Corrosion Under Insulation
Is the Process Industry in control?
Some thoughts and observations
Ki<|MPi master class CUI
October, 2015
T. Knijff, The Dow Chemical Company
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Page 1
Incidents – learning ?
Are we learning from incidents within the industry?
Incidents from open literature
Is your company specific CUI strategy
changed after these incidents within
the industry?
I
T.O.
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Dow Hydrocarbons (HC) Plants, Geographic locations:
Europe
•Terneuzen, the Netherlands
•Boehlen, Germany
•Tarragona, Spain
Canada, Ft. Saskatchewan
Gulfcoast area
•St. Charles
•Plaquemine
•Freeport
Argentina, Bahia Blanca
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Page 3
Dow Hydrocarbons (HC) CUI strategy
The Dow Chemical Company Mechanical Integrity Program
•
The purpose of Dow’s Mechanical Integrity Program is to assure
that equipment used to process, store or handle chemicals are
designed, constructed, installed and maintained to minimize the
risk of release of chemicals. This standard assures compliance
with applicable legal requirements and incorporates industry
consensus, commonly called “Recognized and Generally
Accepted Good Engineering Practices” (RAGAGEP).
•
Guidelines and best practices for compliance with this Program
are mainly based on the API standards. E.g. piping is based on
codes API570, API574, API581 etc. (not limited to this listing).
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Page 4
Dow Hydrocarbons (HC) CUI strategy
Learning from incidents!!!!
• In 2008 a DOW plant
experienced a sudden and
complete line failure on an 8”
crack gas dryer regeneration line
caused by corrosion under
insulation.
T.O.
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Page 5
Dow Hydrocarbons (HC) CUI strategy
1. CUI “Call to action” (completion year 2008).
•
All HC plants to review the last inspection of the crack gas dryer
regeneration lines and ensure the mechanical integrity. Use
lessons learned to improve effectiveness of INSPECTION.
»
Findings are all corrected.
2. Maximize effectiveness of DOW’s mechanical
integrity program for CUI prone equipment & piping
in HC plants.
«
«
«
«
«
Organizational requirements
REGISTRATION, Scope determination
INSPECTION
REPAIR
ASSURE MECHANICAL INTEGRITY (QA/QC, training)
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Dow Hydrocarbons (HC) CUI strategy
CUI “Call to action”, CG Dryer findings (focus cyclic):
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Page 7
Dow Hydrocarbons (HC) CUI strategy
Organization is in place, requirements clear, responsibilities are set
HC Business Team
-Production Directors
-HC Technology Director
Facility Maintenance
Teams (A, B, C)
Local CUI Team Plant A
- Local CUI Team Leader
- Process Knowledgeable Person
- Qualified inspector
- Maintenance Representative
Hydrocarbons Technology
Department
Reliability function
Maintenance Technology
Department
Olefins PCE Team
Focus; yearly goals
- Local CUI Team Leaders
- Qualified Inspector
- HC Maintenance Managers
•Innovation
•Effectiveness increase
•Leveraging
Local CUI Team Plant B
- Local CUI Team Leader
- Process Knowledgeable Person
- Qualified inspector
- Maintenance Representative
Local CUI Team Plant C
- Local CUI Team Leader
- Process Knowledgeable Person
- Qualified inspector
- Maintenance Representative
DoDo
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Dow Hydrocarbons (HC) CUI strategy
Hydrocarbons Technology Department – Reliability function:
« Strategy, guidance and goals in support of the vision “Elimination of CUI
Susceptibility”
Olefins PCE Team:
« This Network is aligned with and guided by the Hc TC- reliability function
« Leveraging and sharing experiences and key learning’s, define best practices,
« Track progress of the goals
« MULTI-DISCIPLINARY APPROACH
Focus; yearly goals
«
«
«
«
Assure Mechanical Integrity: Training & Knowledge transfer
Inspection: Sharing “innovative” inspection techniques.
Repair: Define Best Repair Practices, ensure Quality in Repair (e.g. Field welds)
New Coating & Insulation Technology: Focus on Thermal Spray Aluminum usage.
Local CUI Teams:
« Responsible for registration of all applicable piping (what to inspect)
« Execution of inspections per DOW + Legal Compliance Plans
« Coordination and execution of repairs (e.g. paint/insulation)
« Execution of defined Pilots (e.g. smart NDT (inspections), TSA)
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Page 9
Industry observations & expectations
Process industry in Western Europe ~ 30 to 50 years old.
