Below the Surface: The Importance of Mechanical Integrity at Your Plant. ERI Solutions Inc. All Rights Reserved.

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Natalie Day
6 years ago
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1 Below the Surface: The Importance of Mechanical Integrity at Your Plant

2 Introduction ERI Solutions Inc. (ERI) founded in 2003 to develop insurance markets and standards for the growing ethanol industry. Insurance Risk Management Safety & Health ERM SPC, Ltd. Process Safety Management (PSM) Acquired Environmental Compliance Division from ICM, Inc. Developed Non-Destructive Testing (NDT) Service Developed (Focused Integrity Testing) Acquired Paragon Services, Inc. s Non-Destructive Testing division Acquired Paradigm EH&S Consulting Group, LLC of Owasso, OK

3 Introduction (Cont.) To Date over 100+ API 510 / 570 / 653 inspections in ethanol plants in the past 4 years. Developed or assisted in development of over 40 Mechanical Integrity (MI) programs for ethanol plants. Manage the Ethanol Risk Management SPC, Ltd. captive insurance program for the ethanol industry with over $10 billion dollars of insured ethanol plant assets. Approaching 40 ethanol plants in ERI s Focused Integrity Testing Program where we test a portion of required testing annually along with industry known areas of concern and areas of concern specific to your facility. With over 70 plants we have a lot of skin in the game so to speak.

4 The Age of the Ethanol Industry Year Period of Time Plant s Built (Approx.) Plant Average Age

5 Why is Asset Integrity so Important? Erosion of piping circuits in areas where liquids or gases change direction Underside corrosion of floors of floating roof storage tanks

6 We Want to Avoid this

7 We Want to Avoid this

8 We Want to Avoid this

9 We Want to Avoid this WORKPLACE FATALITY He passed too soon doing a job he loved

10 Maintaining Compliance

11 Maintaining Compliance

12 Inspections for Ethanol ECOGNIZED ND ENERALLY CCEPTED Your plant should be inspected to the same standards that it was built to OOD NGINEERING RACTICES

13 How Your Assets Typically Age Condition Inspections Potential Failure Functional Failure Time P-F Interval

14 What Type of Inspections?

15 Overview of Non-Destructive Testing (NDT) Evaluating the properties of a material, component or structure without doing damage. Other terms Non-Destructive Evaluation (NDE) Non-Destructive Inspection (NDI) Non-Destructive Examination (NDE) NDT is a highly valuable technique that can save both money and time in product evaluation, troubleshooting, and research because it doesn t permanently alter the article being inspected.

16 Non-Destructive Testing (NDT) Uses To assist in product development To screen and sort incoming materials ( Raw Materials) To monitor, improve or control manufacturing processes To verify proper processing (Example: Heat Treating) To verify proper assembly To inspect for in-service damage

17 Non-Destructive Testing (NDT) Methods Ultrasonic (UT) Radiography (RT) Ultrasonic Shear Wave Visual (VT) Certifications & Non-Destructive Testing Methods Utilized Eddy Current (ET) -INTERNAL- Magnetic Flux Leakage (MFL) -INTERNAL- Magnetic Particle (MT) Penetrant (PT)

18 Visual (VT) Inspection Visual is the most basic and common inspection method Robotic Crawlers Borescope Fiberscope Magnifying Glass. Mirrors

19 Liquid Penetrant (PT) Inspection Penetrant Crack Developer Interpretation Application Cleaning Developing Interpretation

These particles are attracted to magnetic flux leakage fields and will cluster to form

20 Magnetic Particle (MT) Inspection The part is magnetized. Finely milled iron particles coated with a dye pigment are then applied to the specimen. These particles are attracted to magnetic flux leakage fields and will cluster to form an indication directly over the discontinuity. This indication can be visually detected under proper lighting conditions.

21 Radiography (RT) Inspection The part is placed between the radiation source and a piece of film. The part will stop some of the radiation. Thicker and more dense area will stop more of the radiation. The film darkness (density) will vary with the amount of radiation reaching the film through the test object. X-ray film = less exposure = more exposure Top view of developed film

22 Radiography (RT) Inspection Examples Naked Eye Naked Eye Naked Eye Inspection Result Inspection Result Inspection Result

electrical conductivity and coating thickness measurements.

