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WELCOMEto one of the best

Petrochemical plants in the World

www.equate.comEQUATE Petrochemical Company

About EQUATEEstablished in 1995, EQUATE Petrochemical is Kuwait’s first-ever

international petrochemical joint venture, and is the single operator of a

fully integrated world-scale Kuwait-based manufacturing facility that

annually produces over 5 million tons of high quality petrochemical

products.


EQUATE at a glance

Providing valued products to the world

PROFIT PRODUCTS EMPLOYEES OFFICES AWARDS

US$ 1.1

Billion (2012)

PE / EG / SM

PX / BZ / HA / PP

1400

Employees

4 Offices

Globally

National &

International

Awards


The Greater EQUATE JV

Global Expansion

To meet increasing

worldwide demand for

first-rate petrochemical

products, EQUATE’s

shareholders and

Kuwait National

Petroleum Company

(KNPC) completed a

multi-billion dollar

expansion project in

2009 which greatly

increased output.

Ethylene GlycolCapacity: 600,000MT

Styrene MonomerCapacity: 450,000MT

ParaxyleneCapacity: 829,000MT

PolypropeleneCapacity: 140,000MT

Company Shareholders Product Capacity Market Outlet

EQUATE

PIC 42.5%

Dow 42.5%

BPC 9%

QPIC 6%

PE

EG

825,000

550,000

EMC

MEGlobal

TKOC

PIC 42.5%

Dow 42.5%

BPC 9%

QPIC 6%

EG 600,000 MEGlobal

TKSCKARO 57.5%

Dow 42.5%SM 450,000 EMC

KPPCKARO 100%

PX

HA

BZ

829,000

80,000

393,000

PIC

PIC

Not for commercial sales. Used only

for SM production.

PIC PP Plant(Operated by EQUATE)

PIC 100% PP 140,000 PIC

KARO PP Plant(Operated by EQUATE)

PIC 40%

KNPC 40%

QPIC 20%

All production of KARO is done by KPPC.

EQUATE as Single Operator

• All capacities are metric tons annually.

• Ethylene is only used as feedstock, not for sale.

• KARO: Kuwait Aromatics Company.


• Unipol Polyethylene Process• Leading Glycol Technology• Global Marketing Expertise

• Utility Infrastructure• Dedicated Port

Facilities• Overall Infrastructure

• Supply of Ethane• Plant Infrastructure• Skilled Personnel

Private Sectors to Promote downstream industries

Providing value through Partnership


OUR MISSIONWe provide valued products & services to the world


OUR VISION We are a global leader &

world class producer

of petrochemicals


OUR

VALUES

• Customer Centricity

• Safety & Reliability

• Teamwork & Partnership

• Sustainability

• Continuous Improvement & Progression


Corporate

Strategy


OUR PRODUCTS


As the proud owner and

operator of several world-class

petrochemical units, EQUATE

manages the production of the

highest grades of;

Ethylene, Polyethylene (PE),

Ethylene Glycol (EG),

Polypropylene (PP), Styrene

Monomer (SM), Paraxylene (PX),

Heavy Aromatics (HA) and

Benzene (BZ).


Environmental

Impact


Reduce CO2

emissions at our

facilitiesGOALUtilize internal

capabilities to

create a green

environment

Full compliance

with Environment

Public Authority

(EPA) - Kuwait

Achieve ZERO

loss of primary

containment of

category II and

III incidents

Optimize

development

of projects to

enhance the

environment

Reduce water

consumption

Reduce energy

consumption

and improve

energy

efficiency


OUR AWARDS & ACCREDITATION

www.equate.comEQUATE Petrochemical Company 16

EQUATE Petrochemical Company

RBI - Risk Based Inspection

TEF Conference, 2-Nov-2014

P. Sukumaran,Senior Mechanical Integrity Specialist,API - 510, 570 & 653 Inspector,ASNT ACCP & NDT Level-III-RT,UT,MT,PT,VT.CSWIP 3.2 Senior welding inspector


What is Risk Based Inspection?

Risk Based Inspection

The Risk-Based Inspection methodology, is used to manage the overall risk of a plant by focusing all inspection efforts on the process containment equipments as per their risk ranking levels.

