables for different welding pro- cesses may he different, with SAW wire and flux stored in a different location than SMAW electrodes, so all consumable storage areas should be observed. Storage conditions for consumables, especially low-hydro- gen electrodes and fluxes, should be checked. Auditors should also review the written records being kept by the stock person to document consum- ables issues. Auditors should ask a sample of welders the following questions: a) “What welding consumable are you using to make this weld?” b) “Where and how did you obtain this con- sumable?” and c) “Has anyone else ‘verified that use of this welding con-sumable for this joint is correct?” Routine free access to welding con- sumables can result in the incorrect ‘welding consumables being used and is not a characteristic of world-class pipe-spool fabricators, The absence of a system to properly store, issue and verify welding consumables is of major concern, 6. Properly equipped and trained nondestructive inspec- tion function. It is eymmon indus- try practice for fabricators to ship pipe spools to the assembly site without hydrostatic leak testing of the spools. This is because the cost of installation and removal of end ‘caps required for leak testing is gen- erally not justified for pipe spools that will be pressure tested after assembly. Yet, pipe spools shipped by world-class fabricators rarely leak when hydrostatically tested after assembly. Even a few leaks during pressure testing after assembly can delay startup and may raise serious con- cerns about the integrity of an entire piping system. Nondestructive exam- ination (NDE), including visual inspection, at a pipe-spool shop is critical to avoid unexpected leaks when the pipe spools are hydrostat- ically tested after assembly. Conse- quently, an audit team must evalu- ate the potential reliability of the NDE process during abbreviated technical audits. “Auditors should have some knowl- edge of NDE equipment and tech- niques, bub instructing auditors to evaluate either radiographic or ultra- sonie inspection is beyond this arti- cle's scope. Auditors knowledgeable in NDE should observe and verify the equipment, training records and inspection reports using their knowl- edge and experience. Auditors with limited knowledge of NDE should ask a selection of ‘welders: a) “Did someone other than ‘you visually inspect and approve the ‘wold preparation and fit-up for this weld?” b) “Is this weld scheduled for radiographic or ultrasonic inspection after you complete it?” and o) “What, percentage of the welds that you make requires repair after inspec- tion?” Auditors should also interview visual and NDB inspectors and ask ‘thom to explain: a) their training and certification in inspection methods; b) the typical requirements for inspecting welds in pipe spools; and ©) the methods for reporting inspec- tion results and tracking required ‘weld repairs, ‘Two technical societies provide standardized testing and certifica- tion of visual and NDE inspectors. Inspectors who meet the require- ‘ments of the American Welding Soci ety (AWS) are designated AWS-Cor- tified Welding Inspectors. NDE ‘technicians who meet the require- ments of the American Society for Nondestructive Testing (ASNT) are designated ASNT Level IIT for a par- ticular testing method. Both certifi- cations require documented previous experience, examinations adminis. tered by the society and periodic renewal, Inspeetors certified by either society have demonstrated experience, knowledge and compe- tence in their field. Employers cer- tify Level IL inspectors and local eri teria may vary compared to the AWS and ASNT programs, ‘Auditors with knowledge of NDE can rank a shop based on that expe- rience and the checklist. Auditors with limited experience can review certifications and use the interview questions to complete the checklist. ‘The absence of a systematic approzeh to inspection and report- ing is justification for concern about a shop's ability to perform reliable NDE. 7. Independent quality-control group. The quality-control (QC) departments of world-class pipe- spool fabricators report to top man- agement and are as independent from production management as is, practical. Reporting is typically through engineering management, which provides a counterbalance to production interests, Auditors should request a briefing on the organiza- tion of the QC function prior to enter- ing a shop. ‘Organizational charts may not reflect the reality of informal rel tionships in which strong personali- ties in production manegement rou- tincly influence quality decisions. Conversations with floor inspectors can reves! these situations. Auditors should ask inspectors: a) “Do shop. ‘workers or