Valero Benicia’s
Mechanical Integrity Program
Karen Muehlbauer
Mechanical Reliability Manager
Thursday, March 27, 2014
1
Mechanical Integrity
The objective of the mechanical integrity (MI)
program is to prevent a “loss of containment.”
-A loss of containment can result in personnel exposure, fire,
equipment damage, or environmental impact.
-MI is a structured system for inspection, testing and preventative
maintenance (ITPM) of refinery facilities. This system is essential to
preserve the mechanical integrity of the equipment and provide an
operation which meets high standards of safety, health, and
environmental performance.
-MI applies to existing facilities, new construction, modifications to
existing facilities, and replacement-in-kind repairs.
2
Mechanical Integrity
- The Mechanical Integrity program addresses
inspection, testing, and preventative maintenance
(ITPM) in the following areas:
Piping
Fixed Equipment
Valves
Rotating Equipment
Electrical
Instrumentation
Alarms
Interlocks
Emergency Shutdown Systems
Relief Systems
Vent Systems
Controls
Monitoring Devices
3
History and Benefits of RBI
Benicia utilizes a Risk Based Inspection Program (RBI) in accordance with API RP 580/581
Program Development:
 Benicia has a strong RBI heritage (approved program since 2003)
 November 2011 initiated plant wide roll-out:
• 3rd Party asset management company (Pinnacle)
• Inspection Data Management System (PCMS)
• Consistent approach across the VLO circuit
4
History and Benefits of RBI
Risk Based Inspection Program (RBI) (Cont.)
Benefits of a Comprehensive RBI Program:
 Insures that inspection resources are focused in the areas of highest risk:
• Defined Inspection Plans
• Damage Mechanism Specific
• Defined Inspection Effectiveness/Inspection Credit
Other benefits:
 Drives appropriate and timely equipment replacements and upgrades
 Drives the T/A Risk Based Work Selection process
 Generates Corrosion Model Diagram (CMD), Material Operating Envelope (MOE)
limits
5
Mechanical Integrity
Stream Data – Process Eng
- AspenTech: Hysys Model
- Confirmed through sampling
Field Inspection
- External Visual
- Ultrasonic Thickness
- Cracking Inspection
- Special Emphasis (
High Temp Sulfidation,
CUI, Nap Acid, Etc.)
• Crude Selection/
Evaluation Guidelines
• Unit Health
Monitoring (UHM)
• Industry Knowledge
Materials Review
- Review of Damage Mechanism
- Establish Matl Operating Envelop
Inspector Review
- Review Inspection History
- Develop Appropriate
Inspection Plan
6
Operations
x
Process
Engineering
Inspection
Planning &
Optimization
Environmental
x
x
x
x
Validation Mtg
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Inspection
Planning
Conseq Review
x
Damage Mech
Review
x
System Review
x
PID
Review
Unit Margins
Conseq of Failure
(CoF)
Process Info
Personnel
Master Equip List
(MEL)
Valero Support
x
Mechanical Integrity
- A multidisciplined group is key to developing a
successful RBI program
- RBI is a focused inspection program reducing the risk
and improving mechanical integrity of fixed equipment
and piping across the refinery.
8