Contents · representative material described in API 581 code. In petrochemical plant, however, there are relatively In petrochemical plant, however, there are relatively abundant

1

LNG LNG 플랜트의플랜트의 RBI (RiskRBI (Risk--Based Inspection) Based Inspection) 방법론방법론

하하 제제 창창

제1회 대한민국 산업자산관리 Conference 2008

하하 제제 창창

JeJe--Chang Ha*Chang Ha* (Ph.D)

11 Dec. 2009

가스안전연구원가스안전연구원(Institute of Gas Safety R&D)(Institute of Gas Safety R&D)

한국가스안전공사한국가스안전공사(KGS)(KGS)

ⅠⅠ IntroductionIntroduction

ContentsContentsContentsContents

ⅢⅢ Development of KGS-RBITM and RBM program for LNG PlantsDevelopment of KGS-RBITM and RBM program for LNG Plants

ⅡⅡ What is RBI (Risk-Based Inspection) and RBM(Risk-Based Management) ?What is RBI (Risk-Based Inspection) and RBM(Risk-Based Management) ?

ⅢⅢ Development of KGS RBI and RBM program for LNG PlantsDevelopment of KGS RBI and RBM program for LNG Plants

ⅣⅣApplication of KGS-RBITM program on the BTX System in Petrochemical PlantApplication of KGS-RBITM program on the BTX System in Petrochemical Plant

ⅤⅤ Results and DiscussionResults and Discussion

ⅥⅥ ConclusionConclusion

Ⅰ. Introduction (1)Ⅰ. Introduction (1)

• Many refinery and petrochemical plants are being operated in Korea since 1968.

• Thus continuous operation while sustaining their integrity through good maintenance

practices becomes an important issue.

• Recently, regulatory bodies (KGS, etc.) quite often encourage to adopt risk-based

inspection (RBI) and management programs because they can enhance safety

simultaneously with deregulation in Korea.

• Therefore, risk assessment for each plant and estimation of an inspecion interval are

not defined forcibly by the government but aim at establishing autonomous safety

( )management and rational inspection systems; to do this, Risk-Based Inspection (RBI)

recently highlighted throughout the world is becoming the most viable alternative in

practice.

Table 1. List of refinery and petrochemical plants in Korea

The examples of petrochemical facilitiesIn Korea

CategoryCategory RefineryRefinery PetrochemicalPetrochemical TotalTotal

Number of Number of PlantsPlants

6363 442442 505505

Number of Number of CompaniesCompanies

44 103103 108108

* Fertilizer and steel plants are included in * Fertilizer and steel plants are included in petrochemical plantspetrochemical plants


• The possibilities of accidents owing to aging equipment have increased in

refinery and petrochemical industries.

• Unanticipated accidents may cause significant social and economic losses.

• To reduce the possibility of such incidents, maintenance activities such as

inspection, repair or replacement of aging equipment has to be carried out.

• Thus, a risk-based inspection (RBI) methodology for refinery and

Half of knownHalf of known loss loss causes can be influenced causes can be influenced by inspectionby inspection

Half of knownHalf of known loss loss causes can be influenced causes can be influenced by inspectionby inspection

petrochemical plants should be established by the regulatory bodies.

Unknown18%

Process Upset8%

Natural Hazard6%

Design Error4% Sabotage/Aroson

3%

Operating Error20% Mechanical

Failure41%

The cause classification of major industrial accidents

From M&M Protection ConsultantsFrom M&M Protection Consultants

Piping systems

Tanks

Reactors

-Abroad (1992-2001) From NBBI Annual Report

Equipment Failure Category in Hydrocarbon-Chemical IndustryEquipment Failure Category in Hydrocarbon-Chemical Industry

Ove 80% of the Eq ipment


Drums

Pumps/Comp.