supervisors appeal your decisions to higher authority?” b) “How often are your decisions reversed?” and ¢) “When your deci- sions are reversed, who makes that, decision” In addition, auditors need to request some inspectors explain Commissioning and Support? “Right Choice ‘Oman Energies, ne, serves the refining, petrochemical, ofl and ges, and power generation eogeneraton induties. Our pofesionals around the wad ae experienced specialists, delivering proven technical expertise. When you outsource erica industrial procs to ‘al Energes, you not ony eat ensts ‘and ad profits, but als tap extensive Iknowtedge among the most expesienced ‘consultants. Oma gives you a eg up in teampettve markets, assembling a highly ‘qualified team to execute your project, Without the burden of long-term ‘etsonnel or wasted idle time and ‘vereod That the Omni Advantage, Maintenance act Support Personnel auatity PROFESSIONAL SERVI g mini nergles Cen eave Clrele 133, 121and demonstrate their approach to inspecting pipe spools. At some fabricators, the inspectors only examine the work at predetermined hold or witness points. At these shops, there is no control of the work= in-progress. Observing that the QC function either is or is per- ceived to be a weak department within a pipe-spool fabricator’s orga- nization is cause for céncern. A PMT ‘ean compensate for a weak QC func- tion by inserting its own inspectors in the shop for the order's duration. But this additional inspection adds to the project cost without a guar- antee of on-time delivery of specified products, 8. Traceable written inspec- tion records. World-class pipe-spool fabricators have systems in place that routinely generate written inspection records that provide trace- ability of pipe spools through the pro- duction and inspection sequence. Written traceability, including worker sign-offs and inspection records, should document what has, been produced and inspected, and the disposition as a result of that inspection, World-class inspection systems use nonconformanee reports (NCRs) to document and track the disposition of conditions that do not conform to the specified require- ments. NCRs should be prepared and issued shortly after (within about 4 hours) the discovery of the nonconformance. In no case should an NCR be issued later than the end of the shift on whieh the nonconfor- mity was discovered. Consequently, inspectors should complete all NCRe discovered before leaving at the end of thoir shift. Some fabricators quarantine non- conforming components to desig- nated areas while awaiting disposi- tion. Discovering during an audit nonconforming material or welds that have not been documonted by written NORs or placed in quaran- tine is cause for concern about the inspection system, unless it ean be demonstrated that insufficient time ‘has lapsed for preparing an NCR or transfer to quarantine. Resolution of nonconformities must be docu- mented, When nonconforming mate- xial or welds are accepted for deliv- exy to a customer, the identification of the person responsible for the de sion and the reason for the accep- tance must be documented. Usually, the original NCR serves to document, disposition, wuditors should request access to the inspection records for at least one active order and one order that was shipped within the past month. Ibis advantageous when the selected orders are of similar complexity as the potential order related to the audit. The inspoction file should include as a minimum: a) the writ ten instructions to the inspection group relating to the specific order; b) records relating to material identifi- cation; ¢) records relating to verifi- cation of the WPSs used for the selected order; d) records relating to the results of all inspection activi- ties; and e) NCRs with disposition records. Discovering incomplete doo- umentation, especially for an order that has been shipped, is cause for major concern. Checklist and Survey. The recom- mended checklist provides an audit, team with a method to record and score their findings during an abbro- viated technical audit. Auditors should circle the best description of cach characteristic on the checklist during their visit to the shop floor. When two or more auditors are work- ing as a team, it is useful for each to mark his or her checklist prior to dis- cussion with the other auditor(s) If time is available, the audit team should ask for a private meeting to discuss their scoring before leaving a fabricator’s facility. If there are major differences of opinion, there may be time to revisit the shop to far- ther explore the characteristic in question. If there is insufficient time for a private meeting at the shop, the audit results should be discussed as soon as is practical after