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Dealing with Aging Process Facilities and Infrastructure
CENTER FOR CHEMICAL PROCESS SAFETY of the AMERICAN INSTITUTE OF CHEMICAL ENGINEERS New York, NY
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Library of Congress Cataloging-in-Publication Data
Names: American Institute of Chemical Engineers. Center for Chemical Process Safety, author. Title: Dealing with aging process facilities and infrastructure / Center for Chemical Process Safety of the American Institute of Chemical Engineers. Description: New York, NY : Wiley, 2018. | Includes bibliographical references and index. | Identifiers: LCCN 2018010560 (print) | LCCN 2018012416 (ebook) | ISBN 9781119430766 (pdf) | ISBN 9781119430759 (epub) | ISBN 9781119430834 (cloth) Subjects: LCSH: Chemical plants--Maintenance and repair. | Chemical plants--Equipment and supplies--Deterioration. | Service life (Engineering) Classification: LCC TP155.5 (ebook) | LCC TP155.5 .D425 2018 (print) | DDC 660--dc23 LC record available at https://lccn.loc.gov/2018010560
Cover images : Courtesy of CCPS Cover design by Wiley
LIST OF TABLES
Table 2.2-1. Deaths and Injuries Statistics for MARS Reportable Major Accident Hazard Incidents
Table 2.2-2. Total Losses (Million € Equivalent) for MARS Reportable Major Accident Hazard Incidents
Table 2.3-1. Examples of Corrosion Mechanisms
Table 2.3-1. Examples of Corrosion Mechanisms, continued
Table 2.3-2. Typical Refinery Elements Contributing to Elevated Corrosion Rates
Table 3.2-1. Component Condition Health Metrics
Table 3.2-1. Component Condition Health Metrics, continued
Table 4.2-1. Guidelines for Risk Based Decisions
Table 4.3-1. RBD Documentation Guidelines
Table 4.6-1. Corrective and Preventive Metrics Definitions
Table 4.6-1. Corrective and Preventive Metrics Definitions, continued
Table 5.4-1. Estimated Mean Life for the 500-kV Reactors (IEEE, 2006)
Table 6.1-1. Budgeting Guidelines for Various Types of Infrastructure to be maintained
Table 7.1-1. Analogous Inspection Practices for Structures
Table 7.1-1. Analogous Inspection Practices for Structures, continued
Table 7.1-2. Example Checklist for Structural Assets
Table 7.2-1. Inspection Practices for Electrical Infrastructure
Table 7.2-2. Example Checklist for Electrical Systems
Table 7.2-3. Inspection Practices for Control Systems Infrastructure
Table 7.2-4. List of UPS Disturbance Causes
Table 7.3-1. Inspection Practices for Road Infrastructure
Table 7.3-2. Example Checklist for Roads Maintenance and Inspection
Table 7.3-2. Example Checklist for Roads Maintenance and Inspection, continued
Table 7.3-3. Inspection Practices for Earthwork Infrastructure
Table 7.3-4. Example Checklist for Earthworks Infrastructure Maintenance and Inspection
Table 7.3-5. Example Checklist of Inspection Practices for Rail Spur Infrastructure
Table 7.4-1. Inspection Practices for Marine Infrastructure
Table 7.4-2. Example Checklist for Marine Infrastructure
Table 7.5-1. Inspection Practices for Underground Cable Systems
Table 7.5-2. Example Checklist for Maintenance and Inspection of Underground Cable Systems
Table 7.5-3. Inspection Practices for Underground Utility Piping Infrastructure
Table 7.5-3. Inspection Practices for Underground Utility Piping Infrastructure, continued
Table 7.5-4. Example Checklist for Underground Utility Piping Infrastructure
LIST OF FIGURES
Figure 1.1-1. Image of an Aging Facility Containing Silos
Figure 1.1-2. Vintage Vessels Fastened with Rivets
