Guidance for Non-Intrusive Inspection of Pressure Vessels

2010 ◽  
Author(s):  
Carl E. Jaske
Keyword(s):  
Essential Elements ◽  
Pressure Vessels ◽  
Confined Space ◽  
Inspection Planning ◽  
Mechanical Integrity ◽  
Future Performance ◽  
Integrity Management ◽  
Key Aspects ◽  
Periodic Inspections ◽  
Inspection Techniques

Pressure vessels must undergo periodic inspections to help ensure their mechanical integrity and continued safe operation. Such inspections are usually mandated by regulations or prescribed in the integrity management programs of prudent operators. Traditionally, internal visual inspections have been employed. These can be costly because of the need to shut down the vessel, isolate it, prepare it for entry, and follow requirements for confined-space entry. Furthermore, vessel entry may even have an adverse effect on its future performance. For these reasons, it is desirable to utilize non-intrusive inspection methods where a vessel can be non-invasively inspected from its exterior. However, the use of non-intrusive inspections must not compromise safe and reliable vessel operation. Compared with traditional intrusive internal inspection, non-intrusive inspection is relatively new and there are a wide variety of inspection techniques available. Each technique has its strengths and weaknesses, and many engineers are not fully acquainted with the capabilities and limitations of the various non-intrusive inspection techniques. To address this issue, Recommended Practice DNV-RP-G103 on Non-Intrusive Inspection (NII) was developed [1]. This paper reviews the recommended practice and discusses example applications of the recommended practice. The recommended practice provides guidance on the following key aspects of non-intrusive pressure vessel inspection: (1) determining when its use is appropriate, (2) information that is needed for inspection planning, (3) defining requirements for inspection methods, (4) selecting inspection methods based on requirements, (5) evaluating inspection results, and (6) requirements for proper documentation of inspection results. The essential elements of the procedures covered in the recommended practice are performing a mechanical integrity review, deciding if non-intrusive inspection is possible, planning for the inspection, performing the inspection, and evaluating the results of the inspection. Finally, the inspection interval is evaluated.

Essential Elements of an Asset Integrity Management Program for Ammonia and Methanol Plants

2017 ◽  
Author(s):  
Carl E. Jaske ◽  
Steven J. Weichel ◽  
Michiel P. H. Brongers
Keyword(s):  
Risk Management ◽  
Emergency Response ◽  
Essential Elements ◽  
Pressure Vessels ◽  
Management Program ◽  
Near Misses ◽  
Wide Range ◽  
Key Factor ◽  
Integrity Management ◽  
World Class

World-class ammonia and methanol plants typically produce more than 500,000 metric tons of ammonia or methanol per year. These plants utilize pressure vessels, piping, and tanks that operate over a wide range of temperatures and pressures. The materials of construction range from carbon steel to corrosion-resistant and heat-resistant alloys. Ensuring the safe and reliable operation of these facilities requires an effective asset integrity management program. This paper reviews the essential elements of an asset integrity management program and provides recommendations for judging the effectiveness of the program. The essential elements of an asset integrity management program include leadership, risk management, personnel and contractor competence, management of change, learning from events, emergency response, and implementation of quality assurance, maintenance, inspection, fitness-for-service assessment, repair, and replacement. Management commitment to the program is a key factor in leadership. Risk is managed by mitigating the consequences of an incident as well as minimizing its likelihood; a robust risk-based inspection (RBI) program is typically part of the risk management. In-service degradation mechanisms of the materials that are used in pressure vessels, piping, and tanks include corrosion, fatigue, creep, and metallurgical embrittlement. If defects are identified by inspection, fitness for service assessment is performed to determine what action is to be taken. Training and certification of personnel and contractors is required to make sure that this work is properly performed. Incidents and near misses that occur in the plant and in the industry need to be reviewed to identify areas for potential program improvements. Timely and appropriate emergency response can minimize the consequences of an incident.