H/E

Towers

Heaters/Boilers

Others/Unknown

00 2020 2525 3030 35351515101055Number of Failures

Over 80% of the Equipment- Caused by the Failure to Pressurized equipment

Accident of LP Gas Station nearby Seoul in Korea, 1998.09.11

2

At Petrochemical Plant in Korea

Accident in Steam BoilerAccident in Steam BoilerSkikda, Algiers, Jan. 20, 2004Skikda, Algiers, Jan. 20, 2004

Ⅰ. Accident of Refinery Plant caused by HTHA in Korea

Fatigue and HTHAwith

Design Error

23:11, Oct. 20, 2003, hydrogen piping of Refinery Plants in Korea

Extinguishing after Accident at Hydrogen Pipeline

Ⅰ. Accident of Refinery Plant caused by HTHA in Korea(1999.05.13)

When you cannot measuremeasure it,when you cannot expressexpress it in numbersin numbers,your knowledge is of a meager and

Lord Kelvin


your knowledge is of a meager and unsatisfactory kind.

Data GatheringData GatheringReview and IntegrationReview and Integration

Criteria Criteria Risk AssessmentRisk Assessment

All Threats EvaluatedAll Threats Evaluated

ThreatThreatEvaluationEvaluation

ThreatThreatEvaluationEvaluation

Plant Integrity Management Plan ProcessPlant Integrity Management Plan Process

All Threats EvaluatedAll Threats Evaluated

Integrity Management PlanIntegrity Management Plan

Tool Selection And InspectionTool Selection And Inspection

Mitigation(Repair, Prevention)Mitigation(Repair, Prevention)DetermineDetermine

ReRe--InspectionInspectionIntervalInterval

DetermineDetermineReRe--InspectionInspection

IntervalInterval

ManagingManagingChangeChange

ManagingManagingChangeChange

3

Integrity Management PlanIntegrity Management Plan

• Leadership & Management CommitmentLeadership & Management Commitment• Asset Integrity• Management of Change• Risk AssessmentRisk Assessment

Protocol ElementsProtocol Elements

• Safe work Practices, Standards & Procedures• Information Records and Data ManagementInformation Records and Data Management• Training & Competence• Corporate Memory Process• Contractors & Procurement• Investigation & AuditInvestigation & Audit• Specific Programs & Equipment Types• Employee Behavior & CultureEmployee Behavior & Culture

RAMS(Reliability, Availability, Maintainability and Safety)RAMS(Reliability, Availability, Maintainability and Safety)

SAFETYSAFETYEngineering reliability

Book Name : Risk Analysis and Reduction in the Chemical Process IndustryAuthor : J.M. Santamaria Ramiro & P.A. Brana Aisa, Page : 285

Intrinsic safety Process design Equipment design Plan layout Maintainability

Written procedure Incident investigation Meetings Audits and reviews

Training Organization Procedure Ergonomics Design

Responsibility & authority Safety policy Written procedure Emergency planingHuman reliability in the operations

Process management (control, communication, information)

Organization, Management System

SOCIAL ENVIRONMENTSOCIAL ENVIRONMENT(laws, economic pressure, public opinion)

Figure. Pyramid showing how different aspects of a management system affect the achievementof a safety operation(based on “Jessen, T. K. “Systems for good management practicesin quantified risk analysis.” Process Safety Prog., 12(3), 137)

Audits and reviews Permits to work

Emergency planing Internal audits

Integration of Several Work Processes Leading ToIntegration of Several Work Processes Leading ToHigh Levels of Asset IntegrityHigh Levels of Asset Integrity

Integration of Several Work Processes Leading ToIntegration of Several Work Processes Leading ToHigh Levels of Asset IntegrityHigh Levels of Asset Integrity

Long Term Asset Integrity

FF dd AA tt II t itt it RR ii

Ⅱ. Integrity Management Process in Shell Global Solution –

in USA (Shell)

Ⅱ. Integrity Management Process in Shell Global Solution –

in USA (Shell)

Design and Materials Selection Corrosion

Control & IOW’sRisk-BasedInspection

Asset Integrity Management is a balancing process designed to achieve lowest total cost of ownership

FFocused ocused AAsset sset IIntegrity ntegrity RReviewseviews

Case Study Case Study –– Reference of RIMAP Workshop(28 June, 2005, Poland)Reference of RIMAP Workshop(28 June, 2005, Poland)Case Study Case Study –– Reference of RIMAP Workshop(28 June, 2005, Poland)Reference of RIMAP Workshop(28 June, 2005, Poland)

LIKELIHOOD OF EVENTLoF

X CONSEQUENCECoF

=RISK

Generic Failure Damage Factor Injury ($)X

What is the definition of RISK ?

