pressure equipment integrity the keys to success api 2011 j.reynolds

The Keys to Success in

Maintaining Pressure Equipment Integrity and Reliability

Owner-User Panel Discussion

John Reynolds - ModeratorPrincipal ConsultantPro-Inspect, Inc.A Moody International Co.

The Keys to Success in Maintaining Pressure

Equipment Integrity and Reliability

Owner-User Panelists – 240+ years PEI experience

• Mike Urzendowski – 26+ years experience with leading PEI

programs most recently with DNV, Shell and now Technology Director for

Metallurgy with Valero Energy in San Antonio. Mike is co-chair of the

API T/G on IOW’s

• Joey Poret – 15+ years experience with leading PEI/NDE programs;

now with Chevron Corporation as Fixed Equipment Inspection &

Reliability Supervisor in the Gas Project in Nanba, China, and Co-chair

of the API Inspection Summit

• Dave Wang – 20+ years with leading PEI programs in the Shell

Companies, as a PEI & NDE engineer; currently is a Principal Inspection

and Asset Integrity Engineer located at the Shell Westhollow Technology

Center in Houston. Dave is the on API SCI and Chair of API T/G on

Inspection Codes and RPs and the NDE Technology T/G

• Joe Krynicki – 19+ years experience and leading PEI/NDE

programs; now an Advanced Engineering Associate with ExxonMobil

Research and Engineering in Fairfax, VA. Joe is the XOM

representative for the API SCI and Vice Chair of the NDE Technology

T/G



Owner-User Panelists – 240+ years PEI experience

• Steve Bolinger – 28+ years with several companies

contributing to and leading PEI programs most recently with Shell

and now with the BP Texas City Refinery as Asset Integrity

Manager and Engineering Authority.

• Clay White – 27+ years experience with leading PEI/RBI

programs; previously with Equity Engineering and now the

Corporate Fixed Equipment Network Leader with ConocoPhillips

in Houston. Clay is the COP representative and Vice Chair on

the API SCI & Chair IOW T/G

• Mark Geisenhoff – 31+ years experience with leading PEI

programs; now the Global Fixed Equipment Leader with Flint

Hills Resources in St. Paul. Mark is the FHR representative on

the API SCI and Chair of API 510 T/G on the pending 10th edition

• Art Jensen – 31+ years experience in fixed equipment

integrity and reliability programs in Sunoco; now the Corporate

Mechanical Reliability Specialist with Sunoco in Philadelphia

•



What are the keys to success?

• It’s not about the 75+ metallurgical and corrosion

degradation mechanisms in our industry. Those are just the

final physical causes of failures; you can learn about them by

studying for the API ICP Exam on API 571.

• They are not the root cause of most pressure equipment

failures.

• The root causes of 95%+ of pressure equipment failures are

embodied in lack of effective employment of adequate

preventive Pressure Equipment Integrity Management

Systems (PEI MS’s).

• The best operating sites have all 10 of the required PEI MS’s

in place and functioning effectively to prevent the physical causes

of failures from occurring.

• It’s the key elements of those 10 PEI Management Systems that

we are going to talk about this morning.

What is a Pressure Equipment Integrity

Management System (PEI MS)?

• It’s simply a compendium of all the necessary

information that is required in order to maintain

pressure equipment reliability and integrity at each

operating site. Each PEI management system and

subsystem describes in detail how the operating site is

going to manage every important PEI issue:

• what must be done,

• why it needs to done,

• how it is to be done,

• what triggers the need for it,

• how often it needs to be done,

• when it needs to be done

• who is responsible for it, and• everything else you need to know about it.



What are the top 10 PEI MS’s?

