IN SAMENWERKING MET ESSENSCIA MODULE 1. Frank Candreva, Principal consultant, DNV Solutions Belgium

PROCESSAFETY

IN SAMENWERKING MET

ESSENSCIA MODULE 1

AGEING VAN PROCESINSTALLATIES Frank Candreva, Principal consultant, DNV Solutions Belgium http://www.prebes.be/prenne/2012-06-14/processafety.pdf

Prenne 14 juni 2012 Flanders Expo Gent

PREBES VZW | DIESTERSTERSTEENWEG 88 | 3510 KERMT | TEL 011 28 83 40 | FAX 011 28 83 49 [email protected] | WWW.PREBES.BE | IBAN BE24 6451 1932 9738 | BTW BE 0424 273 050

Prebes Studiedag – Gent 14 juni 2012 Dr Frank Candreva - DNV Belgium 14 Juni 2012

[email protected]

DNV Services - Asset Risk Management

Asset Integrity assessment

Benchmarking

Risk based inspections - RBI

Production optimization

Data management - ORBIT

Performance forecasting

RCM

Reliability studies

PAS 55

Performance monitoring

Asset Operations

Maintenance & Inspection Management

BIP Scorecard

Failure investigation

Criticality screening

Solution development

Asset Life Investment plan

Material selection

Due diligence

Material testing & analysis

Fitness for Purpose

Risk based verification

Technology verification

Lifetime extension Veroudering van Seveso installaties en hoe hiermee omgaan 14 Juni 2012 © Det Norske Veritas AS. All rights reserved.

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DNV services across the entire life cycle of a plant

Veroudering van Seveso installatiess en hoe hiermee omgaan 14 Juni 2012 © Det Norske Veritas AS. All rights reserved.

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Agenda Positionering Probleemschets Mogelijke oplossingen voor veroudering van installaties Voorstel voor plan van aanpak PAS55 / Asset Management

Veroudering van Seveso installaties en hoe hiermee omgaan 14 Juni 2012 © Det Norske Veritas AS. All rights reserved.

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Positionering Veroudering in diverse industrie sectoren

Best Practices


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Wat is veroudering ? Ageing is not about how old your equipment is; it’s about its condition and how it’s changing over time (Petroleum Safety Authority, 2008)

Ageing is a process of degradation related to the progression of time and/or the use of the facility and the systems related to the facility (OLF, 2008)

Ageing plant is a plant which is, or may be, no longer considered fully fit for

purpose due to age related deterioration in its integrity or functional performance Meer dan 4500 niv. 1 Seveso bedrijven in Europa zijn onderhevig aan veroudering Veroudering van Seveso installaties en hoe hiermee omgaan 14 Juni 2012 © Det Norske Veritas AS. All rights reserved.

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Positionering Best Practice richtlijnen in de offshore & nucleaire sector

Integrity level

AMR 1

AMR 3

AMR 2

decommissionning lifetime extension

AMR = Ageing Management Review

best practice integrity level

alarp integrity level time

25 yrs design lifetime

25+x yrs extended lifetime

7 Veroudering van Seveso installaties en hoe hiermee omgaan 14 Juni 2012 © Det Norske Veritas AS. All rights reserved.

Positionering - Veilig omgaan met veroudering van installaties / 1 Offshore installaties & Nucleaire industrie

Levensduur vd installaties op voorhand bepaald Decommissioning is reeds voorzien na de verwachte normale levensduur, tenzij …. Aanvraag voor « Levensduur verlenging» voor een bepaalde periode: ► BEOORDELING TECHNISCHE INTEGRITEIT Analyse van material degradatie / Identificatie van dominante degradatie mechanismen (corrosieverschijnselen) ► GAP ANALYSE – Actuele wettelijke & reglementaire voorschriften ► ANALYSE VAN TEKORTKOMINGEN / FAALKANSEN & CHALLENGES ► BEPALING VAN MAATREGELEN TBV RISICO REDUCTIE ► GLOBAAL RISICOPROFIEL (voor investeerder) ► LIFE EXTENSION MANAGEMENT / PLAN


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Positionering Best Practices in de procesindustrie


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Positionering Veilig omgaan met veroudering van installaties / 2 Onshore industrie – Seveso bedrijven Geen voorafbepaalde levensduur van een installatie & geen voorafbepaalde periode voor decommissioning Wettelijk kader voor bepaalde type inspecties (vnl stoomvaten / PED Directieve) Systeem van vergunningverlening (exploitatievergunningen / MER / SWA-VR ….) Seveso – Voorschriften mbt veiligheids management systeem - UK : COMAH Safety Reports / Safety Cases - België : Milieu- inspectie / MES & PAM audits / Notities vanuit FOD / Chemische Risico’s & ander inspectie – instrumenten