FrequencyGFF

gDF

AgeDamage

Mechanism(s)& Rates

InspectionEffectiveness Downtime ($)

Item repair ($)

Env. clean up ($)

Adjacent repairs ($)

TOTAL ($)

X

Steps of a Fully Integrated RBI system for InSteps of a Fully Integrated RBI system for In--Service (Refinery & Petrochemical)Service (Refinery & Petrochemical)

Plant Database

Risk Based Inspection

Inspection Planning

I i R l

QIP(Quality

Fitness For Service

Inspection Result

Inspection Updating

System Audit

(Quality Improvement

Process)

Consequence Consequence factorfactor will carry more weight in determine total risk than will the Likelihood component

Consequence Consequence factorfactor will carry more weight in determine total risk than will the Likelihood component

From the API 581 Based Resource Document, 2000

4

Overview on Development ofOverview on Development ofKGSKGS RBIRBITMTM d RBMd RBMKGSKGS--RBIRBITM TM and RBMand RBM

Qualitative ApproachQualitative Approach(APPENDIX A)

Likelihood Category

Damage Consequence

Plant DatabasePlant Database

User Level

SemiSemi--Quantitative ApproachQuantitative Approach(APPENDIX B)

Release Calculation

Likelihood AnalysisTechnical Module Subfactor

Inspection Effectiveness

Quantitative ApproachQuantitative Approach(APPENDIX C)Inventory Group

Release calculation

Likelihood AnalysisLikelihood AnalysisTechnical Module Subfactor

E i t M difi ti F t

Structure of Structure of KGSKGS--RBIRBITMTM S/WS/W

Health Consequence

Inspection Effectiveness

Flammable Area

Toxic Area

Equipment Modification FactorManagement system Evaluation

Equipment Damage Cost

Business Interruption

Potential Injury Cost

Environmental Cleanup

Risk Ranking Matrix Risk Ranking MatrixInspection Planning

Consequence Analysis

Release Mass Factor

Risk AreaFinancial Risks

Inspection Planning

Consequence Analysis

Release Mass Factor+

Consequence Area, Environmental, Economical

Consequence

Qualitative Approach to Qualitative Approach to RBI RBI

Consequence factor will carry more weight in determine total risk than will the Likelihood component

Qualitative FiveQualitative Five--byby--Five Risk MatrixFive Risk MatrixQualitative FiveQualitative Five--byby--Five Risk MatrixFive Risk Matrix

GORY

GORY

5

4

HighMedium High

CONSEQUENCE CATEGORYCONSEQUENCE CATEGORY

LIK

ELIHOOD C

ATEG

LIK

ELIHOOD C

ATEG

A B C D E

4

3

2

1

MediumLow

Qualitative Qualitative RBIRBI FlowchartFlowchartStart Plant Database

Equipment Factor

Damage Factor

Process FactorDetermine Likelihood Category

Inspection Factor

Condition Factor

MechanicalDesign Factor

Chemical Factor

Quantity Factor

State Factor

Determine Damage Consequence Category

Autoignition FactorPressure Factor

Credit Factor

22

Toxic Quantity Factor

Credit Factor Determine Health Consequence Category Dispersibility

Factor

Population Factor

Choose the highest from the Two Consequence

Category

Convert to a Risk MatrixConvert to a Risk Matrix using Likelihood Category and Consequence Category

Quantitative Quantitative RBI RBI Flowchart Flowchart -- LkelihoodLkelihood AnalysisAnalysis

