RISK-BASED INSPECTION STUDY AND ITS CONTRIBUTION TO .

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RISK-BASED INSPECTION STUDY ANDITS CONTRIBUTION TO OPTIMIZE T&IEXPENDITURE AT JNGLF PLANTPresenter: Zakariya Al-Ashwan Copyright 2015, Saudi Aramco. All rights reserved.Saudi Aramco: Public

Outline IntroductionRisk Based Inspection (RBI) TechnologyMethodologyRBI Study Results and Benefits for The Studied UnitConclusionReferencesSaudi Aramco: Public

Introduction Ju’aymah NGL Fractionation Department Rerun Unit consists of Depentinizer, Red Vapor Pressure(RVP), Decolorizer Systems Contain of pressure vessels, heat exchangers and piping. Last Rerun Unit T&I “2013” and business interruption costSaudi Aramco approximately 9.2 millions. Decision was made by JNGLFD Management to utilize RBITechnology.Saudi Aramco: Public

Risk Based Inspection (RBI)Technology To evaluate the integrity of operating equipment by managingrisk and damage factors. Based on scientific calculations and experience.Saudi Aramco: Public

Continue Risk Based Inspection (RBI)TechnologyProbability of Failure (POF)Risk “Susceptibility of damage mechanisms,historical failures and equipmentinspection history”X Risk and damage factor limits. Saudi Aramco uses Area Risk Limit as 6 ft2/year andDamage Factor Limit as 500Saudi Aramco: Public

Methodology API-RBI methodology was used based on the API 581publication, second edition, September 2008. API-RBI software, version 8.03.03.Saudi Aramco: Public

RBI Study Results and Benefits for theRerun Unit All possible damage mechanisms for the Rerun unit were identified. Rerun unit equipment and piping were divided to components andclassified as per their risk level. An inspection plan was established to show all Rerun unitequipment and piping with specific needed inspections for specificdue dates as per their possible damage mechanisms and risk level.(Similar effect to the below chart previously shown)Saudi Aramco: Public

Continue RBI Study Results andBenefits for the Rerun Unit Year 2013 compared to year 2020 without inspection for evaluationof T&I extension for 2 years.This line in the figurerepresent the limits. AreaRisk Limit as 6 ft2/yearand Damage Factor Limitas 500Saudi Aramco: Public

Continue RBI Study Results andBenefits for the Rerun Unit All 18 components were fin-fan tube banks, which are close toreaching their life end. Fitness for service was conducted forthese components, which recommend to not extending theT&I date for these components. The T&I date for other components can be extended by 2years, which will result in saving approximately 3.4 millions“T&I Cost & BIC.” This T&I extension will assure continuous operation andproduct supply with less interruption time for a 7 year T&Icycle instead of 5 years since the last T&I “2013.”Saudi Aramco: Public

Conclusion The Ju’aymah NGLF Department conducted a quantitativeRBI study utilizing the API RBI program, API-571, API-580,API-581 and SAEP-343. The RBI study was able to prove that extensive (overdoing)inspection methods and the T&I cycle were used during thelast T&Is, which rises the T&I and business interruptioncost. The Ju’aymah NGLF Department succeeded in supportinga deviation for Rerun Unit T&I by utilizing RBI Technology.Saudi Aramco: Public

References Saudi Aramco, Risk Based Inspection “RBI” for Saudi Aramco Facilities “SAEP-343,” Inspection Engineering Standards Committee,2013.American Petroleum Institute “API”, Risk-Based Inspection “API580,” International Organization for Standardization “ISO,” 2009, 2ndedition. American Petroleum Institute “API,” Risk-Based Inspection Technology “API-581,” International Organization for Standardization“ISO,” 2008, 2nd edition.American Petroleum Institute “API,” Damage Mechanisms AffectingFixed Equipment in the Refining Industry “API-571,” InternationalOrganization for Standardization “ISO,” 2011, 2nd edition. Ju’aymah NGLF Department, Risk Based Inspection “RBI”Assessment at JNGLF Plant R-84 Rerun Unit “SAER- S6536-13,”Saudi Aramco, KSA, 2013.Saudi Aramco: Public

Saudi Aramco: Public References Saudi Aramco, Risk Based Inspection “RBI” for Saudi Aramco Facilities “SAEP-343,”Inspection Engineering Standards Committee, 2013. American Petroleum Institute “API”, Risk-Based Inspection “API-580,”International O

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