PMI in the Petrochemical

Transcription

1 PMI in the Petrochemical Plant and Refinery

2 2009: Niton XL3t GOLDD 7th Generation 2

3 Operation of HHXRF 3

4 Excitation Source Atomic Level Process of Fluorescence Production 4

5 The Complete System Primary X- Ray Beam Excitation Source Spectra to µp Alloy Sample Pulses From Detector Detector DSP Fluorescent X-Rays Microprocessor (µp) Display Data Storage 5

6 How it works 1 Each individual element produces its own set of characteristic x-rays; the basis for qualitative analysis By counting the number of characteristic x-rays of a given element we can determine its concentration; the basis for quantitative analysis 6

7 Results display 7

8 Element Range for Alloy Measurement Not possible with portable XRF, use OES May require GOLDD technology Ideal for routine HHXRF Measured with portable XRF 8

9 HHXRF Selected Alloying Element Channels 25/30 elements analyzed in alloys Note: Analytical capability is not limited to the elements shown; the full analytical range extends from Mg to U 427 alloys in grade library 9

10 PMI Overview 10

11 PMI is Mission Critical for Verification Power Plants Fast ID With FP Analysis Automated Sample Data entry Refineries Producers Fabricators Small size Light weight Ergonomic Design Simple Point & Shoot Operation Aerospace Test 800 F Vibrating Pipes Test tight Corners & & fillet welds 11

12 Consequences of Using Incorrect Materials Can Range From To 12

13 Why do PMI? Source: Marsh and McLennen (property protection and risk consultants) 13

14 PMI can Prevent the Largest Losses 41% of the 170 largest losses in the hydrocarbon process industry resulted from failures of piping systems Second International Symposium on the Mechanical Integrity of Process Piping January 1996, Houston, TX, USA 14

15 PMI Cycle Overview 15

16 PMI in Petrochem Industry analytically speaking We are facing a seemingly impossible task: analyzing with sufficient accuracy and precision to be able to distinguish one alloy from many thousands of others (estmates are up to 50,000 alloys grades in use today) Percent concentration of element NICKEL 200 Monel 500 Inco 625 Inco 750 Inco 825 Haynes 230 RA 333 Hastelloy B-2 Hastelloy C-276 Hastelloy X Stellite 6B Stellite 188 A l T i N b C o W C u M n M o F e C r N i 16

17 Fortunately, Petrochem Alloys Are Few 17

18 PMI in Petrochem Industry analytically speaking con t We are facing a second seemingly impossible task: Correcting for an awesome variety of samples forms, sizes and shapes 18

19 FP with Normalization Automatically normalizes for size, shape, curvature and distance (up to ~6 mm) Mathematical iteration continues until all measured elements add to ~100% 19

20 PMI Tool in Petrochem Industry Automatically corrects for an intimidating set of environmental and sampling conditions Ambient heat Ambient cold Rain Hot samples Vibrating samples High noise Small samples Hotfoot Adapter Temp up to 850 o F / 440 o C extension handle keeps hand well away from heat volcano suit protects plastic case Velcro flip cover for ease of viewing 20

21 Remote Display Option Wireless data transfer up to 300 ft Remote control of analyzer 21

22 PMI Testing of Welds with WeldSpot TM and CamShot TM 22

23 Thermo Scientific Niton XL3t XRF Analyzer with GOLDD Technology Geometrically Optimized Large Area Drift Detector

24 GOLDD Technology Thermo Scientific presents the Niton XL3t XRF Analyzer with GOLDD Technology This new analyzer delivers Light element detection (Mg, Al, Si, P, S) without helium or vacuum purging The lowest limits of detection and the fastest analysis available True lab-quality performance in a handheld instrument 24

25 GOLDD SDD (Silicon Drift Detector) Similar to Si PIN, but unique electrode array that guides electrons to very low capacitance anode This means that the detector Has a short rise time, achieving high count rates with minimal pile up Provides better resolution Has lower noise GND C1 drift field C2 Anode -V U BACK Homogeneous thin entrance window GOLDD with external Field Effect Transistor (FET) Shorter processing, lower cost No partial charge collection under FET No effects on FET from SDD Up to 450,000 counts per second input 25

26 GOLDD: Quantum Advancements with XL3 Analyzers 2 W, 50 kv X-ray tube, SDD GOLDD Improved sensitivity, speed, accuracy, precision, stability and confidence New ability to analyze residual elements New ability to determine light elements Significantly lower LOD s for critical elements 26