leaving the site, It is critical to discuss the audit, and document its results while the observations and impressions are still fresh. The audit scores provide a quan- 122 HYDROCARBON PROCESSING /OCTORER 1998 titative measure for compar- ing the probable performance of several candidate fabrica- tors. Scores from audits exe- ‘cated by different teams may depend on the way the check- lists were applied and this should be considered when comparisons between fabrica- tors are made, However, sig- nificant differences between scores for different fabricators likely indi cate significant differences in their potential to perform. Guidelines for evaluating the scores are provided on the checklist, but acceptablo scores should be tai- lored to the complexity of each order. For example, the acceptable scores, when piping is to be exposed to high- pressure sour gas should be highor ‘than when it is to be exposed to low- pressure and/or noncorrosive fluids. However, establishing minimum scores for a given pipe-spool order is, beyond this article's scope. Evolution of these recommendations into an industry consensus of minimum expeetations for world-class pipe- spool fabricators could benefit both consumers and fabricators. ‘Strong performance on all eight of the selected characteristies typically indicates a shop that can be charac- terized as a world-class pipe-spool fabricator. Expect this shop to con- vert a customer's requirements into the desired product on or befors the promised delivery date. Low scores should raise significant concern for that fabricator’s ability to meet the specified technical requirements and/or delivery. Magnitude of the con- cern inereases along with the com- plexity of the pending project. Such a fabricator should either be excluded from the approved suppliers list or subjected to a comprehensive shop audit before receiving an order. In between these audit perfor- mance extremes, poor to marginal performance in up to three charac- teristics should raise questions about the fundamental control sys- tems in place at the shop. These audit results indicate that the shop may be able to execute small and/or simple orders. But, in all likelihood, the fabricator may not be able to deliver large and complex orders to the specified requirements on the promised schedule. In another light, poor performance on several of these eight character-isties indicates inadequate manage- ment oversight and control of the ‘actual spool fabrication process. Lack of management direction and control can result in significant schedule impacts, especially when a customer strictly enforces specification requirements that are not familiar to the workers on the shop floor. PMTs evaluating a bid from a shop with poor performance on several of the eight characteristics should con- sider the potential impact of late delivery of pipe spools. Other considerations ean and should influence a decision relating to inclusion on approved supplier lists and placement of orders. How- ever, evaluating the characteristics discussed will provide useful infor- ‘mation about the potential of a pipe- spool fabricator to deliver large and complex orders on schedule, and at the quoted cost. Clear understand- ing of this potential is erucial because ‘The authors ©) Robort Mi. Billings, Pro- ject Engineer in the Pro- Jct and Facity Engineer- Ing Rosearch and. ‘Technical Services group 4, Of ARCO Exploration and Production Technology, ‘has over 20 years of exp0- ‘ence with the oll and gas industry Including ‘hands-on involvement with Ingpection and Surveillance of welded fabrication of piping systoms and structures. He resided in Sin- (ganore while quality manager for the ARCO Yachong 13-1 project, which included off- shore facile in the South China Sea as well 1s the Second longest subsea pipeline in the World, Mr, Bilings earned both BS and MS ‘degrees in metalurgical engineering trom the University of Cincinnatl and an MBA from the University of Texas at Dallas. He is aregitered professional engineer in Texas. Davia H. Derres, Sr. Qual- iy Assurance Engineer for ARCO Alaska, inc, has ‘over 22 years of experi / ‘ence in QA/QC for North He participated in devel | ‘ping and implementing |*” ‘quality systems for pro~ curement, fabrication, ‘construction, revamp and functional checkout ‘of Prudhoe Bay production facies, the largest (ll fold hn North America. Production facies fare asembled in lower-49 fabrication yards ‘rom components delivered by vendors in ‘North America, Europe and the Pacific Rim ‘and then sba-ifted by barge train to the North ‘Siqpe during the annual breakup ofthe Aretio ‘Ocaan foe pack for assembly, check-out and ‘Start, Mc Derrer eerned a BA degree in eco- homies and studied welding engineering