• Management Leadership and Support for PEI

• Integrity Operating Windows (IOW)

• Management of Change (MOC)

• Deterioration Management and Control

• Risk Assessment and Inspection Planning

• Life Cycle Management (LCM)

• PEI Codes and Standards (C&S)

• Site Procedures and Work Processes for PEI

• PEI Record Keeping and Data Management

• Continuous Improvement for PEI

Each of these top 10 PEI MS’s is then sub-

divided into multiple subsystems to fully define

the content of each PEI management system

of each of the top 10 MS’s

Excellence

in PEI

Risk

Assessment

and Inspection

Planning

Deterioration

Management

and Control

Management

Leadership

and Support Integrity

Operating

Windows

Management

of Change

Site

Procedures

and Work

Processes

Record

Keeping

and Data

Management

Continuous

Improvement

Life Cycle

Management

Codes ,

Standards and

Regulations

Anything

Missing?



PEI Excellence – the bulls eye!

What does it mean?• It means achieving Pressure Equipment Integrity & Reliability

• Ideally with all the effective PEI MS’s in place, each site should

be able to maintain pressure equipment integrity (i.e. no

breaches of containment) and to achieve pressure equipment

reliability (i.e. having pressure equipment available to function

as designed to meet the business plan)

• PEI excellence does not mean over-blown, expensive systems

or “Cadilacing”; it simply means doing all the right things at the

right time to maintain pressure equipment integrity and reliability

• Vince Lombardi, one of the most famous football coaches in

the history of the NFL, once said “Perfection is not attainable,

but if you chase perfection, you will catch excellence”

• That is certainly true when it comes to maintaining pressure

equipment integrity and reliability of our process plants



Organizing for Success in PEI

• These 10 PEI MS’s are the back bone of all PEI organizations

• Knowing what needs to be accomplished in order to achieve

excellence in pressure equipment integrity is one thing; but

knowing how to organize it all into effective management

systems to achieve continual success is quite another

• The structure of the human organization chart can vary

widely from site to site, and any one of those various

organizations can succeed IF all the right PEI MS’s are in place

and being effectively implemented

• We will not be talking today about organizing the human

hierarchy for success in PEI; but rather organizing around the 10

most important PEI MS’s; and we will provide some examples

of what happens when they are not in place or not functioning

well



Creating and Implementing PEI MS’s

• The top 10 PEI MS’s are only what you see from the

10,000 foot level

• Down in the trenches, each of those top 10 PEI

MS’s includes 101 detailed subsystems,

procedures, work practices and site standards that

must be effectively implemented day after day in order

to achieve success

• And it “almost goes without saying” that creating

these PEI MS’s is just half the process

• If they are not followed up with very effective

implementation and continuous improvement,

then the best written words of the PEI MS’s will not

likely achieve excellence in PEI

Excellence

in PEI

Risk

Assessment

and Inspection

Planning

Deterioration

Management

and Control

Management

Leadership

and Support Integrity

Operating

Windows

Management

of Change

Site

Procedures

and Work

Processes

Record

Keeping

and Data

Management

Continuous

Improvement

Life Cycle

Management

Codes ,

Standards and

Regulations

Anything

Missing?

Management

Leadership

and Support

for PEI

“Walking the

Talk”

PEI

Competency

Improvement

PEI

Resources PEI

Staffing and

Contracting

PEI

Training and

Certification

PEI

Knowledge

Transfer

Shared

Stewardship

of

Assets

OEMI

Teams

Roles

Responsibilities

Accountabilities

Gray Zone

Equipment MS

PEI

Management

System

Reviews

Management

Leadership

and Support

for PEI

“Walking the

Talk”