27 Optimized Excitation To take advantage of a detector with a higher count rate, more fluorescent x-rays should be produced by the sample That is achieved using a higher voltage x-ray tube Niton XL3t: 50kV Typical older technology: 40 or 45kV Excitation intensity is 2x more sensitive to increase in high voltage compared to other factors (current, Z of anode material). Increasing the excitation voltage by 25% has a 50% greater effect than increasing the tube current by a similar amount 27

28 Optimized Geometry To take advantage of a detector with a higher count rate, you want to collect more of the fluorescent x-rays from the sample For the same size detector, the closer it is to the sample, the more fluorescent x-rays it will detect The Niton XL3t was designed with this optimized geometry 28

29 Large Area Drift Detector A large detector will collect more fluorescent x-rays than a small detector The Niton XL3t employs a unique 25 mm 2 detector, instead of an off-the-shelf 10 mm 2 detector Therefore, the Niton XL3t collects 2.5 times more signal 29

30 The GOLDD Advantage This all adds up to the GOLDD Advantage 10X better than conventional Si PIN detectors 2.5X better than analyzers with off-the-shelf SDD detectors 30

31 Twin Alloys and Solutions Guideline to PMI Alloys that Mix (or May Mix) with XRF based on UNS Spec Ranges ALLOY/ ELEMENT Ti V Cr Mn Fe Ni Cu Cb Mo Other 9Cr(F9) * Bal Cr+V(F91) * Bal Long test times on XL3p (30-40s). XL3t with low filter will pick up low V content in seconds M405( R) - 2.0* 2.5* Bal - M500(K) * 2.0* Bal Al Long test times on XL3p (30-40s). XLt3 with low filter will separate R/K Monel in seconds. Al determination requires GOLDD Unit SS * Bal ~0.5* C 0.08* SS304L * 8-12 C 0.03* SS * Bal /304L C (OES) / Long test times on XL3p (30-40s). XL3t 304/321 Ti with low filter in seconds / Remove 301 from alloy grade library Usually unseparable unless Cr, Ni, Cu values at nominal composition F Bal Si F Bal Si Long Mtime for Cr / Si determination requires GOLDD Unit Bal C Bal C Not possible with XL3p / Use XL3t with 20s measuring time, or GOLDDD Unit with 5s test time * Indicates maximum (Mo not specified in 304 but most always present) 31

32 Thermo Scientific NITON Analyzer Turnkey PMI Kit Button Reader Extension Pole Hotfoot CMB Buttons PMI-15 Certest EPI Manual Wireless Printer GPS Button mounted On plate Wireless Bar Code Reader 32

33 CMB Buttons: Traceability to Field Components Computerized Monitoring Buttons ( CMB )-API rd Edition, Page 30 PMI data are traceable to the point of installation XRF Analyzer data file can tie Report Documentation to the field PI&D drawings 33

34 PMI of Hot Pipes and Difficult to Access Areas Extension Pole /Tri-Pod Variable pole length Dual Electronic Triggers Clip on Tri-Pod adapter for hands-free analysis of samples on ground or table XL3t/p without heat shield: 315 o C XL3t with heat shield : 450 o C XL3p with heat shield : 540 o C 34

35 API 578 Material Verification Program for New and Existing Alloy Piping Systems May 1999

36 API RP-578 (section 1) 1. Scope Guidelines for material QC of ferrous and nonferrous alloys C steel not included Covers owners /users, and indirectly vendors, fabricators, contractors Owner must define roles and responsibilities of each above 36

37 API Recommended Practice 578 (section 2 and 3) 2. References API 570 Piping Inspection Code, Publ. 581 RBI, ASME Boiler and Pressure Vessel Code, B31.3 Process Piping, PFI ES22 Color Coding 3. Definitions See full report for glossary of definitions 37

38 API Recommended Practice 578 (section 4) 4. Extent of Verification Owner must establish written program for PMI including up to 100% PMI for higher risk systems Must provide for review of: Third party testing Fabrication assembly testing Cannot substitute mill test report for PMI 38

39 API Recommended Practice 578 (section 4 cont) Examples of components covered Pipes lengths Pipe fittings Flanges Forgings Process valves Pressure containing welds Instruments Weld overlays or cladding Bolting Expansion joints and bellows 39

40 API Recommended Practice 578 (section 4 cont) PMI of welding consumables PMI one electrode per lot Compare markings on balance PMI of weld metal or button is alternative PMI of longitudinal pipe and weld fittings Verify base metal and weld metal PMI of autogenous welds PMI on base metal only 40

