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Asset Integrity Management at Memorial University, St. Johns

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New generation of Fitness-for-Service techniques (Level 2 & 3), rule development, ... 15 journal articles and presentations. Four Ph.D. and two M.Eng. ( completed) ... – PowerPoint PPT presentation

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Title: Asset Integrity Management at Memorial University, St. Johns


1
Asset Integrity Management at Memorial
University, St. Johns
  • Faisal Khan
  • Director, Oil Gas Engineering
  • Seshu Adluri
  • Asset Integrity Research

2
Outline
  • Brief account of AIM at Memorial
  • Risk Based Integrity Management
  • Asset Integrity Engineering- Advanced techniques

3
AIM at Memorial Capabilities
  • Asset Integrity Engineering
  • Fitness-for-Service,
  • Structural Mechanical Integrity of Assets
  • Risk Based Integrity Management
  • Risk Based Integrity Modeling
  • Risk based inspection and maintenance planning

4
AIM at Memorial Researchers
Canada Research Chair Dr. R. Seshadri
  • Dr. Seshu Adluri
  • Dr. Claude Daley
  • Dr. A. Swamidas
  • ..
  • Dr. Faisal Khan
  • Dr. M. Haddara
  • Dr. Shawn Kenny
  • .
  • 25 Ph.D. M.Eng.
  • 20 other students

5
AIM at Memorial Collaborators Supporters
  • PRAC
  • Lloyds Register EMEA
  • Hollyrood Power Plant
  • MadRock Solution Inc
  • Agip
  • ExxonMobil
  • Shell
  • TransCanada
  • WorleyParson
  • Canada Research Chairs Program
  • NSERC
  • Terra Nova (Owners Group)
  • CFI (Can. Found. Innovation)
  • MUN
  • Govt. of Newfoundland Lab.
  • BMT, NRC, ACOA, TC, DRDC, SSC, ISSC, ABS, DNV,
    HHI, GL, Chalmers, TKK, ...)

6
Major Funding (since 2002)
  • CRC 1.4 Million
  • PRAC 110,000
  • DRDC Transport Canada - 500,000
  • NSERC Discovery - 600,000
  • CFI Co - 1.25 million
  • Petro-Canada - 250,000
  • MUN 280,000
  • AIF (C-CORE) - 4 million

7
AIM at Memorial Achievements
  • New generation of Fitness-for-Service techniques
    (Level 2 3), rule development, lab testing,
    advanced numerical techniques
  • New Risk Based Integrity Assessment, Inspection
    and Maintenance planning methodology and models
  • Industry implementation of the developed
    techniques and continued interest
  • Doctoral and Masters Graduate students

8
Detailed Presentations of the Two Main Thrusts
  • Risk Based Asset Integrity Management
  • Faisal Khan
  • Fitness-for-ServiceStructural Integrity
  • Seshu Adluri

9
Why Risk Based Approach?
  • Traditional engineering methodology
  • Deterministic
  • Limited quantitative frameworks to assess
    condition relative to common datum or benchmark
  • Difficult decision making
  • Incentive
  • Focus allocation to optimize risk, which is
    function of hazards and its likelihood
  • Efficient and effective decision-making making
  • Help to prioritize resources

10
Risk Based Approach
It Involves Engineering and Management Science
Risk Based Asset Integrity Management
Risk Based Design
Risk Based Integrity Modeling
Risk Based Planning and Management
11
Risk Based Approach
  • Attempts to answer
  • What may go wrong? Hazard
  • How may it go wrong? Mechanism
  • How likely is it to occur? Frequency
  • What would be the impact? Consequences
  • What measures (design, inspection, and
    maintenance) would reduce the likelihood of
    occurrence or impact? Risk Mitigation