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Probleemschets Impact van Veroudering


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Probleemschets Mapping the impact of ageing assets at site level CONDITION OF ASSETS • Corrosion status • Leakage rate & trending • Deterioration •

AVAILABILITY & RELIABILITY

• •Trending in reduced plant or unit availability • Reliability of safety critical assets / instrumentation • Trending in MTBF

MAINTENANCE & INSPECTION

•Maintenance budget trending • Trending in MTTR / MTBM • Trending in % overdue regulatory inspections • Trending in temporary repairs

HAZARD POTENTIAL

•Status of knowledge about design, operation & deterioration mechanisms • % Completion of action items from HAZOPs / PHAs • Trending of reported incidents (LOC’s…) OPERATIONAL INTEGRITY

•Trends in process excursions from normal operating envelope •Use of safety critical equipment in a failed state ENVIRONMENTAL EFFICIENCY

•Trend in energy costs per unit of production / per headcount


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Trends in ongevallenstatistiek / arbeidsongevallen

Incidents per 200,000 work hours

5

4 API Bayer BP

3

Chevron Texaco Concawe ConocoPhillips

2

Dow DuPont ExxonMobil OMV

1

Shell Trend Line

05 20

03 20

01 20

99 19

97 19

95 19

19

93

0


Process Incidents Statistics – Worldwide (2005 – 2009) 800

Process industry categories covered:

700 600

Chemical

500 Total Nr of Process Incidents (*) Worldw ide

400

Fraction allocated to Metal/Mining

300

Petrochemical Metal processing Mining industries

200

Onshore oil and gas installations,

100

Storage facilities Pipelines

0 2005

2006

2007

2008

2009

(*) Process Incidents Database (DNV owned) covers the following undesired events as reported in public sources: Major Accidents (Seveso definition) + other problem events such as process upsets, prosecutions, fines and other regulatory actions.


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Process Incidents Statistics – Europe vs Belgium (2005 – 2009) Europe

Belgium Nr of process incidents (*) Belgium

180 160 16

140 14

120 12

Nr of process incidents (*) Europe (EU-27 + EFTA)

100

10

Fraction allocated to Metal/Mining

80

Nr of process incidents (*) Belgium

8

60

6

40

4

20

2

0

0

2005

2006

2007

2008

2009

2005

2006

2007

2008

2009


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Link between Major Accidents & Ageing Plants Conclusions from the HSE Plant Ageing Study – RR823 (2010)

Overall it can be concluded that plant ageing does constitute a threat to health and safety performance of hazardous installations onshore. Within the uncertainties of the review conducted a reasonable statement to describe the size of the ageing issue is that “approximately 60% of major hazard loss of containment incidents are related to technical integrity and, of those, 50% have ageing as a contributory factor”. It therefore concluded that plant ageing mechanisms are a significant issue in terms of major hazard accidents.


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Patroon van basisoorzaken van zware ongevallen statistiek 100% Inspection

80%

Maintenance program 60%

Design Process analysis

40%

Supervision Training

20%

Procedure

ch em

to ta l

wh o

fin

e

pe t ro

le sa le /re ta il m et al re fin in g

ica ls ch em

ic al s ch em ge ne ra l

ic al s

0%

Similar pattern of underlying causes regardless of the industry type All industry types have weaknesses in ‘process analysis’ and ‘procedure’ as the most common underlying causes. Veroudering van Seveso installaties en hoe hiermee omgaan 14 Juni 2012 © Det Norske Veritas AS. All rights reserved.

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Kosten gepaard gaande met veroudering van installaties Trends in refinery material damage costs 1400 DAMAGE COSTS (2010 $m) Linear (DAMAGE COSTS (2010 $m)) 5 per. Mov. Avg. (DAMAGE COSTS (2010 $m))

Annual Total Loss from Largest Major Hazard Incidents

1200

1000

800

600

400

200

Plant Lifetime Management for the process industry 29 December 2010 © Det Norske Veritas AS. All rights reserved.