Testing of Acoustic Emission Technology to Detect Cracks and Corrosion in the Marine Environment

2010 ◽  
Vol 26 (02) ◽  
pp. 106-110
Author(s):  
Ge Wang ◽  
Michael Lee ◽  
Chris Serratella ◽  
Stanley Botten ◽  
Sam Ternowchek ◽  
...  
Keyword(s):  
Acoustic Emission ◽  
Structural Integrity ◽  
Pilot Project ◽  
Development Project ◽  
Management Program ◽  
Pipeline System ◽  
Inspection Planning ◽  
Structural Degradation ◽  
Integrity Management ◽  
Acoustic Emission Technology

Real-time monitoring and detection of structural degradation helps in capturing the structural conditions of ships. The latest nondestructive testing (NDT) and sensor technologies will potentially be integrated into future generations of the structural integrity management program. This paper reports on a joint development project between Alaska Tanker Company, American Bureau of Shipping (ABS), and MISTRAS. The pilot project examined the viability of acoustic emission technology as a screening tool for surveys and inspection planning. Specifically, testing took place on a 32-year-old double-hull Trans Alaska Pipeline System (TAPS) trade tanker. The test demonstrated the possibility of adapting this technology in the identification of critical spots on a tanker in order to target inspections. This targeting will focus surveys and inspections on suspected areas, thus increasing efficiency of detecting structural degradation. The test has the potential to introduce new inspection procedures as the project undertakes the first commercial testing of the latest acoustic emission technology during a tanker's voyage.

Mooring Sense Project: A Risk-Based Integrity Management Strategy for Mooring System of Floating Offshore Wind

2021 ◽  
Author(s):  
Alessandro La Grotta ◽  
Róisín Louise Harris ◽  
Clive Da Costa
Keyword(s):  
Energy Production ◽  
Management Strategy ◽  
Offshore Wind ◽  
Risk Level ◽  
Mooring System ◽  
Inspection Planning ◽  
Potential Cost ◽  
Operational Costs ◽  
Floating Offshore Wind Turbines ◽  
Integrity Management

Abstract While Floating Offshore Wind (FOW) represents a significant opportunity to foster wind energy development and to contribute to remarkable CO2 emissions reductions, its associated operational costs are still substantially above grid parity, and significant innovation is needed. MooringSense is a research and innovation project which explores digitisation technologies to enable the implementation of risk-based integrity management strategies for mooring systems in the FOW sector with the aim to optimise Operations and Maintenance (O&M) activities, reduce costs, and increase energy production. As part of this project, a risk-based assessment methodology specific for the mooring system of Floating Offshore Wind Turbines (FOWT) has been developed; this allows the development of a risk-based Mooring Integrity Management Strategy that can result in more cost-effective inspection planning. The methodology shall utilise the information made available by numerical tools, sensors, and algorithms developed in the project to update the risk level of the mooring system and set the required plan to mitigate the risk. Leveraging the additional information from monitoring technologies and predictive capabilities to determine the mooring system condition and remaining lifetime, the strategy provides the criteria for optimal decision making with regards to selection of O&M activities. The risk-based strategy developed allows for optimal planning of inspection and maintenance activities based on dynamic risk level that is periodically updated through the interface with the Digital Twin (DT). The validation of the strategy will demonstrate potential cost saving and economic advantages, however, it is expected that the overall MooringSense approach can reduce FOW farm operational costs by 10-15% and increase operational efficiency by means of an Annual Energy Production increase by 2-3%. The MooringSense project comprises of the development and validation of innovative solutions coming from multiple disciplines such as numerical modelling, simulation, Global Navigation Satellite System (GNSS), Structural Health Monitoring (SHM), and control systems which will provide valuable input to the risk-based mooring integrity management strategy.

Integrity inspection planning updated with cost of risk

2017 ◽  
Vol 57 (2) ◽  
pp. 647
Author(s):  
Yury Sokolov
Keyword(s):  
Oil And Gas ◽  
Cost Benefit Analysis ◽  
Cost Benefit ◽  
Individual Risk ◽  
Plant Management ◽  
Inspection Planning ◽  
Worst Case ◽  
Integrity Management ◽  
Inspection Data ◽  
New Generation