41 API Recommended Practice 578 (section 4 cont) PMI of components from distributor Higher degree of testing due to handling mix-up potential Existing piping systems In service but procedures were not in accord with above PMI limited to pressure containing components and attachments Owner determines if retro PMI appropriate and for prioritizing testing Prioritizing considerations Likelihood of mix based on past verification program Consequences of failure Reason for alloy spec (corrosion, etc) Historical data on past issues with the process unit or plant See API 581 (RBI) for more detailed discussion 41

42 API Recommended Practice 578 (section 4 cont) Carbon steel substitutions in LA systems Greatest number of mixes have been C-steel in place of Cr-Mo steels SS, Monels, and non-ferrous mix is easier to spot (appearance, weldability) Other Factors Site specific experience Past construction and maintenance practices Past PMI procedures - lax vs rigorous Reason for material specified how critical? May not be mission critical (SS used for oil purity) 42

43 API Recommended Practice 578 (section 4 cont) Component prioritization factors Some systems have higher likelihood of mix* Pump and check valve warm-up and bypass lines Small dia. piping & welds (less than 2 ) Valves and removable devices (discs, spacers, gaskets, etc) Thermowells Bolting Piping as part of packaged system Components without ASTM stamp * Note: especially in older plants (author s anecdotal experience - - data not extracted from API 578) 43

44 API Recommended Practice 578 (section 4 cont) Factors in determining extent of PMI Historical inspection PMI records Number of plant modifications Material control at time of construction or modification Material PMI program quality during construction and fabrication Likelihood of corrosion/degradation Consequence of release Material Verification Program as element of maintenance systems Owner must establish written procedures program for repair maintenance activities as well as for receiving and suppliers 44

45 API Recommended Practice 578 (section 5) 5. Material Verification Program Test Methods Intended to ID the alloy, not to establish conformance Existing visual stamps and markings not a substitute for PMI Methods P-XRF Principle Interpretation of results Spectral match or composition percentage Not possible to detect all elements (S, C) P-OES Principle Interpretation of results Spectral match or composition percentage May be able to detect S, C 45

46 API Recommended Practice 578 (section 5 cont) Chem lab Owner approved lab using XRF, OES or wet chemical methods Accuracy higher than needed for PMI May be destructive to sample May be costly and slow Chemical spot tests Produces colors to indicate presence of specific elements Slow and subjective Resistivity testing Thermoelectric principle, comparative test only Not capable of consistently sorting LA and austenitic SS s Other Eddy current, EM, etc., qualitative only; not specific 46

47 API Recommended Practice 578 (section 5 cont) Equipment calibration Accuracy verification: follow mfg s recommendations; or owner must provide procedure Precision Repeatability: must be consistent with test objectives; owner must establish acceptance criteria Personnel qualifications Operator must be knowledgeable in all aspects of test method and operation Operator qualifications must be approved by owner Safety issues PMI method: must include review of any mechanical prep and it s effect on sample (integrity) Arcing equipment: will require Hot Work permit (OES) Chemical tests: take appropriate cautions in use of chemicals 47

48 API Recommended Practice 578 (section 6) 6. Evaluation of PMI Test Results Methods for material acceptance Confirm alloying elements against relevant spec (ASTM, ASME, etc) Classify by qualitative sort (ID only) Material out of spec can be accepted if owner (knowledgeable person) evaluates damage mechanisms and confirms performance is OK If material is rejected based on portable or qualitative method a more accurate method can allow acceptance* Dissimilar metal welds must take into account dilution effect If representative sample of a lot is rejected, extend testing to rest of lot * Modern P-XRF analyzers rival lab methods 48

49 API Recommended Practice 578 (section 7) 7. Marking and record keeping Material ID process Materials should be ID ed by alloy designation (grade) or composition Acceptable methods Color coding Low stress stamp Color Coding/Marking Record according to PFI ES22 Document PMI result and location (drawing) Marking components Specify Life of marking legibility If for temporary use, can be semi-permanent paint 49

50 API Recommended Practice 578 (section 7 cont) Material certifications (mill reports, CoC s) Not substitute for PMI Shop and field test documentation Individuals performing PMI testing must follow owner approved test procedures New and existing piping system documentation Must keep PMI records as long as piping exists in original location PMI test record information PMI procedure used Date Instrument ID or serial number Name and company of test person Result of tests Basis and action for resolution Documentation of criteria for prioritizing piping systems for PMI testing 50

51 API Recommended Practice 578 (section 7 cont) PMI test procedures Must include Techniques Equipment calibration Qualification requirements for PMI test personnel Test methodology Documentation requirements Traceability to field components All test record info must be traceable to point of installation 51