Technical Module Subfactor

Universal SubfactorUniversal Subfactor

Damage RateInspection Effectiveness

Plant ConditionCold Weather

Equipment Modification FactorXGeneric Failure FrequencyManagement SystemsEvaluation Factor

X

101 가지평가를통해서 0.1에서 10까지값을가짐

Mechanical Subfactor

Process Subfactor

Cold WeatherSeismic Activity

Equipment ComplexityConstruction CodeLife CycleSafety FactorsVibration Monitoring

ContinuityStabilityRelief Valves

Quantitative Quantitative RBI RBI FlowchartFlowchart –– ConsequenceConsequence

AnalysisAnalysisRelease RateRelease Rate

Fluid Properties:In Equipment andAt Ambient Condition

Range of Hole Sizes0.25”, 1”, 4”, Rupture

CONTINUOUSUse flow rateCONTINUOUSUse flow rate

DETERMINEFINAL PHASE

Total Mass AvailableFor Release

DETERMINETYPE

INSTANTANEOUSUse total massINSTANTANEOUSUse total mass

DETERMINEFINAL PHASE

Continuous LiquidContinuous Liquid Continuous GasContinuous Gas Instantaneous LiquidInstantaneous Liquid Instantaneous GasInstantaneous Gas

ENVIRONMENTALCLEANUP COST

FLAMMABLECONSEQUENCE

TOXICCONSEQUENCE

BUSINESS INTERRUPTION EQUIPMENT DAMAGE COST POTENTIAL INJURY/FATALITY COST

Adjusted Failure Frequencyfor Each Hole

MITIGATION

5

Plant DB

Database

MaterialManagement

Program

Data

DocumentGraphic

• The 3-tier structure of proposed KGS-RBITM program ver.2.0 which had

been developed by KGS.

Ⅲ. Development of KGS-RBITM for petrochemical plant program (2)Ⅲ. Development of KGS-RBITM for petrochemical plant program (2)

ManagementSystem RBI DB

Fluid Material DB

ADOConnection

Risk AssessmentProgram

Picture

AssessmentResult

UserInterface

Presentation Layer Application Layer Database Layer

- Window Environment

- Visual C++, Visual Basic

- Microsoft Access 2000- Visual Basic

• List of input data for using the KGS-RBITM : Total 51 items

Process UnitEquipment IDEquipment TypeP&ID No.PFD No.Stream No.Inventory Group NameMaterialService Start DateDesign Life (yr)

Length (mm)Diameter (mm)Thickness (mm)Operating Pressure (kg/cm2)Operating Temp(C.)Design Pressure (kg/cm2)Design Temp (.C)Insulation (Y/N)

No. of ValvesNo. of BranchesNo. of Injection PointsNo. of ConnectionsNo. of NozzlesConstruction CodeVibration MonitoringPlanned ShutdownU l d Sh td

Equipment InformationEquipment Data Likelihood Data


Design Life (yr)Lining TypePWHT (Y/N)

Unplanned ShutdownStability RankingRV MaintenanceFouling TendencyCorrosive Service (Y/N)Very Clean Service (Y/N)

Rep. MaterialInitial fluid stateToxic MaterialToxic PercentDetection RatingIsolation RatingMitigation SystemsLiquid PercentGas Density (kg/m3)Inventory Input TypeInventory (User input)

Include Environmental Cleanup cost% Released from Diked areaRelease TypeType of FoundationMethod of DetectionDetection Times

Input Data(Excel File)Input Data(Excel File)

Consequence Data

Financial Data

Next Page

Material Name Material Name

H2 Hydrogen C5H6 1-Pentene-3-yne

CO Carbon monoxide C5H8 1-Pentyne

Fluid Material

C1-C2C3-C4

Representative fluids in refinery plant

The example of material list in ethylene facilitiesin petrochemical plant

The example of material list in ethylene facilitiesin petrochemical plant

In the view point of fluid materials making up the equipments, it is available to consider only one material per equipment based on NBP for oil refinery plant and to estimate the COF with a representative material described in API 581 code. In petrochemical plant, however, there are relatively abundant materials per equipment with regard to heat and chemical reaction process. As a result, when using the representative material only according to current method proposed in API 581, the calculated COF would not be accurate.


