CUI Conference 14-1-2004

© 2003 Shell Global Solutions International B.V.

Shell Global Solutions

SHELL RISK-BASED INSPECTION (S-RBI)

Basics & Related Approach
to Corrosion under Insulation (CUI)

Presented by:
Maarten Lorenz
Materials & Inspection Technology
Shell Research & Technology Centre,
Amsterdam, The Netherlands
 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Shell Global Solutions’ Pacesetting Concept

PACESETTING sustained top 10%

performance for
PROGRAM more than 5 years

HSE PROGRAM
HYDRO CARBON MANAGEMENT
M anufacturing
E nhanced
MERIT REVIEW R eliability
I mprovement
T eam
ORGANISATION
MANAGEMENT OF ASSETS

RISK AND Integrated versions of:

¾ Reliability Centred Maintenace
RELIABILITY
¾ Risk-Based Inspection
MANAGEMENT ¾ Instrumented protective functions

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

S-RBI in Relation to Risk & Reliability Management

RISK AND RELIABILITY MANAGEMENT (RRM):

• RISK-BASED INSPECTION
-> optimised inspection plan

• RELIABILITY CENTRED MAINTENANCE

-> cost effective maintenance plan

• INSTRUMENTED PROTECTIVE FUNCTIONS

-> minimum design and testing requirements

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Why Apply Risk-Based Inspection ?

• To move away from time based inspection governed by
minimum compliance with rules, regulations and standards
for inspection.
• To apply a strategy of doing what is needed for safeguarding
integrity and improving reliability as well as availability of the
plant by planning and executing those inspections that are
needed.
• Risk-Based Inspection may provide economic benefits:
reduce inspection scope, shorter shutdowns, longer run
length, fewer unplanned shutdowns.

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

RBI = TEAM EFFORT

CORROSION ENGINEER
PLANT INSPECTOR
MAINTENANCE ENGINEER
PROCESS TECHNOLOGIST
OPERATOR

AUTHORITY REPRESENTATIVE (on request)

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

S-RBI RELATED TOOLS

Maintenance Electronic Corrosion
and Inspection Drawings Control
Database (VISIO) Manual

S-RBI (RRM) Trending

Manual Software

S-RBI ANALYSIS
S-RBI (RRM) Statistical
Software Recipe Book

Degradation NDT FFP

Library Handbook Handbook

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

S-RBI Analysis based on Corrosion Loops

What is a “Corrosion Loop”?
“A PRACTICAL WAY TO DESCRIBE, UNDERSTAND
AND CHECK DEGRADATION MECHANISMS IN A UNIT”
• part of the unit subjected to:
¾the same process conditions CORROSION LOOP
¾the same failure mechanisms
12-E-102
¾the same materials selection criteria Loop
2
Loop 3
• one “operating window”

12-D-101
12-E-101
¾ control of degradations via 12-K-101
1st stage
process control Loop 1
¾ values agreed by team 12-G-101
(boundary conditions for RBI) to burn pit

¾ deviation should be reported

• same process conditions
• same degradation mechanisms

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

The Shell Risk-Based Inspection (S-RBI) Process

DEGRADATION MECHANISM

SUSCEPTIBILITY CONSEQUENCE

Criticality
HISTORY &
Matrix
REMNANT LIFE CONDITION

INHERENT Interval CONFIDENCE

CRITICALITY Matrix RATING

INSPECTION
PLAN

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Susceptibility To Failure
• Determine potential degradation mechanisms for the Loop

• For those degradation mechanisms, identify the StF per item

¾ for each item since there can be differences in temperature etc.

• For each item, analyse the different degradation mechanisms

separately since they may result in different failure modes

¾ Different inspection techniques/intervals may be required

¾ Monitoring scheme to be indicated for non-age realated

degradations

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Assessment of Consequence of Failure

Score Table on:
• Economic consequences
• Health & Safety consequences
• Environmental consequences

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

S-RBI Criticality Matrix

EXTREME
HIGH L MH H E E RECTIFY
Susceptibility

MEDIUM L M MH H E
LOW N L M MH H
NEGLI-
GIBLE N N L M MH
NEGLI LOW MED HIGH
S-RBI
GIBLE IUM HIGH EXTEN
SIVE
DETAILED
Consequences
NEGLIGIBLE ANALYSIS
NO INSPECTION MEDIUM-HIGH
REVIEW ONLY MEDIUM
LOW
INSPECTION PLAN

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Confidence Rating

• indicator for confidence in forecast of degradation

• rating - very low to very high – reflects:

¾ stability/predictability of degradation
¾ number and quality of previous inspections
¾ process stability

⇒ BETTER CONFIDENCE YIELDS

LONGER INSPECTION INTERVALS

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© 2003 Shell Global Solutions International B.V.