Focusing more on high risk items by using RBI, rather than generic time based, fixed frequency inspection systems.



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Driving Forces for RBI• Increase Safety• Reduce Cost• Maximise Productivity• Deal with Aging Plants• Prevent Catastrophic Failures• From Fixed Inspection Intervals to

Flexible



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• Risk allows people to view potential hazards that simultaneously accounts for both the likelihood and consequences of an event.

• Risk-based inspection will be focused on processing plants and will be phased in over time as each component is thoroughly evaluated and analysed and improvements are made.

• RBI system has been designed using a fully transparent process that has drawn upon the input and expertise of all stakeholders.



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Processing Industry is recognising that benefits may be gained from adopting formal risk-based inspection (RBI) approaches to plant integrity management through improved targeting and scheduling of inspection and maintenance effort.

Is risk-based inspection designed to save money or eliminate inspection program personnel?

Applying risk-based inspection in processing plants will not reduce the amount of money, nor it reduce the number of inspection program personnel. Risk-based inspection is designed to apply the information regularly collected to better predict and prevent catastrophic failure and improve plant reliability.



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RBI provides the basis for making informed decisions oninspection frequency, the extent of inspection, and the mostsuitable type of NDE.

In most processing plants, a large percent of the total unitrisk will be concentrated in a relatively small percent of theequipment items.

These potential high-risk components may require greaterattention, perhaps through a revised inspection plan.

The cost of the increased inspection effort may sometimesbe offset by reducing excessive inspection efforts in the areasidentified as having lower risk.



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Define Role of RBI that supports Plant Site

Strategic Goals

Define RBI Objectives Define RBI Deliverables that supports the Site

Strategic Goals

Define Expected Benefits to Site.

Define KPIs

Get Estimate of RBI Implementation Costs

& Timeframe

Carry out ‘Costs vs. Benefits’ Analysis.

Allocate & Authorize Budget for RBI

Understand RBI and its Benefits

Nominate a Person at site with ‘Single

Point Accountability (SPA)’ for RBI

Implementation

Plant Site RBI Strategy – Management Commitment & Obligations



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Select a robust RBI Methodology and

RBI Service Provider

Finalize RBI Study Team composition &

Draft Project Plan

Management Review and Decision Making

Finalize RBI Implementation

Master Plan

Ensure RBI team studies are completed

as per Master Plan

Integrate RBI process and Study Output into existing site practices

KPI Reviews & Feedback

Set RBI Project Criteria to cover all static items

RBI Implementation Process – Plant Site Tasks



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Item Design DataInspection History

Operational Data /History

RBI Team Study & Updates Report plant Operational Changes

beyond RBI study defined limits

Inspection Dept implement –

RBI Procedures …..Guidelines …..

Ground Rules …..Competency …..

Training …..Audit …..

Optimized Inspection Interval & Inspection Method for each item,

based on its Damage Mechanisms & Risk profile

Inspection Dept implement – Risk Based Inspection plans

RBI Study defined Operational Limits

Manufacturing Dept implement –procedures to manage operational limits &

notify changes

Inspect item to RBI planReport Inspection findings

RBI Technology Implementation – ‘best practice’ Model



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The multi-discipline RBI Study Team

The RBI study must be carried out by a competent multi-discipline team, themembers of which each have suitable qualifications and experience. Normallythe team membership would be covered by four core disciplines:-• RBI team study Facilitator (RBI and Fitness-for-Service assessment

expertise)• Plant Inspection Engineer or Inspection SME• Plant Operations and Process Engineer• Metallurgist (or Corrosion Engineer)

It is imperative that experienced engineers assigned to the RBI study team and representing core disciplines such as inspection, operations and process must be from the plant site. Industry experience clearly shows that without their commitment and input to the team study, RBI cannot be successfully implemented and managed subsequently



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Damage Mechanisms at Plant Units Fuel Ash Corrosion Overheating – plastic collapse

