: , Conference 2013

LNG plant R&D center

LNG
Development of Smart RBI program
for LNG Plant System

BEXCO Busan, 18 January 2013

Ph.D. Song-Chun Choi ()

Institute of Gas safety R&D

Korea Gas Safety Corporation

. Research background and

purposes
. Research plan
. Research Promotion System on this Project
The research results
.
. The research goal
. Overview on the Smart RBI implementation of
LNG plant system

1
 1. Background and Purposes of this Project
- Natural gas from gas wells is delivered by pipeline or distribution mains to the liquefaction plant
where it is changed into a liquid.
- The process equipment necessary to make the liquid, the plant also contains equipment to treat
or prepare the gas prior to liquefaction and tankage for storage of the LNG.

- Risk assessment and safety systems are critical to all gas plant. Therefore, the goal of this project is
how to use known risk assessment codes (API 581 581,, ISO etc) to address such safety analysis require
etc
ments for risk management in the LNG plant
plant..
terminal
treatment liquefaction
wells
LNG carrier

Gas wells Liquid product Transportation Storage

Gas wells : confirm of hazard factor in wells

Treatment : evaluation of piping corrosion , Material
degradation and development of the safety index
Liquid product : Risk analysis of parent metal /welding
point from ultra low-temperature materials ,
unification safety management system
Storage : Safety assessment mode in gas plant

Cold Box 2

Liquefaction Plant Block Flow Process Facilities

Institute of Gas Safety R&D

2

Institute of Gas Safety R&D

Internet based network Risk Assessment System for LNG Plant

ASP Application
Supply Assessment Results
Risk Analysis SW
Inspection Scheduling SW Data Degradation Information
Repair Scheduling SW Application
Warehouse System for Materials
Cost-Benefit Analysis SW W S
Server
Safety Integrity Level (SIL) S/W Server Inspection Monitoring Data
Based on Web
PHA S/W
Financial Risk Analysis S/W
Internet
Based
Network
System
Decision Making Tool System
Management Information System Management
GUI Application & User Interface Server
Web
W b Base
B

Engineer & Expert Judgment

Basic Engineering
Virtual Reality Based
on WEB System

3
 2. Research plan [2008. 11 ~ 2014. 6]
1st Year 2nd year 3rd 4th 5th(2012~2013) 6th(2014.6.17)
Standard/code Material DB/ Risk assessment Safety management
Code, data survey Inspection Planning
analysis System design development Guide development

ISO, BS, API ect. check the

main equipment Reliability Review
Inspection point
Survey
S

Review
R i Main
M i material
t i l
and guideline
Pre-reserch survey
Compare of Risk
Manual Writing
asessement technical
Check the Survey of Non destructive Design of material
Benchmark ing of LNG plant DB destructive
Research goals
Design of data management
Risk check of reuipment , In LNG plant system safety index design
Design

plant module

Design of NDE signal Design of non-destructive

Development of Safety management
image viewer history, result
Frameworks in Integrated system
global code
Development of Inspection
Planning module
Development of NDE signal
Development of
Development

analysis module
LNG Plant NDE DB
Defined of RISK
in LNG plant Development of Management KGS -RBIM
tool of LNG NDE Reliability confirm For LNG plant
NDE system
Development of
Risk assessment
Development LNG RBI s/w
Web-based Platform

RAMS(Reliability, Availability, Maintainability and Safety)

Intrinsic safety Training
Process design Organization
Equipment design Procedure
Plan layout Ergonomics
Maintainability Design

Written procedure
SAFETY Responsibility & authority
Incident investigation Safety policy
Engineering reliability
Meetings Written procedure
Audits and reviews Emergency planing
Permits to work
Human reliability in the operations Internal audits

Process management (control,

communication, information)

Organization, Management System

SOCIAL ENVIRONMENT
(laws, economic pressure, public opinion)
Figure. Pyramid showing how different aspects of a management system affect the achievement
of a safety operation(based on Jessen, T. K. Systems for good management practices
in quantified risk analysis. Process Safety Prog., 12(3), 137) 2
5