Figure 1.4-1. Suggested Spectrum for Aging Facilities
Figure 1.4-2. External Corrosion of a Pipe Due to Leakage of Steam Tracing (Sastry, 2015)
Figure 1.4-3. Image Showing Scoring on a Shaft
Figure 2.2-1. High Level Categorization of MARS Incidents
Figure 2.2-2. Causes of Technical Integrity Incidents in MARS Data
Figure 2.3-1. Typical Stress vs. Strain Diagram Indicating the Various Stages of Deformation
Figure 2.3-2. Catastrophic Failure of Electrical Generator Rotor
Figure 2.3-3. Rotted Railway Ties Providing Weakened Support
Figure 2.5-1. Grain Loading Conveyor Collapse in Ama, Louisianna
Figure 2.5-2. Image of Corroded Oil Recovery Vessels
Figure 2.5-3. Image of Aging Iron Making Facility
Figure 2.5-4. Image of Aging Gas Plant
Figure 2.5-5. Image of Aging Process at Marine Facility
Figure 5.3-1. Codes and Standards Applied to Facility Assets
Figure 5.3-2. Probability of Failure vs. Time for a Safety Instrumented System (Dräger, 2007)
Figure 5.4-1. Basin Curve for Failure Rate of Equipment
Figure 5.4-2. Relationship Between Failure Rate and Age for a Normal Probability Distribution
Figure 5.4-3. Relationship Between Failure Rate and Age for a Weibull Probability Distribution
Figure 5.4-4. Relationship Between the Value, Time, and Preventive Maintenance for Aged Equipment
Figure 5.5-1. Aged Conveyor System in Backup Service
Figure 6.1-1. Vintage Steel Mill Retired from Active Service
Figure 6.1-2. Vintage Chemical Plant Dust Reduction Facility
Figure 6.1-3. Cable Failure Rates
Figure 6.4-1. Vintage Grain Elevator Awaiting Renewal (or Refurbishment)
Figure 6.4-2. Expected Uniform Annual Cost
Figure 7.1-1. Image of a Building That Developed a Crumbling Crack
Figure 7.1-2. Photo of Primitive Structural Supports
Figure 7.1-3. Liquefied Petroleum Gas (LPG) Storage Sphere Collapsed While Being Filled for a Hydrostatic Pressure Test
Figure 7.1-4. Chemical Plant Shelter Showing Signs of Severe Deterioration
Figure 7.1-5. Building Presenting Aging Signs
Figure 7.1-6. Photo of Aged Chemical Silos
Figure 7.2-1. Motor Control Center (MCC) Thermal Scan of a Phenol Unit – Photo
Figure 7.2-2. Motor Control Center (MCC) Thermal Scan of a Phenol Unit – Photo
Figure 7.2-3. Thermography Image Showing Hot Terminals
Figure 7.2-4. Damaged Contacts in Lighting Panel Circuit Breaker
Figure 7.2-5. Loose A Phase on 3 Phase Circuit Breaker and Possible Unbalanced Load
Figure 7.2-6. Loose Connection on A Phase in a 2 Speed Motor Contactor
Figure 7.2-7. Medium Voltage (15kV) Indoor Open-Air Switchgear
Figure 7.3-1. Picture of Vintage Tank Car Fastened with Rivets
Figure 8.1-1. Image of Building Awaiting Demolition
Figure AP.1-1. Example of an Old Facility Presenting Aging Signs
Figure AP.1-2. Sketch Showing Bending Moment as a Result Unbalanced Buoyancy Forces
ACKNOWLEDGMENTS
The American Institute of Chemical Engineers (AIChE) and the Center for Chemical Process Safety (CCPS) express their appreciation and gratitude to all members of the Aging Process Facilities and Infrastructure Subcommittee for their generous efforts in the development and preparation of this important concept book. CCPS also wishes to thank the subcommittee members’ respective companies for supporting their involvement in this project.
We appreciate the involvement and writing contributions of Brian Kelly and Terry White. Special thanks are extended to the team of technical writers from ioMosaic Corporation who coordinated inputs and developed the manuscript. The ioMosaic team consisted of Elena Prats, Peter Stickles and Kathy Anderson.