Maximum Inspection Interval

WALL
THICKNESS
INSPECTIONS

WT new REMNANT LIFE

X X
MAXIMUM INSPECTION
X INTERVAL

MINIMUM ALLOWABLE THICKNESS

WT (min)

LIFETIME IN YEARS

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Corrosion Under Insulation…

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

The S-RBI Process for CUI:

remnant life not available
CORROSION UNDER INSULATION

SUSCEPTIBILITY CONSEQUENCE

Criticality
HISTORY &
Matrix
REMNANT LIFE CONDITION

INHERENT Strategy CONFIDENCE

CRITICALITY Matrix RATING

MAINTENANCE
& INSPECTION
STRATEGY

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Determining CUI Susceptibility

Score Table on:
• Operating Temperature
• Initial Coating Status
• Insulation Type
• Wall Thickness & Surface Features
• Internal Corrosion/Erosion Rate
• External Coil/Steam Tracing
• External Environment

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Determining CUI Consequence

Score Table on:
• Economic consequences (including production loss!)
• Health & Safety consequences
• Environmental consequences

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Confidence Rating
An item’s criticality basically determines the
inspection/maintenance strategy to be applied.
Depending on how well the condition of an item is known, a
limited degree of conservatism/opportunism is applied in
choosing the inspection/maintenance strategy.
CUI Confidence Rating depends on:
• cladding & insulation condition
• number & quality of CUI inspections
• knowledge of CUI promoting conditions

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

CUI Strategy Matrix for CS/Low Alloy Steel

CONFIDENCE RATING
CRITICALITY VERY LOW LOW MEDIUM HIGH VERY HIGH
STRATEGY 0
EXTREME
STRATEGY 1
HIGH STRATEGY 1

MEDIUM-HIGH STRATEGY 2 STRATEGY

STRATEGY 2 3

MEDIUM STRATEGY 3
STRATEGY 3

LOW STRATEGY 4
NEGLIGIBLE NO INSPECTIONS
(review only)

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

CUI Inspection/Maintenance Strategies

• Effectively five strategies have been developed for the six
criticality levels.
• The coverage and quality of the applied coating/paint may add
up to 8 years of CUI protection.
• Inspection intervals start at the moment the coating/paint
protection has ended.
• Inspection intervals are based on recommended maximum
timing.
• Initial inspection actions always involve delagging.
• Inspection results may lead to adjusting the strategy level.

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Inspection/Maintenance Strategy’s Loop

YES Corrective
Action

Initial Significant Corrective

Inspection CUI? Action
YES
Follow-up Significant
Inspection
NO CUI ?
NO

Review
Strategy

(one cycle)

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Non-Intrusive Inspection Techniques for CUI…?

¾ Thermography ?
¾ Pulsed Eddy Currents ?
¾ (real-time) Radiography ? - suitable for small bore connections
¾ Guided-Waves ?
- finds wet spots, not CUI
- requires experienced operator
- local measurement of wall thickness
- difficult to apply on complex geometries
- excellent for determining wall thickness
through corrosion products
- accessibility and safety issues
- screening technique to detect wall loss
- requires experienced operator
- only simple pipe geometries

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

CUI Inspection/Maintenance Plan:

… requires pre-screening of the assets prior to application
(not applied to items with negligible susceptibility to CUI).
… does not rely too much on non-intrusive inspection results
(screening inspection techniques used to indicate susceptible
areas).
… is harmonised with the S-RBI methodology.
… is also available for insulated stainless steel items
(CUI = Chloride Stress Corrosion Cracking).
… does not eliminate CUI failures completely, but reduces the
effects of these failures to your business to a tolerable level.

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 CUI Conference 14-1-2004
© 2003 Shell Global Solutions International B.V.

Shell Global Solutions

SHELL RISK-BASED INSPECTION (S-RBI)

Basics & Related Approach
to Corrosion under Insulation (CUI)
- thank you for your attention -
ANY QUESTIONS OR REMARKS?
Presented by:
Maarten Lorenz
Materials & Inspection Technology
Shell Research & Technology Centre,
Amsterdam, The Netherlands