4
 1st Stage(2008 ~2009) 2nd Stage 3rd Stage
(2010~2011) (2012~2014)

Data
Component Pakage RAM based
Application
Server Warehouse
Server
Interface Internet
Based
Network

Application Program
System
Materials information
Management
Materials DB Equipment Server
component
components
Based on Risk Assessment
Codes

Leak model Scenario component

Plant design
GUI + VR

mming
Application
A li i

Consequence model
Database Biz Logic

23

virtual
plant
program
cording

SKKU
KICT (Sub joint)
(Core
Institute)
Institute
Gas Safety JSPS 180th
RBM
R&D Committee
in Japan
(Joint)

5
4. The research results

ISO(International Standardization Organization)

ISO/IEC 15504-4:2004 Process assessment
ISO/TS 16732:2005 Guidance on fire risk assessment
ISO 17776:2000 Guidelines on tools and techniquesq
for hazard identification and risk assessment
ISO 15615:2002 Safety requirements in high-pressure devices
ISO 21789:2009 Gas turbine applications - Safety
ISO 19706:2007 Guidelines for assessing the fire threat to people

BS(British Standard)
BS 08/30183974DC, 2008 BS EN 31010. Risk management.
BS EN12308:1998 Installations and equipment for LNG
LNG.
BS EN710:1998 Safety requirements for foundry molding and
coremaking machinery and plant and associated equipment
BS ENISO17666:2003 Space systems. Risk management
BS PDISO/IECGUIDE73:2002 Risk management. Vocabulary.
Guidelines for use in standards

4. The research results

API Code and ANSI ect.

ect.
ANSI/AAMI14971:2000 Risk management
- Part 1 : Application of risk management

API RP 581, 2008 Risk-Based Inspection Technology, Second Edition

IEEE 16085 : 2004(1540-2001), 2006

Software Life Cycle Processes-Risk Management

CAN/CSA Z276-01, 2003 Liquefied Natural Gas(LNG)

- Production, Storage and Handling

CSAZ276-07, 2007 Liquefied Natural Gas(LNG)

- Production, Storage, and Handling, Includes Update

LNG Preventive Maintenance Guide,1984(AGA)

Introduction to LNG for Personnel Safety,1986(AGA) ect.

6
4. The research results of first year

Identify Risk Areas

- Experience and Lessons Learnt from past and similar projects
- Logical analysis : Criticality Rating, QRA, RBI, HSE etc.
- Project Environment

Inlet Facilities
- Uncertainty of feed stock property
- Slug design basis
- Insufficient separation of gas & liquid
- Fouling

Acid Gas Treatment

- Foaming
- Vibration d
due
e to ttwo
o phase flo
flow
- Sudden vaporization

Dehydration & Mercury Removal

- Batch process
- Replacement of Molecular sieve
- Disposal of activated carbon

Institute of Gas Safety R&D

4. The research results of first year

Liquefaction
- High temperature around gas turbine
- Large bore piping & piping support
- Vibration of large rotating machine
- Large liquid inventory
- Cracking of cryogenic component

Storage & Loading

- Jetty head : Connect & disconnect operation
- Spillage
- Maneuvering operation
- Leakage from LNG Tank

Institute of Gas Safety R&D

7
 Damage, Risk
Risk,, Hazard

reason,
Cause,
Factor?
Risk
Ri k can be formally defined
as the potential of loss(e.g.,
material, human, or
environment, losses) resulting
from exposure to a hazard.

Institute of Gas Safety R&D

()

Piping systems
Tanks
Reactors
Drums
Pumps/Comp.

H/E
/
Towers
Heaters/Boilers
Others/Unknown
0 5 10 15 20 25 30 35


Institute of Gas Safety R&D

8
 What is the definition of ~~~ ?
Hazard : is considered as a source of danger
danger
but the concept does not contain any notion
of the likelihood with which that danger
will actually impact on people or
on the environment.

