Maintaining a Real-Time RBMI Program. Dan Mahoney Reliability Engineer HollyFrontier Corporation El Dorado, KS

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1 Maintaining a Real-Time RBMI Program Dan Mahoney Reliability Engineer HollyFrontier Corporation El Dorado, KS

2 Agenda Introduction & Background RBMI basics and the importance of good data Achieving: How do you build a quality RBMI database from the ground up? Maintaining: How do you keep a robust RBMI program that adapts to plant changes?

3 HollyFrontier HollyFrontier Corporation (HFC) is an independent petroleum refiner headquartered in Dallas, TX, and was formed by a merger of Holly Corp and Frontier Oil in HFC owns and operates through its subsidiaries five complex refineries with 443,000 bpd of crude oil capacity (Artesia, NM; Cheyenne, WY; El Dorado, KS; Tulsa, OK; Woods Cross, UT). HFC owns a 34% interest in Holly Energy Partners, LP, and a 75% interest in the UNEV pipeline.

4 El Dorado Refinery 135,000 bpd refinery located in El Dorado, Kansas One of the largest refineries in the Plains/Rocky Mountain region Access to a variety of crudes via pipeline connections to the Cushing, OK hub

5 RBMI in El Dorado Initial implementation of RBMI began in 2001 and was completed in 2005 El Dorado plant has identified an RBMI Repair project that will improve the quality of the database and inspection processes

6 The Key to RBMI Success Is not blindly following the inspections that RBMI tells you to do (although you still need to keep up with them!) Is about data integrity and data management! This data goes well beyond inspection reports and thickness readings!

7 Some Key Questions How good is the quality of the data in my RBMI database? How do I know? How does my facility maintain quality RBMI data over time? Do I have personnel with the appropriate skill sets to maintain a quality program? Do I have training processes in place?

8 RBMI Why Data Integrity is So Important Once adopted, RBMI has a drastic impact on pressure equipment management in a facility. RBI: Is the foundation of all future inspection plans Permits inspection intervals longer than required by traditional API 510/570 programs Allows flexibility in equipment inspection and turnaround dates through custom risk analyses Assists in end-of-life asset decisions The catch all of these features of RBMI are completely dependent on quality data!

9 Example Impact of Data Quality Propane product stripper tower in an HF Alky strips any residual acid out of propane before it is sent to storage for sale and transport Insulated and the tower top section operates at 130 F Tower top section is primarily propane vapor, but some HF is present

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11 Example Impact of Data Quality Errors The tower was not indicated to be insulated in RBMI CUI evaluation not triggered Process data was correct except that 1% HF in a toxic mixture was not included in the tower overhead

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13 Example Impact of Data Quality Impact on Inspection Work Plan (IWP) IWP Before UT on 10 year frequency Internal Visual on 10 year frequency IWP After UT on 10 year frequency Internal Visual on 10 year frequency CUI inspection on 50% of potential locations on 5 year frequency

14 Thoughts on Data Quality The sources of errors are extremely varied the example given only hits the tip of the iceberg A number of fields (design pressure/temperature, material of construction, diameter) can directly affect tmin calculations in the NDE module The effects of errors can be as varied and unpredictable as the sources

15 QC Random or 100%? Depends on your confidence in the quality of your data, but it s probably best to start out with a random QC effort As more problems start to be uncovered, you may shift to planning a 100% QC effort When QC ing (and potentially correcting) 100% of the fields in your database, you re essentially conducting a re-implementation project

16 Maintaining an RBI Program In Real Time RBMI implementation is a LOT of work how do I keep it up? Protect the data in your RBMI database Ensure people running your program are qualified Adapt to plant changes

17 A Few Prerequisites Management buy-in to RBMI Good P&IDs A robust MOC process A solid system of tracking maintenance repairs to pressure equipment (inspection work requests, repair instructions, whatever you call them) A good, organized NDE program and qualified NDE contractor to supply reliable data (you need this even for a good API program) Good documentation of equipment history

18 Protecting RBMI Data RBMI has completely customizable user-specific permissions every individual can have customized add/edit/delete rights for all families of data Limit ability to run risk assessments to only your RBMI/risk experts Limit editing of asset datasheets to only key inspectors or engineers Prevent NDE techs from editing other inspection data when inputting thickness readings Possibilities are endless

19 Ensuring Personnel Qualifications Goes hand-in-hand with data protection only qualified people can access certain data sets How do you gain staff expertise? Intimate involvement in implementation! RBMI software training Lloyd s Register offers a whole set of training classes for RBMI Bring an RBMI expert on site for a project? Foster a team atmosphere among your RBMI people so they communicate and maintain consistency

20 Adapting to Plant Changes Changes to RBMI data come from a variety of sources: Big and small projects Turnarounds Process changes (crude slate, throughput, pressure, temperature, chemical injection, etc) Planned and emergency repairs Rerates/derates Special program updates as a result of audit recommendations (PSM/RMP/Insurance)