4


18

06

04

02

00

98

96

94

92

90

08 20

20

20

20

20

19

19

19

19

88

86

84

DRAFT

19

19

19

19

80

82 19

19

78 19

76 19

74 19

72 19

70 19

68 19

66 19

19

64

0

Wettelijk kader – Aandachtsgebieden vd overheid (1/3)


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20



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Conclusies Veroudering verhoogt de productiekosten Veroudering verhoogt de kans op een zwaar ongeval Er is geen echte neerwaartse trend vastgesteld inzake LOC incidenten wereldwijd, eerder een stabiele situatie, in contrast met het frekwentiecijfer voor arbeidsongevallen. Het wettelijk kader & de aandacht vd inspectiediensten is onvoldoende voor het beheersen van veroudering van installaties en de ermee gepaard gaande risico’s.

De Seveso bedrijven staan er alleen voor om de risico’s en uitdagingen van veroudering te managen Veroudering van Seveso installaties en hoe hiermee omgaan 14 Juni 2012 © Det Norske Veritas AS. All rights reserved.

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Kernvragen inzake

Problematiek van Veroudering ► Hoe kunnen Seveso bedrijven hun installaties op een veilige

& duurzame wijze in stand houden? ► Hoe kan een zwaar ongeval vermeden worden of het risico op een LOC beperkt worden (ALARP)? ► Hoe kunnen de kosten beheerst worden / of “financiële verrassingen” vermeden worden ? ► Hoe erg is het gesteld met veroudering van mijn installatie? Veroudering van Seveso installaties en hoe hiermee omgaan 14 Juni 2012 © Det Norske Veritas AS. All rights reserved.

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Stakeholders / actoren in de procesindustrie

Authorities Inspections & permits

Site

Neighbouring Environment Major Accidents & Environmental Nuisance


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Shareholders Cost issues

Managen van veroudering van installaties – WELKE OPTIES ZIJN ER ? / 1 OPTIE 1 ; BUSINESS AS USUAL ► Rejuvenation of “verjongingskuur”toepassen via de klassieke periodieke turnarounds ► Mogelijke impact & risico’s : hogere productiekosten – Grotere kans op zwaar ongeval (MAP) – Geen inzicht inzake de rest levensduur vd site als geheel installatie - Geen inzicht inzake investeringsbeslissingen – “Financiële Verrassingen” zijn niet ver weg OPTIE 2 : Toepassing RBI & RCM technieken + TURNAROUNDS ► “Verjongingskuur” voor installatie of onderdelen ervan via periodieke turnarounds ► Betere focus op inspecties die het nodig hebben (risk based) ► Beter inzicht op de rest levensduur van die specifieke installaties waarop RBI / RCM wordt toegepast ► Mogelijke impact & risico’s : hogere productiekosten – grotere kans op zwaar ongeval (MAP) – ► ► Geen inzicht inzake de rest levensduur vd site als geheel ► ► Enkel inzicht in specifieke equipment waarop RBI / RCM wordt toegepast ► ► Beperkt inzicht inzake investeringsbeslissingen – “Financiële Verrassingen” steeds mogelijk


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Optie 2: Risk Based Inspection & Reliability Centred Maintenance Service Area

Asset Risk management

Service Line

Maintenance & Inspection

• prioritize equipment for inspection based on risk Challenge ²

• prioritize inspection without compromising on safety • identify inspection techniques and level of detail

• rank equipment within scope according to risk DNV’s approach

• focus on high risk items • plan inspections based on risk acceptance criteria

• apply API581 using Orbit Onshore software

• up-to-date (‘living’) inspection plan Value to the client

• demonstrated value of planned inspections

• accurate inspection data management tool


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Managen van veroudering van installaties – WELKE OPTIES ZIJN ER ? / 2 OPTIE 3 : PLANT LIFETIME MANAGEMENT ► Duidelijk inzicht / overzicht van actuele conditie & status mbt veroudering ► Globale benadering vd installaties op de site (gehele levenscyclus wordt beschouwd) / cfr Franse aanpak ► Mogelijke impact & risico’s : ► ► Inzicht in productiekosten met opties voor verbetering kostenstructuur ► ► Kans op zwaar ongeval (MAP) kan verlaagd worden (ALARP) door Criticality Screening & Risk Ranking of assets ► ► Inzicht & transparantie mbt investeringsbeslissingen ► ► Rest Levensduur vd gehele site wordt inzichtelijk, met minder kans op verrassingen ► ► Detailplannen voor Rest Levensduur installatie onderdelen / structuren (“Asset Life Plans”)


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Pre-screening test voor graad van veroudering : Business Impact Potential / BIP Scorecard 4 performance levels (G-S-B-I) for each leading / lagging indicator