Risk : a set of scenarios Si each of which has

a probability Pi and a consequences Xi.
R = < Si , Pi , Xi > i=1, 2, , n,
Si = () What can go wrong that could lead to an outcome of hazard exposure
Pi = () How likely is it to happen ?
Xi = () Given that it occurs, what are the consequences ?

Kaplan S. and Garrick, B.J., On the quantitative definition of risk

Risk Analysis, 1, 11-27, 1981.

Institute of Gas Safety R&D

What is the definition of

~~~: The?probability that an item will perform
Reliability
a required function, under stated conditions,
for a stated period of time.
~~~ The probability of non-
non-failure in given period.

Maintainability : The probability that a failed item will be

restored to operational effectiveness within
a given period of time when the repair action
is performed in accordance with prescribed
procedures.
~~~ The probability of repair in a given time.

David J. Smith Reliability, Maintainability and Risk Practical methods for

engineers, sixth edition, 2001, Butterworth-Heinemann.

Institute of Gas Safety R&D

9
 Risk Ranking of Equipment

% of Total Risk Vs % of Equipment Items

Plant Unit, ~500 Total Items
100%
90%
% of Total Risk

80%
70%
Most of the total
60%
50% inspectable plant risk
~80% of all
40% is concentrated in a
equipment
30% small percentageitems
of yielding
20% the equipment items
~20% of total
10%
~20% of 0% risk
equipment 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
items yielding % of Equipment
~80% of total
risk

Institute of Gas Safety R&D

What is the definition of RISK ?

RISK = LIKELIHOOD OF EVENT X CONSEQUENCE

LoF CoF
Generic Failure Injury ($)
X Damage Factor
Frequency DF Env. clean up ($)
GFF
Item repair ($)
Damage Inspection
p Adjacent repairs ($)
A
Age Mechanism(s) Effectiveness
& Rates Downtime ($)
TOTAL ($)

Institute of Gas Safety R&D

10
 Managing Risk
a. Human error
b. Natural disasters
c. External events(e.g., collisions or falling objects)
d. Secondary effects from nearby units
e. Deliberate acts(e.g., sabotage)
f. Fundamental limitations of the inspection method
g. Design
D i error
Risk using RBI h. Previous unknown mechanisms of deterioration

Risk with a typical

Risk inspection program

Uninspectable risk

Inspection Activity

Institute of Gas Safety R&D

RBI Program for In-

In-Service Equipment
Plant Database

Risk Based Inspection

Inspection Planning
QIP
(Quality
Improvement Inspection Result
Process)

Fitness For Service

Inspection Updating

System Audit

Institute of Gas Safety R&D

11
 Plant Database
User Level

Qualitative RBI process Semi-

Semi -Quantitative RBI Quantitative RBI process
process
Likelihood Category Release Calculation Inventory Group

Damage Consequence Release calculation

Likelihood Analysis
Technical Module Subfactor
Health Consequence
Inspection Effectiveness
Likelihood Analysis
Technical Module Subfactor
Equipment Modification Factor
Management system Evaluation

Flammable Area Equipment Damage Cost

Toxic Area Business Interruption

Potential Injury Cost

Environmental Cleanup

Risk Ranking Matrix
Risk Area
Risk Ranking Matrix
Financial Risks
Inspection Planning
Inspection Planning
22
Institute of Gas Safety R&D

Results of research(2008.11~2012.12)
Presentation Layer Algorism

Smart-RBI Business Logic

LNG-RBI
LNG RBI Middle Ware NDE monitoring system
Joint to (VR
VR System)
System and Inspection Planning

Modules of Risk Materials DB for Critical

Assessment of Components
LNG Facilities
Command Equipment Data

Data Broker

SAP Data Provider

External ERP System (SAP, Maximo. Etc)

Institute of Gas Safety R&D

12
Example of Presentation Layer with Risk
Assessment Model by using VR

Institute of Gas Safety R&D

Qualitative, quantitative,