Sulphidic Corrosion Refractory Damage – pyro-sulphates

Naphthenic Acid Corrosion Refractory Damage – acidic

Localised Corrosion Chlorides – SCC

Crevice Corrosion Caustic – SCC

Pitting Corrosion CO-CO2 – SCC

General corrosion Amine – SCC

Shielding Corrosion NH3 – SCC

Galvanic Corrosion Wet H2S – SCC

Wet H2S Corrosion Wet H2S – HIC & Blistering

NH4HS Corrosion Wet H2S – SOHIC

HCl Corrosion 475C Embrittlement

Dew Point Acid Corrosion Creep

Erosion Creep-Fatigue

Erosion Corrosion Fatigue – vibration induced

Corrosion under Insulation (CUI) Fatigue – pressure cycling induced



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THE ROLE OF NDT INSPECTION IN RBI PROCESS

When RBI process is used to justify extended inspectionintervals, in particular for high consequence items, or extendedplant run-length times between turnarounds, the role of NDTinspection and the accuracy required are very critical and keyimportance.

Need a very good NDT management at the plant site, with aproper interface with RBI system.



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assesses the likelihood and consequence of failure for fixed equipment and piping and produces a relative risk ranking for plant equipment

is convenient to use and can be easily learned as the risk model allows qualitative as well as quantitative input

includes a regular updated database with all relevant damage mechanisms, as well as guidance on formulating the consequence of failure

allows the user to appraise or focus/defocus the likelihood and consequence attributes for each component, eg the level of inspection and maintenance and thus mitigate the risk of loss or optimise the current inspection programme

identifies the most likely damage locations in each component and allows inspection to be properly targeted

determines the risk of failure with time which provides the rational basis for establishing the optimum period between major inspections

Advantages of RBI Methodology



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Design and Materials Selection

CorrosionControl

Risk-BasedInspection

Long Term Asset Integrity

Asset integrity management is a balancing process designed to achieve lowest total cost of ownership

Focused Asset Integrity Reviews



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Industry is recognising that benefit may be gained from more informed inspection. Certain sectors of industry, particularly the refining and petrochemicals sectors, are now setting inspection priorities on the basis of the specific risk of failure. Improved targeting and timing of inspections offer industry the potential benefits of:

• Improved management of Health and Safety and other risks of plant failure.

• Timely identification and repair or replacement of deteriorating equipment.

• Cost savings by eliminating ineffective inspection, extending inspection intervals and greater plant availability.



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API 580 Risk-Based InspectionAPI 581 RBI Technology

API RP 580 introduces the principles and presents minimum general guidelines for developing a RBI program for fixedequipment and piping.

API 581 provides quantitative RBI methods to establish an inspection program.

Together, these two documents comprise a widely-recognized standard for industry-accepted RBI practices.



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An RBI assessment may be used to increase or decrease the 10-year inspection limit described in Section 6.4. When used to increase the 10-year limit, RBI assessment shall be reviewed and approved by a pressure vessel engineer and authorized pressure vessel inspector at intervals not to exceed 10 years, or more often if warranted by process, equipment, or consequence changes.

6.2 RISK-BASED INSPECTION

API-510 Pressure Vessel Inspection Code:

API-570 Piping Inspection Code

5.1 RISK-BASED INSPECTION

When the owner/user chooses to conduct a RBI assessment it must include a systematic evaluation of both the likelihood of failure and the associated consequence of failure. The likelihood assessment must be based on all forms of degradation that could reasonably be expected to affect piping circuits in any particular service.


• Risk Based Inspection – caution!!!!


As a word of caution, when it comes to implementing RBIsuccessfully at any plant site, it is the reliability of the RBI technology process used, as well as the comprehensiveness of the

team study method and the people involved in this from the

plant site which deliver the set objectives and goals and not the RBI software”.

The software must not be used to drive the best practices in RBI

technology process or team study method; instead it is a

supporting tool.



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It is critical therefore the senior management at plant site must be committed to support the best practices in RBI and provide the required resources from site and the time allocation for the RBI team study and implementation of the output.

This requires the plant site fully understanding the implications of implementing RBI and most importantly recognising the role it will play in confidently achieving a company’s overall strategic goals.

www.equate.comEQUATE Petrochemical CompanyEQUATE Petrochemical Companywww.equate.com

Thank You

EQUATE

Petrochemical

Company

Documents

Click to edit Master title style - TEF Kuwait RBI/128 Presentation-RBI-RISK BA… · CSWIP 3.2 Senior welding inspector. www .equate .com EQUATE Petrochemical Company 17 What is Risk