Fitness for service

1
??????

• ???
• 980922

2
??

• ??
• ??????????
• ????????
• Fitness for service
• ??

3
??

• ?????????????
• ??????????????????????????????????????
• ???????????????????????????????????????
• ???????????????????, ??????,???????????????

4
?????
????????? ????????? ?????.??? ????????? ?????
??????
?????? ???????? ??????? ???????? ???????? ??????
??
5
??Api code

• APIAPI 510Pressure Vessel Inspection Code
  In-Service Inspection, Rating, Repair, and
  Alteration Ninth Edition)
• APIAPI 570Piping Inspection Code Inspection,
  Repair, Alteration, and Rerating of In-Service
  Piping Systems Second Edition
• APIRP 571Damage Mechanisms Affecting Fixed
  Equipment in the Refining Industry First Edition
• APIRP 572Inspection of Pressure Vessels (Towers,
  Drums, Reactors, Heat Exchangers, and Condensers)
  Second Edition
• APIRP 573Inspection of Fired Boilers and Heaters
  Second Edition
• APIRP 574Inspection Practices for Piping System
  Components Second Edition (
• APIRP 575Guidelines and Methods for Inspection of
  Existing Atmospheric and Low-Pressure Storage
  Tanks Second Edition
• APIRP 576Inspection of Pressure-Relieving
  Devices Second Edition
• APIRP 577Welding Inspection and Metallurgy First
  Edition
• APIRP 578Material Verification Program for New
  and Existing Alloy Piping Systems First Edition
• APIRP 580Risk-Based Inspection First Edition
• APIRP 941Steels for Hydrogen Service at Elevated
  Temperatures and Pressures in Petroleum
  Refineries and Petrochemical Plants Seventh
  Edition
• APIRP 945Avoiding Environmental Cracking in Amine
  Units Third Edition
• 598Valve Inspection and Testing Eighth Edition
• APISTD 620Design and Construction of Large,
  Welded, Low-pressure Storage Tanks Eleventh
  Edition

6
????????

• ????????????????????,?????????,?????????,?????????
  ????????????????,????????,????????
• ??????????????????,????????,????(1)?????(2)???????
  ????(????)?(3)??????????(4)??????????(5)??????????
  ?

7
???????

• ???????????????????????????????????????
• ??????????????????,???????????????????????????????
  ????????????????,????????????????(????????????????
  ?)??????????????????????????????

8
????

• 1)?PID?PFD???????????/???????,?????????????,????
  ???????????????????????????????????
• 2)?????????????????
• 3)???????????
• 4)??????
• 5)????????

9
?????????

• ??/??/????
• ??/????
• ??/????
• ????
• ????

10
????

• ?????????????????????????
• ????????????????(???????????????????????,by-pass??
  ??)???????????????????????????????????????????

11
???????

• ?????,??????,??????????????????
• ?????????????(??)????(?????nozzle)??????????(?????
  ????)?????????????????????????????????????????????
  ????????????????
• ????????????????????????,?????????????????
• ?????????,??????????????(????????????),?????????
• ??????????????????????????????????,???????????

12
?????????

• ????????????,????????????????????????
• ?????????????????,???????(RBI)??,?????????????????
  ??????????,??????????????????????
• ??????????????????????????????????????????????????
  ???????????????????????(??????????)??????????

13
????

• ??????????????,?????????????
• ?????????,????????????????????????
• ???????????????????????,???????,??
• ?????????
• ?????????????????????????
• ???,????????
• ?????????????????????????????
• (A) ?????????????(auto-refrigerate)?????????
  ????
• (B) ?????????,?????????,????????????????????
  ?,??C2?C3?C4??????,?????-4??120??????????????????
  ??10??
• (C) ???H2S????3wt??
• (D) ??(????80?)?
• ???????????????????????
• (A) ??????????,?????????,???????????
  ???????
• (B) ??????80????????????????????

14
??????????

• ?????????????????????????????
• ?????,????????????????
• (A) ????
• (B) ???(Deadlegs)?
• (C) ???????(CUI)?
• (D) ??????
• (E) ??????????????????????????
• ??????????????????(???????
• ???)??
• (F) ???????????????
• a). ?????,??????????
• b). ??????
• c). ?????
• d). ???????,??????????
• e). ?????????????(?????????
• ?????)????

15
??????,??????????