21 Adapting to Plant Changes As a general rule, these potential impacts can be categorized in two groups MOCs Repairs

22 MOCs The key is proper evaluation to understand what data needs updating use your RBMI expert(s) Once you know what to change, make sure it happens! Create and track NCRs for data deficiencies until the change happens and the right documentation is obtained Reference the MOC on the NCR RBMI has NCR rankings you can assign lower rankings to data deficiencies and track them as a different class than physical deficiencies

23 MOC Evaluation Mechanical Integrity MOC Evaluation Checklist MOC#: Provide MOC# here Date: Provide date here Will any piping be added, modified, or removed? Will any fixed equipment be added or removed? Will any fixed equipment be modified? Will any relief valves be added or removed? Will any relief valves be modified? Will any feedstock, product, or other stream compositions be modified outside of previous operating parameters? Will any operating parameters (pressure, temperature, flow) be modified outside of previous normal operating envelopes? Will any chemical injections be added, modified, or removed? Y / N Y / N Y / N Y / N Y / N Y / N Y / N Y / N If Yes, provide finalized P&ID markups showing all piping changes If Yes, provide lists of all idled/removed assets. Provide a list of all new assets and provide all applicable documentation (U-1s, drawings, specifications) If Yes, provide drawings of modification and any applicable code documents (U-1A, R-1, etc) If Yes, provide lists of all idled/removed relief valves. Provide a list of all new relief valves with applicable documentation (datasheets, drawings, P&IDs) If Yes, provide updated datasheets for modified valves If Yes, complete a Process Review with the RBI Specialist If Yes, complete a Process Review with the RBI Specialist If Yes, provide P&ID markups showing changes and MSDS's of any new chemicals

24 Repairs Repairs, including replacement in kind, can have a significant impact on RBMI and risk Evaluation of the effects of a repair on RBMI should be performed by your RBMI expert(s) New date in service for an asset? Baselines required? Partial replacement which will reset the clock on only select TMLs? Updates to inspection drawings/isometrics?

25 Repair Tracking Use the initial NCR that triggered the repair as a vehicle to track data conformance Add verbage to the NCR describing what data changes will be required when it is closed out Do not close the NCR until the repair is complete and all pertinent RBMI data has been updated

26 A Workflow for Data Change Management RBI Data Change Management Create/Track NCRs on affected assets Until Data Update Complete No Enter Visual/ NDE Results in RBI MOC Complete MI MOC Evaluation Checklist Impacts MI Data? Yes Update RBI Data as Req d by Evaluation Checklist Data Update 100% Complete? Yes Run Risk Assessment Generate and Review New Inspection Work Plan (IWP) Inspections Due? Yes Perform Updated Visual/ NDE Inspections No No Updates to RBI Data Required New Equipment/Circuits Design/Process/Corrosion Data Systemized/Circuitized P&IDs Inspection Drawings PMI Database Baseline Inspections No RBI Data Update Complete Enter Visual/ NDE Results in RBI Repair Repair Evaluation Impacts MI Data? Yes Add Data Update Description to NCR and Track Until Repair Complete Update RBI Data as Described in NCR Close NCRs Run Risk Assessment Generate and Review New Inspection Work Plan (IWP) Inspections Due? Yes Perform Updated Visual/ NDE Inspections No No Updates to RBI Data Required Systemized/Circuitized P&IDs Inspection Drawings PMI Database Baseline Inspections No RBI Data Update Complete

27 Data Integrity KPIs A Novel Approach to RBMI Excellence? Percentage of total MOCs in past month with properly completed MI Evaluations Total and overdue data NCRs in RBI

28 Additional Thoughts on Piping Piping is more dynamic and more difficult to manage than fixed equipment Good systems and circuits are essential to break down your piping into finite and logical chunks that can be managed in an RBMI database Sometimes the changes can come so fast that keeping accurate drawings (P&IDs, isometrics) can seem an insurmountable challenge

29 Piping Management Tips CAD piping isometrics are easier to update Incorporate P&ID redlining into your piping walkdown and external inspection process Systemized/circuitized P&IDs can be drawn in CAD too! Easier to update than hand-highlighted P&IDs CAD highlighting layers for systems and/or circuits can be an overlay on your master P&IDs System/circuit updates can be an integral part of your plant s P&ID update process

30 A CAD Circuitized P&ID

31 Conclusions Maintaining RBI In Real Time Protect RBI Data only key people can perform key functions or edit critical data sets Ensure Personnel Qualifications groom a small team of RBI experts to perform your most critical functions Adapt to the Changing Plant Environment evaluations of MOCs and repairs need to be done by RBI experts, data updates need to be tracked (KPIs?) Piping Management identify and incorporate best practices

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