12
Industry Success
  • A semi-quantitative model for risk based asset
    integrity management has been developed and
    successfully applied to
  • Thermal power plant
  • Ethylene Oxide plant
  • A new quantitative RBAIM has been developed and
    applied to
  • Process Pipelines
  • Autoclave
  • Separator
  • A new Methodology developed for Risk Based
    Inspection and Maintenance Decision making inline
    with API 580/581 and ASME guidelines

13
Future Direction
  • Application of quantitative RBIAM to Offshore Oil
    and Gas operation
  • Asset Management through Risk based design
  • Integration of safety and integrity in holistic
    asset management framework
  • Integrity Models for rotary equipment integrity
    assessment and maintenance planning
  • Bring facility risk from unit/system level to
    component level
  • Integration of human factor elements to risk
    based integrity management

14
Fitness-for-Service Research
  • Seshu Adluri

15
Asset Integrity Eng. (AIE)
  • Three major phases in AIE
  • Monitoring and testing (NDE)
  • Fitness-for-Service Evaluation
  • Decision making (risk based)
  • In the context of the Oil and Gas Sector,
    Mechanical and Structural Integrity Assessment is
    a multi-disciplinary effort involving
  • process chemistry, process engineering,
    thermo-fluids, mechanics, materials, applied
    physics, and computational technology

16
Asset Integrity Engineering
  • Asset integrity decisions (whether probability
    based or otherwise) need the input regarding
    fitness for service of an existing component
    after some level of damage is suspected or
    detected.
  • This input comes from Design and Analysis groups
    and needs to follow guide lines set out by API or
    other bodies.
  • The procedures must be easy to apply with high
    confidence level.
  • A Canada Research Chair (Dr. Seshadri) and
    several others are actively working in developing
    special techniques for mechanical structural
    integrity

17
Asset Integrity Eng. (AIE)
  • Industry organizes its activities into design,
    construction and post construction phases
  • Post construction phase is further subdivided
    into operations, maintenance and restoration
    activities

18
Asset Integrity Eng. (AIE)
  • Level 1 Conservative Screening criteria that are
    used with a minimum quantity of inspection data
    or information about the component
  • Level 2 Intended for use by facilities or plant
    engineers
  • Level 3 Sophisticated analyses by experts where
    advanced computerized procedures are often
    carried out

19
Asset Integrity Eng. (AIE)
Grouping of Failure modes
  • Category 1 Failures that occur without warning
  • Stringent design limits are placed since failures
    occur without warning
  • Category 2 Failures that occur due to repeated
    application of loads
  • Less stringent limits are placed since damage can
    be detected and inspection/ repairs are possible

20
Res. Development Program
  • A new generation of methods addressing modes of
    failures for components
  • Methods involve advanced concepts (level 3) in
    plasticity and computational methods
  • Develop simplified Level 2 methods for Limit
    Loads and Fitness for Service parameters.

21
Res. Development Program
  • A major thrust is the assessment of
    fitness-for-service of components
  • Pressure vessels
  • Piping,
  • Other equipment,
  • The defects include
  • Corrosion (single and multiple sites)
  • Thermal hotspots
  • Fracture and fatigue, ..

22
Res. Development Program
  • Education and training of personnel
  • 15 journal articles and presentations
  • Four Ph.D. and two M.Eng. (completed)
  • Four Ph.D. (current)
  • Several Industry groups in Canada, UK and the US
    have continued interest in the work
  • Interdisciplinary R D opportunities

23
Advanced Numerical Tech.
  • Advanced computational mechanics for Level 3
    verification
  • Simplified concepts for interaction effects of
    defects in components (Level 2 methods)
  • Shell and plate theory use for deriving simple
    formulas for decay lengths, etc.
  • Advanced computational mechanics for Level 3
    verification
  • Simplified concepts for interaction effects of
    defects in components (Level 2 methods)
  • Shell and plate theory use for deriving simple
    formulas for decay lengths, etc.

