Boiler Rbi

By
Roger Bartlett
Integrity & Reliability Manager
ALLIANCE REFINING COMPANY LIMITED

Topics
Risk management
Risk Based Inspection
RBI applied to boilers
Experience with statutory inspection of boilers
at ARC

Introduction
ARC is a 50/50 Operating Alliance between
the former SPRC and RRC Companies
Previously two refineries separated by some 4
km
Both refineries started up in 1996
A refining complex with 300,000 bpd capacity
One site is a highly integrated HCU refinery,
the other a RFCCU refinery

ARC Operating Alliance
Shell PTT ChevronTexaco
64% 36% 36% 64%
Rayong Refinery Star Petroleum

Co., Ltd. Refining Co., Ltd.
RRC SPRC
50% 50%
Alliance Refining Co., Ltd.

ARC
Risk Management
Risk management is NOT telling you
to take more or uncontrolled
RISKS
Everyone takes risks already
Benefits can be realised by

managing your risks by making
smarter decisions
Risk Management
Being aware of and managing your
risks allows you to apply resources
to critical work and to place less
emphasis on less critical work
(prioritisation).
Industries that do not manage their risks
tend to put as much emphasis on low
priority work as they do high priority
work.
This is expensive and can be
dangerous.
Standard methodology
Semi-quantitative assessment of
RISK based on CRITICALITY
Determines pro-active inspection
activities/condition monitoring for
static equipment
Gives indications where re-
design needed

Balances tasks against CRITICALITY

HIGH Criticality:
High activity to reduce
probability of failure
LOW Criticality:
Reduced or NO activity

RBI Methodology delivers:
An optimised inspection plan

increased availability
- increased run length
- reduced shutdown duration
reduced costs for inspection &
maintenance
Safeguarding of integrity


S-RBI study for a Corrosion Loop
Define the Corrosion Loop
Describe process conditions
Establish the Operating Window
List Items in the loop
Materials and corrosion allowances (design)
Agree Potential Degradation Mechanisms for the loop
Review inspection history - corrosion rates
Give a Confidence Rating for each item and degradation
Do the Criticality rating per Degradation Mechanism
Establish remnant life & max. inspection interval OR monitoring
scheme
Define scope of inspections / monitoring
Corrosion Loops
A practical way to describe, understand and check
degradation mechanisms in a unit
A CORROSION LOOP is part of the unit subjected to:
The same process conditions
The same failure mechanisms
The same materials selection criteria
One operating window
Control of degradations via process control
Values agreed by team (boundary conditions for
RBI)
ALLIANCE
Deviations should be reported
REFINING COMPANY LIMITED
CRITICALITY ASSESSMENT
QUALITATIVE PRE - SELECTION
- corrosion loop level
SEMI-QUANTITATIVE ASSESSMENT
- questionnaires
PROBABILITY of FAILURE
CONSEQUENCES
- HSE
- Production losses and damage
CRITICALITY = PROBABILITY x CONSEQUENCES

Susceptibility to Failure
Age Related Mechanisms:
Internal Corrosion
External Corrosion
Creep
Non Age Related Mechanisms

Thermal Fatigue/Cyclic Stress
Stress Corrosion/Environmental Cracking
Low/High Temperature Embrittlement
High Temperature Hydrogen Attack
Erosion

Susceptibility to Failure Assessment

Direct Assessment of
Consequences of Failure

Criticality Matrix
X = Intolerable
E = Extreme
H = High
M = Medium
L = Low
N = Negligible
Differentiation: Age-Related vs Non-Age-
Related Degradation Mechanisms

Maximum Inspection Intervals

Confidence Rating
Indicator for CONFIDENCE in
forecasting degradation and remnant life
Rating VERY LOW to VERY HIGH

reflects:
Stability/Predictability of Degradation
Number and Quality of previous
inspections
Process stability and control
Better Confidence yields LONGER

INSPECTION INTERVALS
Confidence Rating For Age-Related
Degradation Only

Inspection Plan for Age-Related
Degradation
INSPECTION INTERVALS
Criticality, Confidence and Remnant
Life
Maximum Inspection Interval

= Interval Factor x Remnant Life
TECHNIQUES, LOCATION and SCOPE
QUALIFIED PERSONNEL
Process Monitoring for Non-Age Related
Mechanisms
Parameters to be monitored, as
described in Operating Window
Frequency, as described in
Operating Window
Deviations to be reviewed and

actions reported. Changes via
Plant Change Procedure
Revise Inspection Plans if needed

