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Risk Based Inspection of Pressure

Vessels, Piping and other critical


equipment in Anglo American

Johann F. Oosthuizen
Anglo American
Anglo Field Services
South Africa
The Anglo American Conference on Condition Monitoring and Non-destructive Testing
18 & 19 November 2008

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Order of Presentation
• Current inspection approach
• Risk Based Inspection
– Overview
– Process
– Outcome
• RBI Application & Case study
• Other RBI Applications
• Benefits of RBI

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Risk Based Inspection

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Current plant equipment inspection

• In-service inspection:
– traditionally been driven by prescriptive industry
practices
– fixed locations, fixed frequency (calendar-based) and
fixed methods of inspection
– Two extremes of inspection
• Very little – replace when equipment fails.
• Too often and too thoroughly – becomes uneconomic.
– No encouragement to analyse:
• threats to structural integrity
• consequences of failure
• risks created by each item of equipment
• Do we inspect what needs to be
inspected?
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Risk Based Inspection
• Next generation of inspection
approaches and interval setting
• Adapts risk analysis to the
process of inspecting
equipment
• Addresses ways to manage risk
on an equipment level
• Focus on maintaining the
mechanical integrity of plant
items and minimising the risk of
failure due to deterioration

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RBI Process
• RBI is a combination of the following processes:
Risk Assessment

No unacceptable defects
Engineering
Assessment
Remediation /
Inspection Repair
Planning &

Pass
Scheduling

Fail
Inspection Evaluation of Defects Fitness for Service
Implementation Inspection findings Evaluation

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RBI Outcome
Reduction of safety and operational risk

Engineering
Assessment
&
Inspection
Planning &
Scheduling

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RBI Outcome
• A relative ranking by risk of all equipment
evaluated.
• A Written Scheme of Examination for the
equipment showing what, how and when it should
be inspected.
• Documentation demonstrating that the risk
assessment & inspection planning processes are
implemented effectively and appropriately.

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Application of RBI

• Vessels & Piping


– Non-intrusive evaluation strategies
• On-stream inspections where possible
• Justified by safety cases through consideration of risk
of operation and structural integrity of equipment.

– Latest approach - Remnant life


• Calculations based on tolerance to deterioration,
defects, damage and rate of deterioration
• Apply assessment rules given by API 579 & BS 7190
• Reliability of inspection data very important
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Case Study – Refrigeration
Plant
• Underground Refrigeration plant in gold mine
– 65 Pressure vessels
– Heat exchangers & storage vessels
– Different designs
– Various levels of fitness-for-service
• Age, operating condition, maintenance,
corrosion protection

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Case Study – Refrigeration
Plant
• Applied RBI methodology
Risk Assessment

Engineering
Assessment

Inspection
Planning &
Scheduling

Inspection Evaluation of Defects Fitness for Service


Implementation Inspection findings Evaluation

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Case Study – Refrigeration
Plant
• Fitness-for-Service assessment results

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Case Study – Refrigeration
Plant
• Fitness-for-Service assessment results
Risk Assessment

No unacceptable defects
Engineering
Assessment
Remediation /
Inspection Repair
Planning &

Pass
Scheduling

Fail
Fail

Inspection Evaluation of Defects Fitness for Service


Implementation Inspection findings Evaluation

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Case Study – Refrigeration
Plant
• All vessels with no remaining life:
– 27 vessels required attention
– Max allowable pressure calculated for present condition
– Verify if plant can operate at calculated pressure
• If operating below calculated pressure then vessel require
derating
• If operating above the vessel requires replacement
– Was possible to reduce pressure relief valve setting to
below MAWP in present condition
• 27 vessels on 12-month inspection interval
• 38 vessels on 24-month inspection interval
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Other Applications of RBI

• Haul trucks
– Chassis
– Spindles
– Truck body

• Shovels
– Ropes
– Winders
– Beams
– Bucket

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Other Applications of RBI

• Draglines
– Ropes
– Boom
– Winder
– Bucket

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Other Applications of RBI

• Electrical Motors
– Insulation and Bearings
• Vibration assessment and Partial Discharge Monitoring
• Gearboxes
– Gear sets and Bearings
• Vibration assessment and Lubrication monitoring
• Other Plant Equipment

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Benefits of RBI

• Manage risk on an equipment level.


• Cost-effective actions for risk mitigation.
• An acceptance/understanding of the current risk.
• Identify equipment that does not require inspection.
• Justification for non-intrusive on-stream
inspections.
• Justification for extension of inspection intervals.
• Justification for continued operation or
replacement.
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Benefits of RBI

• Engineering assessment of inspection results.


• Support of inspection planning based on
understanding of allowable defect parameters.
• Evaluation of inspection results and re-assessment
of risk following inspection.
• Fitness-for-service & Remnant life assessments.

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Your strategic partner in reducing risks
associated with safety and production critical
machines, systems and components

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