PEI

Competency

Improvement

PEI

Resources PEI

Staffing and

Contracting

PEI

Training and

Certification

PEI

Knowledge

Transfer

Shared

Stewardship

of

Assets

OEMI

Teams

Roles

Responsibilities

Accountabilities

Gray Zone

Equipment MS

PEI

Management

System

Reviews

Integrity

Operating

Windows

Establishing

Action

Timing

Establishing

Corrective

Actions

Degradation

Assessment

and IOW

Creation Establishing

Upper and

Lower Limits

Standard or

Critical

Classification

Updating

IOW’s

Process

Monitoring

Laboratory

Sampling

Risk

Analysis of

Recommended

Actions

Field

Implementation

Integration

with Other

PEI MS

PEI

Management

of Change

Assessment

of Process

Changes

Assessment

of Physical

Changes

PEI Involvement

in the MOC

Trigger Process PEI Involvement

in the MOC

Assessment

Involvement

of the Right PEI

Knowledge

Resources

Implementation

of Inspection

Changes

Temporary

Installations

Temporary

Repairs

Approval

of MOC

Updating

Inspection

Plan

Integration

with Other

PEI MS

Corrosion

Management

and Control

Water and

Chemical

Treatment

Proactive

Corrosion

Control Deterioration

Control

Manuals

Deterioration

Mitigation

Strategies

Coatings

And

Linings

Corrosion

Control

Industry

Standards

Cathodic

Protection

Systems

External and

CUI Corrosion

Control

Materials

Selection

Corrosion

and Process

Monitoring

Systems

Input to

Inspection and

Maintenance

Plans

Risk

Assessment and

Inspection

Planning

Non-Invasive

vs. Invasive

Inspections

Risk Based

Decision Making

for Turnaround

Planning

Identification

of Degradation

MechanismsRisk Based

Inspection Planning

and Scheduling

Risk

Based Decision

Making for PEI

Options

Risk

Assessment

for HX Bundles

Field

Surveillance

Risk Analysis

for Inspection

Deferrals

Execution

of Inspection

Plan

Special

Emphasis

Inspections

Integration

with other

PEI MS

Life Cycle

Management

for PEI

Repairs and

Replacements

Fitness

for Service

Assessments

Design

and Materials

Selection for

PEIQualified

Suppliers and

Fabricators

Fabrication

& Construction

QA/QC

Materials

Receiving

PMI &QC

Preventive

Maintenance

PEI for Idle

and Retired

Equipment

Temporary

or Permanent

Repairs

Maintenance

QA/QC

Integration

With Other

PEI MS’s

Codes,

Standards

And

Regulations

Other

SDO’s

ASME PCC

New

Construction

In-Service

API CRE

SCI

Staying

Connected with

PEI

Regulators

ASME PTB-2-

2009

OTHERS?

OSHA

Regulations

State

and Local

Regulations

Integration

with All other

PEI MS

Site

Procedures

and Work

Practices

Site Work

Practices

Company

StandardsCompany

and Site Best

Practices

Site

Inspection

Procedures

PEI

Contracting

Process

Turnaround

Planning

Process

PMI and

Materials

Receiving

Welding,

Bolting and

Gasketing

Procedures

NDE

Procedures

Integration

with All Other

PEI MS

Site

Management

Systems

PEI

Records and

Analysis

Data Analysis

Electronic

and Paper

Original

Construction

Records Baseline

Data

Records

Progressive

Inspection

Records

Inspection

and Repair

Recommendation

Tracking

PEI Reports

Records

Retention

Requirements

Deterioration Rate

Calculations

Calculations

of Remaining

Life

Integration

with All Other

PEI MS

PEI

Continuous

Improvement

Solution

Development

Failure

Analysis

Leak

and Failure

Reporting and

TrackingCompany

Failure Memory

System

Incident

and Near-miss

Investigations

PEI

Networking

PEI MS

Auditing

PEI

Metrics and

Goal Setting

Corrective

Actions

Learning

from

Incidents

Integration

with All Other

PEI MS





Would you like to learn more about the top 10 PEI

Management Systems?

• In our limited amount of time this morning, we can only cover a

few of the highlights of the top 10 PEI Management Systems

• It would take a week to even begin to go into any depth for

each of the important issues within each of the top 10 PEI MS’s

• For more information, check out the series of 10 articles

currently running in the Inspectioneering Journal (IJ), as well

as the overview paper on the subject published with the

proceedings of this conference - API Inspection Summit.

• The first six articles in the series have already been published

in the IJ with four more to follow in 2011.

• Some sample copies of the IJ available during the break

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