• (A) ??????????
• a). ????????,??????????????????????,
  ??????????????????
• b). ????????????,???????????????????(Polythioni
  c acid)?????
• c). ??????????
• d). ??????????????(Amine)?????
• e). ????????
• f). ?H2S????????????
• g). ?????????(HIC)?
• (B) ???????????
• (C) ??????????????,????????????????????????
• (D) ???????????????????????????????????,??????????
  ????????????????1.25Cr?????482?(900?)??????????
• (E) ????(???2.25Cr-1Mo?????)???????????????????,??
  ??????????
• (F) ?????????????,???????????,??????

16
????

• ??????????????,???????????????
• ??????????????????,????????????????????????

17
???????

• ???????????????,?????????,???????????????????????
  ???????????????????
• ????NDT?NDE?NDI?
• ?????????????(PT)?????(MT)?????(RT)??????(UT)????
  ??(ET)?????(VT)?????(AE)??

18
PROFILE RT

• ?????1"????????????,???????????????????????,??????
  ?????????????????,?????????,??????,??????????????
  ??????????????????????????????

19
Pipeline Inspection
NDT is used to inspect pipelines to prevent leaks
that could damage the environment. Visual
inspection, radiography and electromagnetic
testing are some of the NDT methods used.
Remote visual inspection using a robotic crawler.
Magnetic flux leakage inspection. This device,
known as a pig, is placed in the pipeline and
collects data on the condition of the pipe as it
is pushed along by whatever is being transported.
Radiography of weld joints.
20
???? LT
(1)???? (2)?????? (3)????? (4)???????
(5)???? (6)?????
21
???????????
? ? ????????(pa.m3/s)
?????? ?????
????? 0.05
??????? 10-4
???? 10-5
???? 10-10
????? 10-12
22
????(PMI)

• ??????(??????????)?????????????????????????,??????
  50mm50mm??,??????,?????????????,?????????????
• ??????pmi??,???????????

23
????

• ?????????????????
• ????????????????
• ???????????????????,????????????,????????????????
  ????,????????????4psig?????,?????,????????????????
  ???

24
Rapid Tube Inspectionusing Eddy Current (ET) or
Remote Field (RFT) methods

• Characteristics of the ET technique
• High speed method. Inspects 500-800, 10m tubes
  per day.
• 100 inspection of the tube.
• Little surface preparation (cleaning).
• Color coded reporting for convenient results
  overview.

25
Heat exchanger Inspection
Periodically, refinery plants are shutdown for
inspection. Inspectors feed eddy current probes
into heat exchanger tubes to check for corrosion
damage.
26
Manual Ultrasonic (UT) Weld Inspection

• Quick and direct results.
• No protection against radiation required, neither
  interruption of other peoples work.
• In-service inspection.
• Inspection of complex geometry welds with profile
  analysis of the weld using a PC.
• Inspections performed according to international
  standards ASME, EN etc.
• Final technical report that contains position,
  depth and type information of discontinuity.
• Storage of the discontinuities signals and
  inspection parameters.
• Sensitivity in critical discontinuities detection
  (e.g. cracking).

27
Automated Ultrasonic (UT) Tube Corrosion Mapping

• Inspection speed up to 100mm per second,
  depending on the desirable resolution.
• The probe for data recording is inserted
  completely automated with a 300mm per second
  speed depending on the required measurement
  precision.
• Complete 2 or 3 axes recording (C-Scan and
  B-Scan) with capability to export the data on
  Excel worksheet for further analysis.
• Inspects tubes with diameters from 12mm up to
  76mm.
• Thickness and corrosion mapping and/or inspection
  for other types of imperfections.

28
Ultrasonic Thickness Measurements

• Quick measurements with direct results.
• High precision measurements.
• The inspected object can be in-service.
• No particular surface preparation required.
• Measurements can be made without removal of the
  paint.
• Measurements on high temperature surfaces
  possible

29
Guided Ultrasonic Waves Pipe Inspection

• A ring with the transducers is placed around the
  pipe No couplant is required
• Usually no surface preparation required
• Instrumentation is fully portable
• Guided waves are sent in each direction
• Data are collected and stored in the portable
  instrument
• Reflections are analysed and results reported
  immediately after the test
• Long sections of pipe can be examined from one
  location, e.g. 30m on either side of the ring
• Capabilities
• Each test is completed within minutes including
  results
• Can be performed at elevated temperatures without
  taking the pipe out of service up to 125?.
• 100 of the pipe is inspected (within the
  diagnostic length of a test)
• Pulse echo type operation provides information on
  feature position and approximate size
• Sophisticated analysis aids interpretation of
  results
• Minimum insulation removal for testing (1m)
• Difficult-to-inspect areas (such as roadways) can
  be screened for defects