Feedback/Review
After each maintenance and
inspection shutdown
At the implementation of Plant
Changes
At deviations from Operating
Window
Actual condition and fitness for service

Degradation Mechanisms and Rate
Confidence Rating
ARC Boilers
ARC has a number of package- and WH

boilers
Capacities 12-100 T/hr
Design Pressures 49-148 kg/cm2
Natural Gas firing (SRU WHB burn
acid gases)
Subject to statutory inspection

Package Boiler Design Data
Parameters Locations
SPRC RRC
Package Boilers 2 -
Design Steam Flow (ton/hr) 70 -
Design Pressure (kg/cm2) 53.5 -
Design Temperature (C) 465 -
Operating Pressure (kg/cm2) 42.5 -
Operating Temperature (C) 399 -
Fuel supply Natural gas -
Co-Gen Waste Heat Boilers Boiler Design Data (cont)
SPRC RRC
Waste heat boilers 2 3
Design Steam Flow (ton/hr) 65 100
Design Pressure (kg/cm2) 55 148
Design Temperature (C) 399 545
Operating Pressure (kg/cm2) 42.5 135
Operating Temperature (C) 395 334
Fuel supply Natural gas Natural gas
Fired-Tube Waste Heat Boilers
SPRC RRC
Waste heat boilers 2 2
Design Steam Flow (ton/hr) 12.9 12
Design Pressure (kg/cm2) 49 50
Design Temperature (C) 371 280
Operating Pressure (kg/cm2) 42 46
Operating Temperature (C) 343 260
Fuel supply Natural gas Natural gas
Statutory Inspection Frequency
Package and Co-gen. boilers that have steam

capacity greater than 20 ton/hr - every 3 years
(exemption given by statutory authorities to extend interval
from 1 year based on good inspection history)
Package and Co-gen. boilers that have steam

capacity less than 20 ton/hr - every year.
(extension not permitted)

Boiler Inspection
Inspection normally includes examination of all, or representative areas of:
Steam and water-side surfaces of piping, headers and drums for deposits, scale,
erosion and corrosion.
Fire-side surfaces of tubing, headers and drums for bulging, blistering and the design
pressure other signs of over-heating and external corrosion.
Tube sheet ligaments for cracks.
Integral piping for internal/external corrosion, erosion, leaks or cracks.
Fireside components such as hangers.
Soot-blowing equipment.
Combustion components.
Refractory linings and burners.
External insulation and casing.
Pressure relief valves shall be removed for maintenance and re-testing.
The boiler drum and associated circuit is subjected to a hydrotest at 1.5x

Boiler Inspection Program
Part of Inspection Description of Inspection
Steam drum - Check internal surface condition for corrosion.
- Carry out fibrescope inspection of tubes.
- Spot UT gauging on shell and covers.
Superheater - Carry out fibrescope inspection of tubes.

Furnace Header - Carry out fibrescope inspection of tubes.

Economizer - Open flanges on inspection nozzles at inlet and outlet header.

- Open both access manways to gas side for VT.
- Carry out spot UT gauging for all headers.
- Radiograph return bends in economizer section
Fire box region - Internal inspection (refractory and adjacent steam drum, roof
tubes and top burner)
- Inspection of all refractory and tips of burners.
- Inspection of all insulation within air register.
- Check tube for any sign of deformation, check membrane weld
for signs of cracking.

Boiler Inspection Program (cont)
Part of Inspection Description of Inspection
Soot blowers - Rotate for inspection and check nozzles
Air and Gas ducting - Inspection of all Expansion Joints.

- Check external and internal insulation for signs of water
ingress.
Stack - Open manway for visual inspection.
Relief valve calibration - Remove to workshop for overhaul

- Apply cold set test pressure. Witness by Inspection Engineer.
- At start up PSVs to test hot setting (blowdown)
Water drum - Carry out fibrescope inspection of tubes

- Spot UT gauging on shell and covers
Blowdown line - Spot UT gauging or X-Ray will be applied to monitor for

erosion- corrosion
Hydrostatic Testing - Apply hydrotest to boiler at 1.5 x D.P.