• CUI occurs typically after 10years.
• Well known Phenomena!
Standards and protocols (not limited to listing):
• EFC WP13 and WP15, Corrosion Under Insulation guideline
• EEPC; Roadmap to Managing CUI (members only)
• API510, 570, 571, 580 etc..
• NACE RP0198, the control of CUI and Fire Proofing Material
• CINI Insulation handbook
• HOIS Inspection platform Europe
Knowledge exchange:
•Numerous conferences per year on corrosion and CUI
Incident reports:
• Killing Rattlesnakes Before They Bite You ( Huntsman)
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Page 10
Industry observations & expectations
Some inspection findings; are these our expectations?
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Page 11
Industry observations & expectations
STANDARDS ARE DEFINED
SPECIFICATIONS ARE AVAILABLE
CONTRACTOR REQUIREMENTS ARE COMMUNICATED
WHY ARE WE SUFFERING FROM CORROSION UNDER INSULATION?
IS IT LACK OF OWNERSHIP & OPERATING DISCIPLINE IN ALL ABOVE?
•Does the Qualified Inspector know the field location of ALL high risk cyclic CUI areas?
•Are you 100% sure that inspection extent and documentation is per standard?
•How do you ensure insulation is adequately installed and if damaged got timely repair?
•Have ALL paint repairs received an adequate surface treatment? Is the applied selected system per
standard. Is quality guaranteed (field welds included) etc.)?
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Page 12
CUI – The circle
Goal: Assure the Mechanical Integrity
Design
Lifetime
Climate
Operations
Cyclic
Sweating
service
Senior Management
Plant staff
Production Engineer
Inspection
Corrosion Engineer
Inspection
Visual vs.
NDT
Repair
TSA or
Coating
Budget
Resources
Process
Methods
(NDT)
location
Damage
mechanisms
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Page 13
Registration – or what to inspect
If Equipment or Piping is NOT registered it will NOT be Inspected
The chosen strategy is
“Operate to failure”
OK, let’s register and inspect everything in your facility. But,……
•Pressure Contained Equipment
company specific
•Utility piping
nitrogen,..
Local legislation +
Steam, condensate, air,
•Process piping
Hazardous chemicals,..
Hazardous service,…
API 570 Chapter 6; Table2&3 protocol is an option
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Page 14
Registration; or what to accept,….
Do we accept before failure? Once occurred,.. Action?
How effective is inspection?
Condensate pipe failure
cb Flow Accelerated Corrosion.
Steam pipe failure cb
thermal fatigue.
“Some” corrosion of a 1”
ethylene pipe with plug cb
CUI.
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Page 15
Construction and repair, QA/QC?
QA/QC during repair
Forgotten or no budget?
Bad
luck?
Pipe supports, before and after
Perfect job?
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Perfect?
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Construction and repair, QA/QC?
Installed tracing & field weld
after “x” years
QA/QC during repair / re-coat
Installed “cold service” insulation
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Page 17
CUI are we in control as Process Industry?
YES WE ARE:
•
•
•
•
WE HAVE THE STANDARDS
WE HAVE THE SPECIFICATIONS
WE ARE LEARNING FROM INCIDENTS
WE HAVE OUR MULTI-DISCIPLINARY TEAMS IN PLACE, THEY ARE ALL TRAINED
NO WE ARE NOT:
•
•
•
•
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WE ARE NOT FOLLOWING OUR STANDARDS
WE ACCEPT THAT CONTRACTORS ARE NOT USING OUR SPECIFICATIONS
WE CONTINUE TO REPORT SIMILAR INCIDENTS THROUGHOUT THE INDUSTRY
WE DO NOT HAVE ENOUGH RESOURCES
OUR RESOURCE TURNOVER RATE IS HIGH, WE CANNOT MAINTAIN KNOWLEDGE
Somewhere in-between
•
•
•
•
WE ARE IMPROVING OUR OPERATING DISCIPLINE & QA/QC PROGRAMS
WE SHARE INCIDENTS AND REQUIRE FOLLOW-UP
WE HAVE TRAINING PROGRAMS IN PLACE
WE ARE TRACKING KNOWLEDGE WITHIN THE TEAMS (CERTIFICATION PROGRAM)
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Thanks for your attention
Any questions?
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Page 19