52 Why PMI is So Critical to Process Safety Management It is too Easy to Mix up Alloys with Serious Consequences Without PMI Serious Accidents Will Happen The OHSA (Occupational Health and Safety Administration) Safety Record for Key Industries Handling Highly Hazardous Chemicals is telling: The Refinery Safety Record is Three Times Worse than the combined Record of the Next Three Vulnerable Industries over the same time period Many of the Serious Incidents have involved Improper or Lack of PMI of Critical Refinery Alloy Components Injuries, Deaths, and Financial Costs have been substantial since 1992: Injuries 250 Deaths 52 Financial Losses Many Tens of Million of Dollars Not Only the PetroChemical Industry, but Many Others are Dependent on Good PMI Utility, DOD, Aerospace, BioTech, Critical System and Subsystem Manufacturing 52

53 Why do PMI? Explains How OSHA Instruction-CLP Nation Emphasis Program (NEP) Applies to The Refining Industry Source: Marsh and McLennen (property protection and risk consultants) 53

54 PMI Can Prevent The Largest Losses Process Safety Management (PSM) 29CFR With Proper Material Verification Program and Training 41% of the 170 largest losses in the hydrocarbon process industry resulted from failures of piping systems Second International Symposium on the Mechanical Integrity of Process Piping January 1996, Houston, TX, USA Understand & Apply API Recommended Practice 578 Positive Material Identification (PMI) Guidelines 54

55 Reasons Why According to OSHA s Data Base: Since May 1992 (36) Fatality/Catastrophe (FAT/CAT) incidents related to HHC have Occurred Incidents include 52 Employee Deaths and 250 Employee Injuries, 98 of which required Hospitalization The number of Refinery Incidents Surpasses the Combined Total of the Next 3 Highest Industries over the same period, and many are due to Lack of or Faulty PMI Chemical Manufacturing-12 FAT/CAT Industrial Organic Chemical Manufaturing-12 FAT/CAT Explosives Manufacturing-11 FAT/CAT 55

56 American Petroleum Institute API Standard API-570-Piping Inspection Code Standard API-510-Pressure Vessel Inspection Code Standard API-653-Storage Tank Inspection Code Recommended Practice API-RP-578-Material Verification Program-MVP/PMI Recommended Practice API 571-HF ALKY Recommended Practice API 939-C-Sulfidation RAGAGEP 56

57 Priority for API nd Edition: Inspection Program for HF ALKY All Refineries Residual Elements in Carbon Steels in Hydrofluoric Acid Alkylation Units: Note: Carbon Steels in HF Acid service have been reported to suffer increased corrosion rates based on the Residual Elements (RE) in steels. In general, it has been reported that steels with a high RE content are likely to suffer enhanced corrosion attack. Operators should review the potential impact of this in HF service. A guideline is that for base metal of C> 0.18% wt% and Cu + Ni + Cr, 0.15% wt % is optimum. These values are critical as the type and concentrations to be measured will directly affect the analytical methods operations need to adopt. API RP 571 Pages 12,38 57

58 Inspection Program for Low Si All Refineries Priority for API PR nd Edition Process Units Susceptible to Sulfidation: Note: Carbon Steels with low silicon (0.10%) content can corrode at an accelerated rate when exposed to hydrogen-free sulfidation conditions. There phenomena are discussed more extensively in API 571 and API RP 939-C. Operators with assets at risk from this type of degradation should consider the risks and the requirements to apply PMI control in order to determine Silicon levels and the extent to which the material may corrode. 58

59 High Temperature Sulfidic Corrosion-API RP-939-C Low Si-33%,PMI-18%,Specification Break-17% 59

60 GOLDD Alloy PMI Stainless Steels for PMI of low Z elements, e.g., Si in Zecor alloy at ~6% Al in 13-8Mo at 1%, 17-7 and 301 separation by 1% Al, 303/304 and 410/416 separation by ~0.3% S HF Alkylation units guideline for base metal of C> 0.18% wt% and Cu + Ni + Cr = 0.15% or less as optimum for minimizing flow accelerated corrosion LOD for sum is 600 ppm (0.06%) at 10 sec per filter Process Units Susceptible to Sulfidation: Carbon Steels with low silicon (0.10%) content can corrode at an accelerated rate when exposed to hydrogen-free sulfidation conditions. Si LOD is 400 ppm (0.04%) in C steels at 15s per filter using He purge 60

61 GOLDD HF Alkylation, cont. Al Oxide disc used with a right angle grinder (<10 sec) approx removed Cu Ni Cr RE Sum