CO2 Carbon dioxide C5H10 1-Pentene

H2S Hydrogen sulfide C5H12 n-Pentane

CH4 Methane C6H6 Benzene

C2H2 Acetylene C6H12 Cyclohexane

C2H4 Ethylene C7H8 Toluene

C2H6 Ethane C7H14 1-Heptene

C3H4 Propadiene C8H8 Styrene

C3H6 Propylene C8H10 Ethylbenzene / O-Xylene

C3H8 Propane C8H16 1-Octene

C4H6 1,3-Butadiene C9-205C n-Paraffin

C4H8 1-Butene H2O Water

C4H10 n-Butane

C3-C4C5

C6-C8C9-C12C13-C16C17-C25

H2H2S

WaterHF

SteamAcid (low)

Acid (med.)

Acid (high)

AromaticsStyrene

Based on API 581 Code Development of Fluid Material Library adopt to RBI Program


• Quantitative RBI module (LoF)(LoF)

Click

Auto-Calculationof Corrosionrate


• Quantitative RBI module (LoF)(LoF) ImprovingImprovingCost Effectiveness

of Inspection &

MaintenancePrograms

StateState--ofof--TheThe--Art and Background ofArt and Background of RRisk isk BBased ased IInspection (nspection (KGSKGS--RBIRBI) Program) Program

Programs

RiskRisk--Based Inspection Based Inspection

TimeTime--Based Inspection Based Inspection

ConditionCondition--Based Inspection Based Inspection Development of Development of

KGSKGS--RBIRBITMTM S/W for S/W for Refinery PlantRefinery Plant

&&Field TestingField Testing

2002- 2003

ReflectedReflected RBI method to the RBI method to the

function of the function of the High Pressure High Pressure

Gas Safety Management Law Gas Safety Management Law

in Koreain Korea

2004Finished to Developing Finished to Developing Another KGSAnother KGS--RBI S/WRBI S/W

to apply to ato apply to aPetrochemical plantPetrochemical plant

Next Page

6

• History of KGS-RBITM program development


KGS-RBITM ver. 1.0A: 2002. 1 ~ 2003. 12 For Refinery Plants with CAU

KGS-RBITM ver. 1.2B: 2004. 6 ~ 2004. 11 Implemented S-Oil company, CDU plant

Developed KGS-RBITM ver. 2.0 forPetrochemical Plant with SKKU

DevelopmentDevelopment

Petrochemical Plant with SKKU

KGS-RBITM ver. 2.1~2: 2005. 7 ~ 2005. 12 Implemented HPC, NCC plant

KGS-RBITM ver. 2.3~4: 2006. 1 ~ 2006. 6 Implemented HPC Apply to PBL & EPS plant

KGS-RBITM ver. 2.5~6: 2006. 7 ~ 2007. 1 Apply to BTX plant

For

Petr

ochemical Pla

nts

Up-GradeUp-Grade

2005 ~ 20072005 ~ 20072005 ~ 20072005 ~ 2007

Developing RBM (Risk-Based Management)Program: 2007. 1 ~ 2009. 12

2007 ~ 20092007 ~ 20092007 ~ 20092007 ~ 2009

Ⅳ. Application of the KGS-RBITM programⅣ. Application of the KGS-RBITM program

• To verify the applicability of the proposed RBI program, proposed RBI

program apply to Benzene Toluene Xylene plant.

• The BTX system in this study has been operated for 14 years since it

started to produce in 1992.

Pipeline system

• In the BTX plant to construct RBI; assessment was made on 184 fixed

equipments and 562 piping systems except utility unit.