The members of the CCPS project subcommittee were:
Eric Freiburger
Praxair, subcommittee chair
Brian Kelly
CCPS staff consultant
Laura Bellman
Covestro
Larry Bowler
SABIC
Bill Callaghan
Nova Chemicals
Derin Adebekun
Air Products
Susan Lubell
Nexen Energy
Bennie Barnes
Pacific Gas and Electric
Jonas Duarte
Chemtura
Reyyan Koc
ExxonMobil Chemical
John Murphy
CCPS emeritus
Jatin Shah
BakerRisk
Ken Tague
Archer Daniels Midland
Sudhir Phakey
Linde
Nancy Faulk
Siemens Energy
Tom Sandbrook
Chemours
Robb Van Sickle
Flint Hills Resources
Terry White
Pacific Gas and Electric
Bob Wasileski
formerly Nova Chemicals
All CCPS books are subjected to a rigorous peer review prior to publication. CCPS gratefully acknowledges the thoughtful comments and suggestions of the following peer reviewers:
Robert Bartlett
Pareto Engineering & Management
Consulting
Andrew Basler
Mallinckrodt Pharmaceuticals
Michael Broadribb
BakerRisk
Mark Jackson
FM Global
Morteza Jafari
ABS Group Consulting (USA)
Pamela Nelson
Solvay
Chad Patschke
Ethos Mechanical Integrity Solutions
Perianan Radhakrishnan
Petrochemical Corporation of Singapore
M.S. Rajendran
ABS Group Consulting (Singapore)
Darrell Wadden
Nova Chemicals Ltd.
Dan Wilczynski
Marathon Petroleum Company
Della Wong
Canadian Natural Resources Ltd.
PREFACE
The process safety community, through professional and industry associations, has focused considerable attention on Asset Integrity Management (AIM) of equipment directly involved in process operations. The purpose of this book is to address integrity management of assets that often fall outside the traditional process safety management asset integrity program, because they are not ranked high as “safety critical’’ and have long lifecycles. In particular, such assets include process supporting infrastructure like pipe racks and bridges, equipment supporting structures, sewer and drain lines, rail spurs, and process buildings to name a few. Failure of these types of assets can be contributing factors to process safety incidents and should not be ignored.
Aging process equipment, facilities and infrastructure are common in industry today. The developed world has expanded at an ever increasing rate placing high demands on our existing infrastructure. In many instances, equipment is now required to operate at conditions well beyond those anticipated in the original design. Service life may also have been extended. The option to retire and replace aging equipment is often not practical or economical. In fact, sometimes decisions are made to run equipment to failure.
Industry needs to better manage what it has built and acquired over the past several decades. There is no established set of rules for doing this. Each company or operating facility must examine its own business practices and goals and determine a strategy that meets its own risk criteria.
Aging equipment presents a challenge to managing the integrity of plants and associated infrastructure. This book examines the concept of aging equipment and infrastructure in high hazard industries. It specifically looks at the causes and effects of aging in many types of facilities. Possible options for dealing with the problem are highlighted without providing prescriptive advice. Related publications from the Center for Chemical Process Safety (CCPS) and others are cross referenced to provide the reader with a better understanding of the problems encountered by others and some of the solutions that have been applied. The challenge of dealing with aging process facilities and infrastructure is merely one component of a “broad based” Asset Integrity management program. The material herein was developed and compiled by a team of industry practitioners to supplement and expand upon the discussion of aging facilities and infrastructure in the CCPS publication “Guidelines for Asset Integrity Management”.
The American Institute of Chemical Engineers (AIChE) has been closely involved with process safety and loss control issues in the chemical and allied industries for more than four decades. Through its strong ties with process designers, constructors, operators, safety professionals, and members of academia, AIChE has enhanced communications and fostered continuous improvement of the industry’s high safety standards. AIChE publications and symposia have become information resources for those devoted to process safety and environmental protection.
CCPS is chartered to develop and disseminate technical information for use in the prevention of major chemical accidents. The center is supported by more than 190 Chemical Process Industries (CPI) sponsors who provide the necessary funding and professional guidance to its technical committees. The major product of CCPS activities has been a series of guidelines and concept books to assist those implementing various elements of a process safety and risk management system. This book is part of that series.