ISO, BS, ANSI act. (Confirm of
semi-quantitative
Risk analysis method
Survey hazard factor
API 581 (Risk based inspection)
feedback in LNG plant Selection of
the Risk
assessment
method for
LNG plant
Survey of NDE tech. from System framework
the international and local Detailed Design of RBI s/w
codes algorism

Reliability Verification

13
 6. Possibility of implementation

IT Solution RBM (Risk

(Risk--Based Management) Based
on ERP & VR System

g
Monitoring
Condition
Monitoring System
Trouble
Monitoring
Virtual Reality

NDE RBM RBI

Links to Risk Based
Integrity
each module Inspection
Inspection
Decision Making scheduling and
Intelligent
Tool management
Diagnosis

Material DB LNG plant blazing information system

Degradation
Information
System
for Materials Currently Available PM Package
- SAP, MAXIMO, MP5, MLS, IFS
Application of Engineering Knowledge Based
LNG Plant Management System

10

Recent Research for the Governmental Project

[2008. 11 ~ 2012. 12] - Smart RBI for LNG Plant -
LNG Plant Management Program
LNG Plant Management System(LPMS)

Conceptual design of LPMS

LNG Plant Design Management System(LPDMS)
LNG Plant Operation & Management System(LPOMS)

<Concept and main window of LPMS>

28

14
 Main window

Linked in P&ID

29

Material Balance Table (artificial neural network)

2

3
1

13

15
Quantitative RBI (API RP 581)

Equipment Data Likelihood Analysis Consequence Analysis Financial Risk

Key Data for Damage Mechanism Assessment

Equipment Fabrication Data

Material specification (including heat treatment, chemistry,
strength level
level, etc
etc.))
Material production flaws: laps, laminations, voids, segregation,
shrinks, cracks
Welding related flaws: lack of penetration and fusion, delayed
hydrogen cracking, slag, undercut, porosity
Construction related flaws: out-of-roundness, forming cracks
Heat treatment related flaws or embrittlement: reheat cracking,
cracking
sensitization, sigma phase embrittlement, 885/430
embrittlement

16
Key Data for Damage Mechanism Assessment

Process Operations Data

Service exposure, normal and upset, typical data includes
Pressure, temperature (normal, max/min, design)
Corrosive concentration (S, etc.)
Existence of trace amounts of contaminants (CN, Hg)
Carryover, leaking valves, and in particular, human factors
Mitigating factors (coking, crack closure, residual stresses,
coatings, chemical additives, water wash)
Timing: How often and how quickly does damage potentially
occur? Is it continuous or episodic? (e.g., process cycle times,
unit rate fluctuations, unit run length effects)

Key Data for Damage Mechanism Assessment

Equipment In-
In-Service Inspection Data
Morphology and rate of known/existing damage
Previous inspections techniques Effectiveness at targeting
the particular mechanisms (pits vs. Cracks vs. general
thinning)
Supplementary monitoring or other warning system data
(probes)

17
Information on Damage Mechanisms Overview

Professional / Technical Societies

American Petroleum Institute (API)
g
National Association of Corrosion Engineers ((NACE))
Welding Research Council (WRC)
American Society of Metals (ASM)
American Society of Mechanical Engineers (ASME)
Company Guidelines and internal publications such as research and
development reports
General Publications (e.g. AICHE, Hydrocarbon Processing, Oil & Gas
Journal, etc.)
Material Properties Councils (MPC) Joint Industry Projects (JIPs); MPE
FFS, MPC HIC, MPC HPV, MPC Omega, MPC HEP
Personal Experience

Information on Damage Mechanisms in API

API Publications
API 571 Damage Mechanisms
API 572 Inspection of Pressure Vessels
API 573 Inspection of Fired Heaters and Boilers
API 574 Inspection Piping Systems
API 575 Inspection of Atmospheric and Low Pressure Storage Tanks