Plant & Assets condition 3

2 Environmental efficiency

Assets availability & reliability 1

0

Operational integrity

Maintenance and inspection

Hazard potential & PSM


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BIP Scorecard (1/3) A set of > 50 leading & lagging indicators of ageing (

Plant and assets condition

Plant and assets availability & reliability

Level of damage observed & potential for deterioration as from inspections and site tour Corrosion status and corrosion allowance

Leakage rate (small leaks of hazardous materials) and trending

Welding status and joint design (from excellent level to old / superseded standards & codes)

Good Housekeeping (including steam leaks)

Level of repeated assets breakdown

Trend of unscheduled unit or plant breakdowns / unplanned stops

Trending in % availability of plant

Trending in % availability of system / unit

Trending in % reliability of assets

MTBF (Mean-Time-Between-Failure)

Trending in % of overdue RCA (Root Cause Analysis) actions from reliability assessments


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BIP Scorecard – Example for Corrosion Indicator 4 performance levels (G-S-B-I) for each leading / lagging indicator

25

wall thickness (mm)

20

corrosion allowance design tolerance

G / Good 15 10 5 0 2000

S / Standard B/ Below-standard I /Inacceptable

2005

2010

2015

date (yr)


30

2020

BIP Scorecard (2/3) Hazard potential & PSM Maintenance and inspection

Increasing trend in maintenance budgets

Extent to which HAZOPS or HAZID’s have been updated as required

% completion of action items from HAZOPs or equivalent risk assessments

Trends of overdue action items from audits and accident investigations

Increasing scope of inspections

Increasing budget of unplanned versus planned maintenance & inspection

Decreasing trend of MTBF (MeanTime-Between-Failure)

Trend of regulatory non-compliance issues wrt HSE & process safety

Trending in number of unplanned repair work orders per month.

Use of safety critical equipment in a failed state

Management of Change: % of work orders / requests that were misclassified as "Replacement in Kind"

The trending of reported incidents (LOC & other CCPS definitions ).


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BIP Scorecard (3/3) Operational Integrity

Reduction in plant efficiency (e.g. pumping capacity)

Operating discipline reporting: Ratio of number of SIF (safety instrumented function) bypassed versus total number of SIF in the unit

Environmental Efficiency

Frequency or trends of process excursions from normal operating envelope limits

Operating discipline : Trend of number of exceedence events of Safety Critical Variables Number of temporary repairs currently in service (deferred maintenance items).


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Amount of energy savings

Trend in Greenhouse Gas Emissions in CO2 tonnes per employee per year

Trend in energy costs per unit of production or per headcountTrend in Energy savings due to conservation & efficiency improvements

Trend in consumption of nonrenewable resources /

energyCarbon footprint of company

Trend in waste generation per unit of production or per headcount

PLM – Methodology /1 1.

Data collection & Condition assessment

Initial BIP Scorecard / Status on ageing of assets

Status : in case of severe ageing (condition of company A) consider PLM approach

Criticality screening Risk assessment & ranking Remaining lifetime of critical assets Mitigation Measures for Plant Lifetime Extension

2. Data collection 3. Scope definition : plant – unit – equipment level 4. Condition assessment


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PLM - Methodology / 2 Criticality Screening Criteria

Data collection & Condition assessment

Knowledge status Asset condition


Functionality

Availability/Reliability

Risk assessment & ranking Remaining lifetime of critical assets Mitigation Measures for Plant Lifetime Extension

Hazard Potential Maintenance/Inspection Spare parts availability

Personal health & safety (PES) Process safety (PRS) Customer & product quality (CPQ) Environment and energy efficiency (EEF) Production downtime (PDT) Financial (FIN)

The criticality screening is consequence based


Business Impact Area

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Criticality screening & scoring (consequence based) Process safety Personal health & safety

Customer & product quality

Status of knowledge

Financial

Environment & energy efficiency Production downtime


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Criticality screening & scoring (consequence based)- Example Status of knowledge 5 Spare Parts Availability & Spares Lead Time

4

Asset condition & fitness for service

3 2 1 0

Maintenance & Inspection Intensity

Functionality

Hazard potential & LOC hazard

Availability & Reliability

Unit/Equipment is considered to be critical when •

for 1 criterion a level 4 or 5 score is obtained OR

•

the total score over all critera exceeds a threshold value


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Unit A Unit B

•

Knowledge status

•

Asset condition

•

Functionality

•

Availability/Reliability

Unit C

Unit A Unit B

Unit C Unit D

Unit E

Unit D

•

Hazard Potential

•

Maintenance/Inspection

•

Spare parts availability


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PLM - Methodology / 3 Data collection & Condition assessment Criticality screening Risk assessment & ranking Remaining lifetime of critical assets Mitigation Measures for Plant Lifetime Extension