at (bio Stato University He has been a certiid 180 :8000 Quatity Systoms Lead Auditor major and/or widespread deficien- cies in pipe spools can have major impacts on the startup of a facility whon assembly and testing of the pipe spools are on the critical path. PMTs can compensate for a fabriea- tor’s marginal management and inspection systems through inten- sive onsite customer inspection and expediting. Unfortunately, customer inspectors are not likely to alter the basic culture of a fabrication shop during just one order, especially against the preferences of the fabri- sgator’s management. In this ease, an er company wanting to establish long-term relationships with providers of goods and services needs to compare the cost of intensive cus- tomer inspection against the per- ceived savings from using fabrica- tors with low audit seores. ning 8, Dare en Hand We, TW tan tate Piao Fa Wl Dg ‘Evbconon, kun 198 James H. McHaney, ‘Consultant for Metallur- {gleal Consultants, Inc. has over 30 years of | industrial experience including hands-on | involvemont with fabrica- tion, welding and inspec {ion for various segments of the energy. related industries. Ho has observed fabrication facilites and practicos from the-most primitive to world-class in arctic, temperate and tropical locations. Business travel has taken him to various facilities Jn most of the 60 states plus 14 countries of North America, Wostern Europe and the Pacifie Rim. Me. Metlanoy earned both BS and MS degrees in metallurgical engi ‘neering from the University of Texas at EI ‘Paso and i a registered professional eng inoor in Texas. Richard W. Wilson, 7 Sonfor Technician for ‘Motalugical Consuttants, Ine, has over 19 years of industria! experience tn welding, heat treatment, (quality control and vari- Sus aspects of metal- furgy, Including failure =| analysis, scanning elec Wn tron microscopy and field tectnica services. Mic Vison’s eld work takes him to various manufacturing and fabrication facilities, ‘chomicel plants and refineries. He was for- Imorly a production supervisor for a major Wondor to the nuctoar Industry where quat- Ity standards wore rigorous and both inter- ‘aland extemal audits wore routine. Mi. ill ‘son attended Henry Ford Community Coflege Jn Dearborn, has completed several techni cal short courses in metallurgy and related fopies and is an AWS Certitied Welding Inspector. 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ALLWEILER (J PUMPS Hee nt abst tay ‘Shanley Pump & Equipment, inc. 2525 South Clearbrook Drive Arlington Heights, tlinois 60005 Fax: 847-439-9388 Visit cur Viento at www shanloypump.com Circle 134 123DISTILLATION/PROCESS TECHNOLOGY Sensitivity analysis is key to successful DC, simulation A refinery shutdown provided a unique opportunity to study high-capacity trays H. 2. Kister and E, Brown, Brown & Root Inc., Alhambra, California, and K. Sorensen, Kuwait Petroleum Danmark, Gulfhaven, Denmark A recent refinery shutdown provided us a unique ‘opportunity to accurately study a depentanizer (DC,) that had been revamped with high-capac- ity trays and to develop performance data for these trays. Extensive component analytical data, coupled with a shortage of stripping trays due to a mislocated feed, rendered our efficiency and capacity determination reliable despite several compromises and inaccuracies. In addition, itis important to perform a sensitivity analysis to reality check a simulation. Our reality checks revealed the insensitivity of our DC; simulation to the number of rectifying stages, mass and energy balance iE “ (te 1% Fa te | ova8 | a8 we | 0 La] ee ne] a ie Lerws | es e (2) exrors, and ASTM D86 analyses of the bottom product. Our final finding is that it is important to rely on component analysis and not on ASTM D86 analysis for simulating this type of tower. Due to the simulation’s insensitivity to a bottom D86 analysis, it can lead to grossly optimistic results. We obtained such grossly optimistic and misleading results in an earlier simu- lation based on the D86 analyses. Backg?dund. In 1994, es part of their reformulated gasoline revamp, Kuwait Petroleum Danmark replaced ‘conventional vaive trays with Nye trays in the strip- ping section of a DC; in its Gulfhaven (Denmark) refin- ery. The retrofit was implemented to reduce the gaso- Tine’s benzene specification to 2 wt%. One way of reducing benzene production in a platformer is to reduce benzene precursors, i.e., compounds that are converted to benzene. ‘The benzene precursors in the platformer feed (besides benzene) include cyclohexane (-100% converted to benzene), n-hexane (~20% con- Fig. 1. Depentanizor and delsopantanizer simplified process echeme with Key test data, 124 HYROCARHON PROCESSING /aCTORER 1808