Stationary Equipments

BTX PlantBTX Plant

Ⅳ. Process of BTX System

Inventory Group of BTX ProcessInventory Group of BTX Process

CUI Results after KGS-RBI ImplementationCUI Results after KGS-RBI Implementation

CUI Results after KGS-RBI ImplementationCUI Results after KGS-RBI Implementation CUI Results after KGS-RBI ImplementationCUI Results after KGS-RBI Implementation

7

Ⅴ. Result of RBI for BTX plant (5)Ⅴ. Result of RBI for BTX plant (5)

• Analysis of damage factor for equipments and pipes

10000

100000

1000000

TM

SF

ThinningSCCBrittle FractureExternal Damage

PIPE

REACTOR

DRUM

EXCHANG

E

TANK

FILTER

COLUMN

ThinningSCC

Brittle FractureExternal Damage

1

10

100

1000

Sum

mat

ion

of T

TMSF Result for BTX Plant


•• RISK Distribution of BTX PlantRISK Distribution of BTX Plant

5 36 11 6 24 1

4 46 15 20 19 13

3 43 20 30 50 5d of

Fai

lure

BTX Plant Risk Distribution

Low29%

MediumHigh

High6%

RISK Ranking for BTX PlantRISK Ranking for BTX Plant

3 43 20 30 50 5

2 104 52 49 141 60

1 1 0 0 0 0

A B C D E

Consequence of Failure

Lik

elih

ood29%

Medium38%

High27%


•• RISK Distribution of BTX PlantRISK Distribution of BTX Plant

Risk of Equipment

High8

Low57

MediumHigh

54

LowMediumMedium HighHigh

216250

300Risk of BTX Plant Pipe

EquipmentTotal

Risk of Pipe

High35 Low

163MediumHigh148

Medium216

LowMediumMedium HighHigh

Medium65

163

57

220

216

65

281

148

54

202

35

843

0

50

100

150

200

Low Medium MediumHigh

High


•• RISK Distribution for UnitsRISK Distribution for Units

Column

High11%

Low21%

MediumHigh50%

DrumHigh0% Low

46%

MediumHigh27%

ExchangerHigh8%

Low30%Medium

High26%

ReactorHigh0%

Low0%

MediumHigh100%

Medium0%

Medium18% Medium

27%Medium

36%

Filter

High0%

Low0%

MediumHigh67%

Medium33%

Tank

Medium67%

MediumHigh0%

Low33%

High0%


• Analysis of damage factor for equipments and pipes

10000

100000

1000000

TM

SF

ThinningSCCBrittle FractureExternal Damage

PIPE

REACTOR

DRUM

EXCHANG

E

TANK

FILTER

COLUMN

ThinningSCC

Brittle FractureExternal Damage

1

10

100

1000

Sum

mat

ion

of T

TMSF Result for BTX Plant


•• ReRe--Inspection (open) interval by Risk Distribution of BTX Inspection (open) interval by Risk Distribution of BTX

SystemSystemReRe--Inspection (open) Inspection (open)

Interval (Interval (yryr))

5 1 1 1 1 1

4 6 6 4 4 1

3 8 8 6 4 4

911 yr

Re-Inspection Interval

Re-Inspection Interval (yr) Total Percentage (%)

1 yr 91 12.20%

4 yr 94 12.60%

6 yr 341 45.71%

8 yr 220 29.49%

Total 746 100%

3 8 8 6 4 4

2 8 8 6 6 6

1 8 8 6 6 6

A B C D E

220

341

94

0 100 200 300 400

Equipmnets(EA)

8 yr

6 yr

4 yr

8

Advanced Knowledge Industry Advanced Knowledge Industry and High Information Society and High Information Society Based on WEB & ERP SystemBased on WEB & ERP System

Advanced Knowledge Industry Advanced Knowledge Industry and High Information Society and High Information Society Based on WEB & ERP SystemBased on WEB & ERP System

InternetInternetB dB d

ApplicationServer

DataWarehouse

Server

• Degradation InformationDegradation InformationSystem for MaterialsSystem for Materials

• Inspection Monitoring Data Based on Web

• ASP Application

• Supply Assessment Results

• Risk Analysis SW

• Inspection Scheduling SW

• Repair Scheduling SW

• Cost-Benefit Analysis SW

• Safety Integrity Level (SIL) S/W

• PHA S/W

• Financial Risk Analysis S/W

Developing of RBM for petrochemical plantsDeveloping of RBM for petrochemical plants