30
Testing Cryogenic Tank Walls with AE

• Global Monitoring - Sensors detect AE signals
  from considerable distances, making this method
  ideal for global monitoring of large vessels and
  systems. Identified problem areas can then be
  inspected using other NDT methods.
• Minor Disturbance of Insulation - Only small
  holes in insulation are required for sensor
  mounting.
• On-Line Testing. Opening a tank introduces oxygen
  into the tank. When the tank is put back into
  service the corrosion process starts all over
  again.
• Cost Reduction. In ammonia applications, it can
  cost up to 1,000,000 just for a nitrogen purge..
  The use of AE can reduce plant maintenance costs
  considerably, while increasing the information
  available about plant integrity. Plant downtime
  for inspection is also minimized.
• Rapid Inspection - The actual AE test takes a
  matter of hours, and in some cases, considerably
  less. No comparable method can provide 100
  volumetric inspection in the same amount of time.
• Permanent Record of Test - Data is digitized and
  stored on disk, providing a permanent record of

31
Leak Detection using Acoustic Emission
Valve Leakage   procedures for the detection of leaks through valves have been developed for use in refineries, chemical plants and offshore platforms. It enables estimation of through-valve gas losses and leak rate.   Pipeline Leakage   Inspection of whole structure performed during operating conditions, even of difficult-to-reach areas. Requires minimum access to surface for sensors mounting.  
32
On-Line Tank Floor Inspection with TANKPAC

• No Need to Empty or Clean the Tank
• 100 Floor Inspection
• Verified Reliability
• Inspection and Evaluation of Annular Ring
• Immediate Results
• Rapid testing 50 meter tank in one day
• Identify tanks that need inspection and repair
• Leave good tanks on-line and save the shut-down
  and cleaning costs

33
Fitness-For-ServiceAPI 579-1/ASME FFS-1

• Fitness-For-Service (FFS) assessments are
  quantitative engineering evaluations that are
  performed to demonstrate the structural integrity
  of an in-service component that may contain a
  flaw or damage.
• This Standard provides guidance for conducting
  FFS assessments using methodologies specifically
  prepared for pressurized equipment. The
  guidelines provided in this Standard can be used
  to make run-repair-replace decisions to help
  determine if pressurized equipment containing
  flaws that have been identified by inspection can
  continue to operate safely for some period of
  time.
• These FFS assessments are currently recognized
  and referenced by the API Codes and Standards
  (510, 570, 653), and by NB-23 as suitable means
  for evaluating the structural integrity of
  pressure vessels, piping systems and storage
  tanks where inspection has revealed degradation
  and flaws in the equipment.

34

• The Fitness-For-Service assessment procedures in
  this Standard cover both the present integrity of
  the component given a current state of damage and
  the projected remaining life.
• Assessment techniques are included to evaluate
  flaws including general and localized corrosion,
  widespread and localized pitting, blisters and
  hydrogen damage, weld misalignment and shell
  distortions, crack-like flaws including
  environmental cracking, laminations, dents and
  gouges, and remaining life assessment procedures
  for components operating in the creep range.
• In addition, evaluation techniques are provided
  for condition assessment of equipment including
  resistance to brittle fracture, long-term creep
  damage, and fire damage.

35
(No Transcript)
36
Fitness-For-Service assessment procedure

• STEP 1 Flaw and Damage Mechanism
  Identification
• STEP 2 Applicability and Limitations of the FFS
  Assessment Procedures
• STEP 3 Data Requirements
• STEP 4 Assessment Techniques and Acceptance
  Criteria
• STEP 5 Remaining Life Evaluation
• STEP 6 Remediation
• STEP 7 In-Service Monitoring
• STEP 8 Documentation

37
Applicability and Limitations of the FFS
Assessment Procedures

• The FFS assessment procedures in this Standard
  were developed to evaluate the pressure
  boundaries of pressure vessels, boiler
  components, piping, and shell courses of storage
  tanks with a flaw resulting from single or
  multiple damage mechanisms.
• The concepts presented in this Standard may also
  be used for the assessment of non-pressure-boundar
  y components such as supports.
• Fitness-For-Service procedures for fixed and
  floating roof structures, and bottom plates of
  tanks are covered in Part 2 of API 653.

38
Assessment Techniques and Acceptance Criteria

• Level 1 Assessment may be performed either by
  plant inspection or engineering personnel
• Level 2 Assessment would typically be conducted
  by plant engineers,or engineering specialists
  experienced and knowledgeable in performing FFS
  assessments.
• Level 3 Assessment primarily intended for use by
  engineering specialists experienced and
  knowledgeable in performing FFS assessments.

39
??

• ????????????????,?????????,???????
• ????????????????,??????????Qualify
• ??????,???FFS???????????