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Unit E

Risk Assessment & Risk Ranking For each critical unit (Unit A & D) representative LOC scenarios are identified and the accompanying risk is evaluated with respect to

Unit A Unit B

• People • Environment • Production

Unit C Unit D Unit D Unit A Unit E


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PLM – Methodology / 4 Life Extension Evaluation Data collection & Condition assessment

Detailed life extension study of equipment will be based on consequence of failure for critical assets with a high risk ranking.

Criticality screening Risk assessment & ranking Remaining lifetime of critical assets

The study includes: - Status of ageing and history of equipment wrt. failures and maintenance - Maintenance study for the last 5-10 years (trends, failures) - Check that likely degradation mechanisms are part of inspection plans - Check maintenance plan - Check slow degradation that could lead to large “overhaul”

Mitigation Measures for Plant Lifetime Extension

- Check vendor support and spare part availability - Define changes in operation condition based on the production scenario - Predict how equipment will perform in changed operation Output : Estimation of remaining lifetime of critical assets conditions


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PLM – Methodology / 5 Data collection & Condition assessment

Initial Plant Assessment

Plant Assessment after upgrade

Initial BIP Scorecard - A

Estimated BIP Scorecard - B

Criticality screening Risk assessment & ranking Remaining lifetime of critical assets Mitigation Measures for Plant Lifetime Extension Output : Extented Lifetime of plant or targeted critical assets &

detailed Asset Life Plans Veroudering van Seveso installaties en hoe hiermee omgaan 14 Juni 2012 © Det Norske Veritas AS. All rights reserved.

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Plant Lifetime Management - Samenvatting PLANT LIFETIME MANAGEMENT HELPT BIJ DE BESLUITVORMING ͇ Levensduurverlenging overwegen of alternatief voor de productie (nieuwe locatie overwegen ….) ͇ Via de Criticality Screening & Risk Ranking ̶ ̶ Hulp bij het kiezen van de juiste actie ͇ Door inzicht en transparantie te bieden inzake te nemen acties (op basis van een lifecycle benadering) ̶ ̶ Prioriteitstelling bij investeringsoverwegingen


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PASS 55 ASSET MANAGEMENT Specification for the optimized management

of physical assets Veroudering van Seveso installaties en hoe hiermee omgaan 14 Juni 2012 © Det Norske Veritas AS. All rights reserved.

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PAS 55 / Asset Management System Structure Asset management policy

ACT

PLAN

Asset management strategy, objectives and plans

Performance assessment and improvement

CHECK

DO Implementation of asset management plan(s)

Asset management enablers and controls


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PAS 55 / Management System Structure - 2 Asset management policy

4.3 Asset management strategy, objectives and plans 4.3.1 Asset management strategy 4.3.2 Asset management objectives 4.3.3 Asset management plan(s) 4.3.4 Contingency planning


Implementation of asset management plan(s)



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PAS 55 / Management System Structure /3 Asset management policy

4.3 Asset management strategy, objectives and plans


4.4 Asset management enablers and controls


4.4.1 Structure, authority and responsibilities 4.4.2 Outsourcing of asset management activities 4.4.3 Training, awareness and competence 4.4.4 Communication, participation and consultation 4.4.5 Asset management system documentation 4.4.6 Information management 4.4.7 Risk management 4.4.8 Legal and other requirements 4.4.9 Management of change


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PAS 55 / Management System Structure / 4 Asset management policy



4.5 Implementation of asset management plan(s) 4.5.1 Life cycle activities 4.5.2 Tools, facilities and equipment



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PAS 55 / Management System Structure / 5 Asset management policy

4.6 Performance assessment and improvement 4.6.1 Performance and condition monitoring 4.6.2 Investigation of asset-related failures, incidents and nonconformities 4.6.3 Evaluation of compliance 4.6.4 Audit 4.6.5 Improvement actions 4.6.6 Records




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PAS 55 / Management System Structure /6 Asset management policy

4.7 Management review



4.1 General requirements




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Safeguarding life, property and the environment www.dnv.com


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IN SAMENWERKING MET ESSENSCIA MODULE 1. Frank Candreva, Principal consultant, DNV Solutions Belgium

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