The industry expenditure savings motive requires a cost/benefit analysis to optimise Integrity Management budgets. The challenge of estimating precise risk costs requires that numeric Probabilities of Failure (PoF) be known at the highest possible level of confidence, as equipment items specific PoFs govern the actual probability of financial losses and safety implications. The first-hand information on the equipment actual integrity condition is contained in numeric results of integrity inspections. In practice, these results are seldom analysed statistically, being collapsed into single ‘worst case’ values. This simplification prevents assessing of equipment specific actual PoFs and from quantifying failure risks when using traditional methods. We developed a new-generation inspection planning and assessment strategy applied to oil and gas pressure equipment. Evaluating equipment PoFs enables assessing risk costs and optimising the budgets, as well as setting justified internal inspection coverage and frequency objectives. This is achieved by a statistical analysis of numeric inspection data. Existing inspection data (such as ultrasonic testing spot-checks) can be used for a first-pass analysis. Statistical plotting of such data automatically visualises the data quality, and the relevant recommendations for improving inspection coverage or tools are drawn where necessary. We found that two criteria drive integrity decision making: failure total costs and annual fatality expectancies. These criteria are mutually complementary. Both need to be considered for a safe and profitable plant operation. Equipment individual risk control strategy is then developed from safety compliance and budget savings maximising standpoints, thereby also enabling confident design and procurement decisions. This is a new-generation strategy suitable for bringing together all branches of plant management and for improving confidence of the parties. We see it as an evolutionary update to Risk Based Inspection and Maintenance practice, which is now in high demand due to cost pressures.

Safe Operation of Jacket Platforms in a Major Oil Field in the North Sea

2018 ◽  
Author(s):  
Ingar Scherf ◽  
Trine Hansen ◽  
Gudfinnur Sigurdsson
Keyword(s):  
Emergency Preparedness ◽  
Structural Integrity ◽  
Fatigue Cracks ◽  
Regulatory Compliance ◽  
Offshore Structures ◽  
Oil Field ◽  
Inspection Planning ◽  
Original Design ◽  
Safe Operation ◽  
Integrity Management

Offshore Structures operate for decades in extremely hostile environments. It is important during this period that the structural integrity is efficiently managed to ensure continuous and safe operation. Increased use of enhanced oil and gas recovery means it is likely that many existing installations will remain operational for a significant period beyond the original design life. The operator needs to capture, evaluate and, if necessary, mitigate design premise changes which inevitably occur during the life of a structure. Further, advances in knowledge and technology may imply changes in codes and standards as well as in analysis methodologies. Changes in corporate structures, transfer of operator responsibility and retirement of experienced engineers call for reliable means to transfer historical data and experience to new stakeholders. Effective emergency preparedness capabilities, structural integrity assessments and inspection planning presuppose that as-is analysis models and corresponding information are easily accessible. This paper presents an implementation of the in-service integrity management process described in the new revision of NORSOK standard N-005 [1] for a large fleet of jackets at the Norwegian Continental Shelf. The process, comprising management of design premise changes as well as state-of-the-art technical solutions over a range of disciplines, has enabled the operator to prolong the service life with decades at minimum investments. A structure integrity management system (SIMS) has been developed and digitized over years and streamlined to meet the needs and challenges in the operation and management of the jacket platforms. SIMS enables a rather lean organization to control the structural integrity status of all load-bearing structures at any time. Platform reinforcements and modifications along with other operational risk reducing measures like unman the platforms in severe storms enable continued use with the same level of safety as for new manned platforms. Advanced analyses are used to document regulatory compliance. Modern fatigue and reliability based inspection planning analyses have reduced the costs needed for inspection of fatigue cracks significantly. The benefits from the SIMS system are substantial and the resulting safety and productivity gains are apparent. The continuity of knowledge and experience is maintained, reducing risk to safety and regularity. The digital transformation related to management of structural integrity status as described in NORSOK standard N-005 is realized through SIMS.

Bayesian Multi-Level Modelling for Improved Prediction of Corrosion Growth Rate

2020 ◽  
Author(s):  
Domenic Di Francesco ◽  
Marios Chryssanthopoulos ◽  
Michael Havbro Faber ◽  
Ujjwal Bharadwaj
Keyword(s):  
Epistemic Uncertainty ◽  
Simulated Data ◽  
Steel Structures ◽  
Pressure Vessels ◽  
Mathematical Basis ◽  
Management Planning ◽  
Integrity Management ◽  
Level Model ◽  
Multi Level ◽  
Inspection Data