BasedBasedNetworkNetworkSystemSystem

ManagementServer

Basic Engineering

Engineer & Expert Judgment

• Decision Making Tool System

• Management Information System

• GUI Application & User Interface

• Web Base

• Virtual Reality Based on WEB System

RBMRBM• Links to

each module• Decision Making

CMSCMS• Condition

Monitoring• Trouble

Monitoring• Virtual Reality

RBIRBI• Risk Based

Inspectionscheduling and

NDENDE• Integrity

InspectionI t lli t

RBM (RiskRBM (Risk--Based Management) Based Management) Based on Web & ERP SystemBased on Web & ERP System

RBM (RiskRBM (Risk--Based Management) Based Management) Based on Web & ERP SystemBased on Web & ERP System


◆ Currently Available PM Package- SAP, MAXIMO, MP5, MLS, IFS

◆ Currently Available PM Package- SAP, MAXIMO, MP5, MLS, IFS

gTool

DISMDISM• Degradation

InformationSystemfor Materials

scheduling andmanagement

• IntelligentDiagnosis

Application of Engineering Knowledge BasedPlant Management System

•• ERPERP 연동을연동을 위한위한 KGSKGS--RBIRBI 프로그램프로그램 컴포넌트컴포넌트 아키텍쳐아키텍쳐 설계설계

•• ““KGSKGS--RBIRBITMTM”” 프로그램과프로그램과 ““위험설비위험설비 재질열화재질열화 진단정보진단정보 프로그프로그

RBM(RiskRBM(Risk--Based Management) Based Management) 기술기술 개발개발

Start


KGSKGS R IR I 램과램과 위험설비위험설비 재질열화재질열화 진단정진단정

램램”” 연동을연동을 통한통한 RBMRBM 기술기술 개발개발

•• 해외해외 석유화학석유화학 플랜트의플랜트의 안정성안정성 평가평가 기술기술(FAIR)(FAIR) 벤치마킹벤치마킹

•• 전사적전사적 자원관리자원관리 시스템시스템(ERP)(ERP)에서에서 관리가관리가 가능하도록가능하도록 설비별설비별 위위

험성에험성에 대한대한 경영지표경영지표 선정을선정을 위한위한 RBMRBM 프로그램프로그램 개발개발

(RBM)(RBM)전사적

자원관리 시스템

(ERP)

비파괴 진단 정보 모듈 개발IOWA Uni. NDE Membership

• 현장 관리자

• 기술자

<KGS-RBITM> <위험설비 재질열화

진단정보 프로그램>

설비 정보

물질 정보

NDE 정보

Damageconsequence

category

Likelihoodcategory

Healthconsequence

category

Choose the highest from two

consequencecategories

Qualitative RBI

Plant database

Risk matrix

KGS-RBITM S/W의 컴포넌트 모듈화에 의한

연동시스템 구현

ERP ERP 연동연동 모듈모듈 개발개발 완료완료

- 재질열화정보 시스템(DISM : Degradation Information System of Materials

• API

• Welding Research Council

• ASME

• Other related Papers

Story BoardStory Board

Developing of DISMDISM : : Degradation Information System of Materials for petrochemical plants (재질열화정보 시스템)

Damage Mech. Info.

PFD (Chemical Plants 9 Units Process)

• Component Information: Material: Temperature: Process: Vibration: Stress State

• ASME DM Screening Table

• Expert Comment

사용자가 필요한 정보만

선택하여 출력 가능

사용자가 필요한 정보만

선택하여 출력 가능

DISMDISM : : Degradation Information System of Materials for petrochemical plants – Web Based System

Click!

9

DISMDISM : : Degradation Information System of Materials for petrochemical plants – Web Based System

비파괴비파괴 진단진단 정보정보 모듈모듈

Click!

Possible Damage Mechanisms in ProcessPossible Damage Mechanisms in Process

Click!