23 Eddy Current (ET) Inspection Eddy current testing is particularly well suited for detecting surface cracks but can also be used to make electrical conductivity and coating thickness measurements. Here a small surface probe is scanned over the part surface in an attempt to detect a crack.

24 Ultrasonic (UT) Inspection High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws. Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect sound. initial pulse crack echo back surface echo crack plate Oscilloscope, or flaw detector screen

25 Inspection of Raw Products Forgings Castings Extrusions Etc.

26 Inspection Following Secondary Processing Machining Welding Extrusions Etc.

27 Inspection For In-Service Damage Cracking Corrosion Erosion/wear Heat Damage Etc.

28 Processing Plant Inspection Tube & Shell Heat Exchangers Periodically, power plants, refineries, chemical plants, biofuels plants and other industrial processing plants are shutdown for inspection. Inspectors feed eddy current probes into heat exchanger tubes to check for corrosion damage. Eddy Current (ET) Inspection 190P Condenser August 1, 2015 Pipe with damage Probe Signals produced by various amounts of corrosion thinning.

29 Processing Plant Inspection Storage Tanks Robotic Crawlers - use ultrasound to inspect the walls of large above ground tanks for signs of thinning due to corrosion Camera - use long articulating arms are used to inspect underground storage tanks for damage. Magnetic Flux Leakage use a magnetic field to map the underside of tank floors to identify corrosion

30 Processing Plant Inspection Pressure Vessels The failure of a pressure vessel can result in the rapid release of a large amount of energy. To protect against this dangerous event, the tanks are inspected using radiography and ultrasonic testing.

31 Common Findings/Issues in the Ethanol Industry

32 Findings from Inspections in Ethanol Industry 1 2 3

33 Findings from Inspections in Ethanol Industry 4 5 6

34 Findings from Inspections in Ethanol Industry 7 8 9

35 Findings from Inspections in Ethanol Industry

36 Findings from Inspections in Ethanol Industry

37 Findings from Inspections in Ethanol Industry

38 Findings from Inspections in Ethanol Industry

39 Findings from Inspections in Ethanol Industry

40 Why Should you Care?

Fines / Citations Willful Up to $70,000 per

Repeat Up to $70,000 per violation Other Than

41 Fines / Citations Willful Up to $70,000 per violation and if found to be criminal, up to $250,000 fine for an individual or $500,000 for a corporation plus up to 6 months imprisonment. Repeat Up to $70,000 per violation Other Than Serious Up to $7,000 per violation Serious Mandatory Minimum of $7,000 per violation

$250,000 depending on company size and risk tolerance) Business Interruption Deductible (Generally 5 to

42 A Property Claim Will Cost You! INSURANCE COSTS Fully-Insured Ethanol Companies Property Damage Deductible (Generally $100,000 to $250,000 depending on company size and risk tolerance) Business Interruption Deductible (Generally 5 to 15 day Average Daily Value or no profit of continuing expenses paid) Self-Insured Ethanol Companies Pay total cost to rebuild Has no profit or continuing expenses covered while rebuilding

43 Other Costs (Uninsurable Portion) Legal / Attorney Insurance Employee Public Customers Production Civil Fees Rate Increases Lose Positive Morale Perception becomes Negative Contract Elsewhere Efficiencies Lawsuits

44 But it is OK because DUMB THINGS HAPPEN 100% of property damage events (excluding acts of God) are preventable Many of them will be prevented because of your Maintenance Activity

45 So What Can You Do? Educate yourself & company management Understand & explain legal requirements Understand and explain how this is about reliability, continued operations and compliance and how it is much more that a Check the Box activity Seek examples (To build your case) o Other similar instances in ethanol or in similar industries (I hope you have several provided here in this presentation) Loss control, reliability, safety and compliance with regulatory agencies is the right thing to do, but it has also proven to be a very smart financial business decision

46 For more Information: (316) N. First Street Colwich, KS

Department of Chemical & Polymer Engineering University of Engineering & Technology Lahore (FSD Campus)

Department of Chemical & Polymer Engineering University of Engineering & Technology Lahore (FSD Campus) 1 Nondestructive testing (NDT) use test methods to examine an object, material or system without