Abstract In pipelines, pressure vessels and various other steel structures, the remaining thickness of a corroding ligament can be measured directly and repeatedly over time. Statistical analysis of these measurements is a common approach for estimating the rate of corrosion growth, where the uncertainties associated with the inspection activity are taken into account. An additional source of variability in such calculations is the epistemic uncertainty associated with the limited number of measurements that are available to engineers at any point in time. Traditional methods face challenges in fitting models to limited or missing datasets. In such cases, deterministic upper bound values, as recommended in industrial guidance, are sometimes assumed for the purpose of integrity management planning. In this paper, Bayesian inference is proposed as a means for representing available information in consistency with evidence. This, in turn, facilitates decision support in the context of risk-informed integrity management. Aggregating inspection data from multiple locations does not account for the possible variability between the locations, and creating fully independent models can result in excessive levels of uncertainty at locations with limited data. Engineers intuitively acknowledge that the areas with more sites of corrosion should, to some extent, inform estimates of growth rates in other locations. Bayesian multi-level (hierarchical) models provide a mathematical basis for achieving this by means of the appropriate pooling of information, based on the homogeneity of the data. Included in this paper is an outline of the process of fitting a Bayesian multi-level model and a discussion of the benefits and challenges of pooling inspection data between distinct locations, using example calculations and simulated data.

Overview of Revisions to the ASME Boiler and Pressure Vessel Code Section VIII Division 3 for the 2017 Edition and Near Future

2017 ◽  
Author(s):  
Daniel Peters ◽  
Gregory Mital ◽  
Adam P. Maslowski
Keyword(s):  
High Pressure ◽  
Pressure Vessel ◽  
Central Area ◽  
Local Strain ◽  
Pressure Vessels ◽  
Conformity Assessment ◽  
Inspection Planning ◽  
Section Viii ◽  
American Society ◽  
Rules Changes

This paper provides an overview of the significant revisions pending for the upcoming 2017 edition of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC) Section VIII Division 3, Alternative Rules for Construction of High Pressure Vessels, as well as potential changes to future editions under consideration of the Subgroup on High Pressure Vessels (SG-HPV). Changes to the 2017 edition include the removal of material information used in the construction of composite reinforced pressure vessels (CRPV); this information has been consolidated to the newly-developed Appendix 10 of ASME BPVC Section X, Fiber-Reinforced Plastic Pressure Vessels. Similarly, the development of the ASME CA-1, Conformity Assessment Requirements standard necessitated removal of associated conformity assessment information from Section VIII Division 3. Additionally, requirements for the assembly of pressure vessels at a location other than that listed on the Certificate of Authorization have been clarified with the definitions of “field” and “intermediate” sites. Furthermore, certain design related issues have been addressed and incorporated into the current edition, including changes to the fracture mechanics rules, changes to wires stress limits in wire-wound vessels, and clarification on bolting and end closure requirements. Finally, the removal of Appendix B, Suggested Practice Regarding Post-Construction Requalification for High Pressure Vessels, will be discussed, including a short discussion of the new appendix incorporated into the updated edition of ASME PCC-3, Inspection Planning Using Risk Based Methods. Additionally, this paper discusses some areas in Section VIII Division 3 under consideration for improvement. One such area involves consolidation of material models presented in the book into a central area for easier reference. Another is the clarification of local strain limit analysis and the intended number and types of evaluations needed for the non-linear finite element analyses. The requirements for test locations in prolongations on forgings are also being examined as well as other material that can be used in testing for vessel construction. Finally, a discussion is presented on an ongoing debate regarding “occasional loads” and “abnormal loads”, their current evaluation, and proposed changes to design margins regarding these loads.

Challenging Experiences in the Usage of Stainless Steels in a Heavy Fabrication Industry

2013 ◽  
Vol 794 ◽  
pp. 316-331
Author(s):  
T. Gurunathan
Keyword(s):  
Stainless Steels ◽  
Pressure Vessels ◽  
Welding Distortion ◽  
Quality Assurance Programme ◽  
Testing Procedures ◽  
Distortion Control ◽  
Leak Testing ◽  
Process Plants ◽  
Inspection Techniques ◽  
Temperature Suitability