Damage Mechanism of each equipment

Damage Mechanism of each equipment

Click!

비파괴비파괴 진단진단 정보정보 모듈모듈

KGS-RBITM for petrochemical plant program

• Quantitative RBI module (LoF)(LoF)

Extended Message Window

KGSKGS--RBI S/WRBI S/W의의 모듈화에모듈화에 의한의한 DISM(DISM(재질열화정보시스템재질열화정보시스템))연동연동

KGS-RBI S/W의 설비별 파손확률(POF)및 피해영향(COF)과 연동

☜☜

모듈화에모듈화에 의한의한 KGSKGS--RBI S/WRBI S/W의의 DISM(DISM(재질열화정보시스템재질열화정보시스템))연동연동 Test Test 완료완료

(( ))DISM(DISM(재질열화정보시스템재질열화정보시스템))과과 상호상호 연동연동

석유화학석유화학 사업장의사업장의 정비정비 및및 설비설비 자산관리자산관리 시스템과의시스템과의

연동연동 가능가능

장치별 Inspection History CARD 와 연동



10

RBMRBMSS

도면,문서관리S

Admin.User

RDBMS

ERPServer

FILEServer

생산관리Server

PDIS

EditUser

PDIS(Plant Data Information System)



RTDB

DCS PLC Analyzer

CMMS Server

Scanner Printer Plotter

ServerServer Server User

DB Server

Admin.User

검사검사//공무부서공무부서

UserUser

WebServer

정비/구매부서

User

생산/기술부서User

Admin.User

User

관련부서User

WEB/ERP기반 대상 설비별 통합/일체형 지식정보시스템 개발

지식정보시스템 현장적용으로 석유화학설비의 안전성 확보

실용화 기술 개발 및 현장 적용

ProductProduct

최종목표: ERP기반의 통합/일체형 위험성 관리 프로그램 개발

정유 및 석유화학 산업설비의 안전성 평가 통합 체계 구축

IT기반 첨단 지식정보화 위험성 관리 시스템 네트워크 구축

선택과 집중

Developing of RBM for petrochemical plants - KGSDeveloping of RBM for petrochemical plants - KGS

20072007 ERP연동을 위한 KGS-RBI 프로그램 컴포넌트 아키텍쳐 설계

비파괴 진단정보 수집에 따른 연동 알고리즘 확보

위험설비 재질열화 진단 정보 프로그램 연동구조 제시

NDE 첨단 진단기술정보 수집 및 ERP연동 모듈 설계

20082008

ERP 기반 “위험설비 재질열화 진단정보 시스템” 연동 구축

• NDE 모듈 개발 및 ERP 인터페이스 구축

• 지능형 정보화 RBM 시스템 구축

통합 위험성 관리(RBM) 구성 요소 및 시스템 개발20092009

결론결론 및및 활용방안활용방안■ 향후 위험도 기반 산업설비의 자산관리기술의 핵심 모듈로써 활용

■ API 581 S/W 컴포넌트의 확장성을 통한 활용 가치 극대화

■ KGS-RBI 및 위험설비 재질열화 진단정보 프로그램의 실효성 및 가치 증대

■ 산업시설에 대한 과학적이고, 경제적인 종합 안전 관리 체계 구축

- 산업 설비자산의 경제적 효용 가치 극대화

- 설비관리 기술의 선진화를 통한 관리 비용의 획기적 절감

- 유지, 보수 등의 관리 활동 및 비용에 대한 통합 정보화를 통한

설비 안전성 관리의 계량화 시도

- 설비별 위험성 평가 및 관리지수에 대한 신뢰성 확보

- 대상 설비의 손상기구에 대한 정확한 정보시스템 제공

- RBI 해석 결과의 객관성 및 신뢰성 확보

- 설비 수리, 보수, 교체, 고장, 관리 등 분산된 정보를 한 곳에 집적

Documents

Contents · representative material described in API 581 code. In petrochemical plant, however, there are relatively In petrochemical plant, however, there are relatively abundant