24
Civil Eng. Installations
  • Storage Tanks Seismic demand mitigation
  • Crack propagation
  • Vibration techniques
  • Steel, wood, and concrete structures
  • NDE

25
Ship Structures Research
ASPECTS DIRECTIONS
  • Rule Development (IMO, IACS, SSC, TC)
  • Arctic Shipping (LNG, Icebreakers, ...)
  • Lab Experiments (frame, grillage, ..impact)
  • Analytical Modeling (Limit states, energy
    methods)
  • Numerical Modeling (ANSYS, LS-Dyna, cluster
    computer)
  • Research Directions (limit states design, hybrid
    construction, sensors, loads, safety, aged
    structures, economics

26

Ship Structures Research
Prof. Claude Daley, Director BMT Ocean and
Arctic Structures Research Program
27
To sum-up
  • Two main thrusts
  • Structural Mechanical Integrity of Assets
    (fitness-for-service)
  • Risk based Integrity Management
  • Seven faculty over 25 grad students
  • Total funding 5 million ()

28
Questions?
29
Qualitative Approach
  • Qualitative Hazard Low, Medium, High
  • Qualitative Probability Low, Medium, High
  • Risk matrix

30
Semi Quantitative Approach
  • Hazard Estimated using simple empirical model
    based on the characteristics of the system
  • Failure Probability Estimated using model as
    well as field observation
  • Risk is estimated as HazardFailure probability
  • Inspection interval is decided based on the Risk
    factor

31
Quantitative Approach
  • Hazard Estimated using detailed source model
    based on the characteristics of the system
  • Failure Probability Estimated using
    reliability/statistical model as well as field
    observation
  • Inspection interval is decided based on the Risk
    factor

32
Divide the system into independent (process)
components
Select one component and identify degradation
mechanisms
Model component failure using Gamma Stochastic
process
Estimate the consequence using cost data for
inspection, failure, and replacement
Develop a prior for each degradation mechanism
Obtain Past Inspection results for the unit under
investigation
Determine Failure probability using a Posterior
and past inspection results
Risk Calculations
RBIM Methodology
Estimate optimal inspection and replacement
intervals
Have all components been considered?
Develop inspection plan for the integrity of the
process system
33
AIM at Memorial Major Funding (since 2002)
  • CRC 1.4 Million
  • PRAC 110,000
  • DRDC Transport Canada - 500,000
  • NSERC Discovery - 600,000
  • CFI Co - 1.25 million
  • Petro-Canada - 250,000
  • MUN 280,000
  • AIF (C-CORE) - 4 million

34
Risk Based Integrity Management
Consider one component
1
Identify degradation mechanism
Estimate failure probability/frequency
Estimate failure consequences
Estimate risk for the degradation mechanism
All degradation mechanism Assessed ?
No
Yes
Estimate Aggregate risk for the component
A
35
RBIM Methodology
A
1
Is Risk within acceptable limit ?
Yes
No
Develop inspection plan based on Past inspection
result and risk profile
Are all units studied?
No
Yes
Units having acceptable risk profile Revise
inspection plan based on recent inspection
results and risk profile
36
Risk Based Design
  • Optimization and risk mitigation process
  • Data, model uncertainty
  • Technical, economic, environmental and safety
    targets
  • Risk evaluation followed by design action
  • Probabilistic methods for
  • Process failure
  • Explosion and fire modeling
  • Environmental load effects
  • Structural strength
  • Collision and accidental loads

37
Risk Based Integrity Modeling
  • It aims to model integrity and decide inspection
    and maintenance tasks to satisfy requirements for
    safe operation at minimum cost
  • Three main approaches
  • Qualitative
  • Semi Quantitative
  • Quantitative

38
Risk Based Planning and Decision Making
  • Aggregative Hierarchical Risk Based Decision
    Making (AHR)
  • Logical representation, easy to follow and
    assessed
  • Relative importance of different degradation
    mechanism
  • Contribution as per their active participation
  • Easy to upgrade/revise the risk profile
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