Stainless steels are regularly used as one of the preferred material of construction in the pressure vessels and heat exchangers manufactured by welding for process plants and energy sector at BHEL, Tiruchirappalli. They are considered mainly because of their corrosion resistance and high temperature suitability. But the practising welding engineers have to face innumerable challenges with stainless steel with regard to defects minimization, distortion control and dimensional stability on large and complex assemblies. Use of Nickel based filler wires or development of welding procedures simulating the true configuration of the product and by conducting specific tests and NDE are followed for weld defects control. Sequence welding, development of special fixtures, etc have come as handy options for welding distortion control of SS. Innovative inspection techniques for the certification of dimensions including geometrical tolerances especially on large constructions using SS welding and evolution of special Helium leak testing procedures for certain in-process checks in critical products are inevitable in the SS fabrication industry as a part of Quality Assurance programme. As a pioneer in SS fabrication, some of our challenging experiences pertaining to these three areas are discussed in this paper.

scholarly journals Decision-theoretic inspection planning using imperfect and incomplete data

2021 ◽  
Vol 2 ◽  
Author(s):  
Domenic Di Francesco ◽  
Marios Chryssanthopoulos ◽  
Michael Havbro Faber ◽  
Ujjwal Bharadwaj
Keyword(s):  
Imperfect Information ◽  
Structural Integrity ◽  
Expected Value ◽  
Inspection Planning ◽  
Multiple Sources ◽  
Damage Models ◽  
Monitoring Strategies ◽  
Subject Matter Expertise ◽  
Integrity Management ◽  
Expected Value Of Information

Abstract Attempts to formalize inspection and monitoring strategies in industry have struggled to combine evidence from multiple sources (including subject matter expertise) in a mathematically coherent way. The perceived requirement for large amounts of data are often cited as the reason that quantitative risk-based inspection is incompatible with the sparse and imperfect information that is typically available to structural integrity engineers. Current industrial guidance is also limited in its methods of distinguishing quality of inspections, as this is typically based on simplified (qualitative) heuristics. In this paper, Bayesian multi-level (partial pooling) models are proposed as a flexible and transparent method of combining imperfect and incomplete information, to support decision-making regarding the integrity management of in-service structures. This work builds on the established theoretical framework for computing the expected value of information, by allowing for partial pooling between inspection measurements (or groups of measurements). This method is demonstrated for a simulated example of a structure with active corrosion in multiple locations, which acknowledges that the data will be associated with some precision, bias, and reliability. Quantifying the extent to which an inspection of one location can reduce uncertainty in damage models at remote locations has been shown to influence many aspects of the expected value of an inspection. These results are considered in the context of the current challenges in risk based structural integrity management.

101 Essential Elements in a Pressure Equipment Integrity Management Program for the Hydrocarbon Process Industry: Part 2

2002 ◽  
Author(s):  
John T. Reynolds
Keyword(s):  
Petrochemical Industry ◽  
Essential Elements ◽  
Management Program ◽  
Process Industry ◽  
Work Processes ◽  
Minimum Compliance ◽  
Preventative Measures ◽  
Integrity Management ◽  
Physical Assets ◽  
Operational Excellence

This is part 2 of a two part paper that outlines the 101 essential elements that need to be in place, and functioning well, to effectively and efficiently, preserve and protect the reliability and integrity of pressure equipment (vessels, exchangers, furnaces, boilers, piping, tanks, relief systems) in the refining and petrochemical industry. Part 1 of this paper was published in the proceedings of the 2000 ASME PVP Conference. Each of the two parts outline half of the 101 essential elements of pressure equipment integrity management (PEIM). This paper is not just about minimum compliance with rules, regulations or standards; rather it is about what needs to be accomplished to build and maintain a program of operational excellence in pressure equipment integrity that will permit owner-users to make maximum use of their physical assets to generate income. Compliance is not the key to success in pressure equipment integrity management (PEIM); operational excellence is. Each of the 101 work processes outlined in this two part paper, is explained concisely to the extent necessary, so that owner-users will know what needs to be done to maintain and improve their PEIM program. This paper does not prescribe how each of these 101 key elements is to be accomplished, as that description would result in a book rather than a paper. This paper simply outlines all the fundamentals that are necessary to avoid losses, avoid safety incidents, and maintain reliability of pressure equipment. It pulls together a complete overview of the entire spectrum of programs, procedures, and preventative measures needed to achieve first quartile performance in maintaining pressure equipment integrity (PEI).

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