API 581 RBI Base Resource
API 751 Sate Operations of HF Units
API 939A Wet H2S Cracking
API 939C Sulfidic Corrosion in Refineries
API 941 Hydrogen Attack
API 945 Environmental Cracking in Amine Units
Guide for Inspection of Refinery Equipment, Chapter 2 (old)
API Meeting Summaries
CRE Subcommittee on Corrosion & Materials and/or Inspection
Operating Practices Presentations

18
Information on Damage Mechanisms in NACE

STG 34 Minutes (RefinCor)

NACE Annual Corrosion Papers
Materials Performance (NACE Publications) Articles
Standards and Publications
Pub 34101 Refinery Injection and Precess Mix Points
RP 0170 Polythionic Stress Corrosion Cracking (SCC)
RP 0296 Wet H2S Inspection
RP 0205/0294/0391 H2SO4 Handling
SP 0403 Caustic SCC
SP 0472 SCC of Carbon steel in Refineries
SP 0590 Deaerator SCC

Smart RBI Program Result for Damage Factor module(RBI)

based on API RP 581

38

19
 LNG Plant Operation & Management System

Qualitative, Quantitative Interface

Inspection Planning

API RP 580, 581, 571,

ASME Document

39

LNG Plant Inspection Management System

Inspection Planning with
Target Risk
for Web based Smart
Smart--RBI

Target Risk

Target Date.
Inspection
Performed
Next Inspection Date
2014 09
2014. 09. 12

40

20
 NDE Reliability System
Probability of Detection for UT Equation of POD
PD ( s ) s( s ) ds
s
(s ) : The rate of detection
POD Grade (s ) : probability density function
1 Less than 0.6
2 0.6~0.7
Inspection effectiveness(API581)
3 0.7~0.75
4 0.75~0.82
Inspection Eff
Inspection
5 Over 0.82
ectiveness Cat NDE Inspection Example
Category
egory

Shear wave ultrasonic testing of 25-

Highly 100% of weld/cold bend; or Radiogr
A

Reliability Matrix Effective aphic testing of 50-100% of weld/co

ld bends
Inspection Method Inspection Effectiveness
Shear wave ultrasonic testing of 10-
Base on API 581 Code
RT UT MT U ll
Usually 24% off weld/cold
ld/ ld bbend;
d or R
Radiogra
di
Five Effectiveness B
categories Effective phic testing of 25-49% of weld/cold
ECT PT AE bends
Damage type
NDE Shear wave ultrasonic testing of less
Inspection
Diagnosis Fairly than 10% of weld/cold bend; or Rad
POD Reliability A C
Inspection Effectiveness

Effective iographic testing of less than 25% of

General Examination B
System Requirements weld/cold bends
C Low
Procedure Requirements Medium
Poorly
D Medium D Visual inspection for leaks
Qualification High
Effective
E
Requirements High

1 2 3 4 5
Probability of detection(POD)
E Ineffective No inspection

41

NDE Data Management System

NDE Diagnosis Record NDE Diagnosis Signal
Equipment ID
Equipment Type

P&ID No.
Inspection date Network

Inspector

Result

Equipment Inspection Result of Damage NDE Diagnosis

Equipment ID P&ID No. PFD No. Inspector
Type date Inspection type Reliability Signal

LNG-E-XX1 Steel pipe(2) E6358-XX1 E6001-XX1 2010/11/15 WJ KIM PASS *** HIGH DS101
LNG-E-XX2 Steel pipe(6) E6358-XX2 E6001-XX2 2010/11/16 WJ KIM FAIL *** MIDDLE DS102
LNG-E-XX3 Steel pipe(18) E6358-XX3 E6001-XX3 2010/11/17 WJ KIM REPAIR *** LOW DS103
42

21
 20

ERP FILE Production

Server Server Server

Virtual LNG Plant Prototype

PDIS(Plant Data Information System

PDIS
RDBMS

Admin.
User Edit
Risk Assessment Design(3D)
RBI Server Documentation User
Server
Procurement
DB Web Admin. Inspection User
Server Server User User Civil/Tech.
User

Admin Assistance
Admin.
Maintenance User User
Scanner Printer Plotter RCM/ CMMS
Server RTDB

RTDB : Real-Time DataBase

RDBMS : Relational DataBase Management System
DCS : Distributed Control System
PLC : Programmable Logic Controller
CMMS: Computerized Maintenance Management System

DCS
DCS PLC
PLC Analyzer
Analyzer

21

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