- To be witnessed be Authorized Engineer

Boiler Water Treatment
To control internal corrosion it is
essential to have an effective water
treatment programme
BFW, boiler water, steam and

condensate quality are maintained
within set limits
ARC has a water treatment programme

from a partnership contract with
ONDEO-Nalco to treat and monitor
water and steam quality
Water Treatment Quality
Reverse Osmosis Simplified Flow Scheme: Water treatment at SPRC
raw water
or fire pond water 42S115 42D117 42D102
Clarifier Clearwell Clarified
Tank Water
42G102A/B/C
42S112 42G116A/B/C
42S116A/B/C/D
Sludge Blowdown Sump Gravity Filters 43D101
Portable
water
LGC Boiler
HGC Blowdown
UT Distribution
CoolingTower Salt
To users
regen.
RO Reject
42D108
Surge Tank
42G110A/B/C
42S121A/B/C
41G111A/B 42S123A/B/C Softener
42S124A/B/C/D Catridge Filters
RO Membrane Unit Sodium Zeolite Resin
HGC
41D101
BFW HP BFW
41D102 HP Boiler
41G109A/B Deaerator
LGC
41G101A/B
MP BFW

Process Parameters Monitored
High Pressure Boiler on SPRC
Test Required Target 40F101 40F102 40F103 40F104
pH 9.5 - 11.5 10.83 10.5 10.5 10.49
Conductivity (uS/cm) < 500 266 142 127.6 125.2
S-Phosphate (mg PO43-/l) 5-10 7.3 7.07 6.31 5.8
Silica (mg/l) <30 21.4 19.83 20.56 19.54
T-Iron (mg Fe/l) <1 0.13 0.14 0.12 0.21
T-Alkalinity (mg CaCO3/l) <200 80 40 35 35

Process Parameters Monitored (cont)
High Pressure Boiler on RRC
Test Required Target F3301 F3302 F3303

pH 9.2 - 9.6 9.51 9.5 9.43
Conductivity , uS/cm <50 25.2 23.7 19.8
Silica , ppb <1200 190 105 110
S-Phosphate , ppm 4-6 5.6 5.4 4.8

Degradation Mechanisms in Boilers
Internal Corrosion (AR)

External Corrosion (AR)
Creep (AR)
Erosion (NAR)
Caustic Cracking (NAR)
Fatigue (inc. Corrosion-Fatigue)
(NAR)
Thermal Fatigue (NAR)

Other Factors
Thermal Cycling of Refractories

shutting down/starting up
Corrosion during shutdown:

- External fuel oil sulphur
- Internal O2
Better to minimise shutdown

duration/scope

RBI Applied to Boilers
Internal Corrosion:
- Water Treatment and Monitoring
- Internal Inspection every 3 (or 1) years
- Measured Corrosion Rates (Low)
External Corrosion:
- Fuel Gas Firing (clean)
- Low Temperature vs Design
Creep:
- Operating Window carefully controlled
- No flame impingement
- Low Temperature/Pressure vs Design
RBI Assessment - Example
Steam Drum:
Susceptibility to Failure = Low

Consequences of Failure = Med/High
Criticality Factor = Med
Confidence = Very High
Corrosion Allowance = 3mm
Corrosion Rate = 0.1 mm/year
Remnant Life = 30 years
Interval factor = 0.6
Maximum Inspection interval = 18 years
Interval Set (Statutory) = 3 years

RBI Assessment - Example
Superheater Tubes:
Susceptibility to Failure = Low

Consequences of Failure = High
Criticality Factor = High
Confidence = Very High
Corrosion Allowance = 0.25mm
Corrosion Rate = 0.01 mm/year
Remnant Life = 25 years
Interval factor = 0.5
Maximum Inspection interval = 12.5 years
Interval Set (Statutory) = 3 years

RBI Inspection Intervals for Boilers
Analysis concludes that the inspection intervals
calculated using RBI are much longer than the
statutory inspection periods
Many components have assessed inspection

intervals in excess of 6 years
At 3 year (or 1 year) statutory inspections, not all

components need to be inspected (RBI)
ITEMS REQUIRING STATUTORY
INSPECTION ARE ALWAYS INSPECTED AT
SPECIFIED INTERVALS
An inspection plan can be developed using a

combination of intrusive/non-intrusive
inspections to manage integrity
RBI Inspection Intervals for Boilers
NOTES:
RBI analyses and the results are

specific for each plant, not
generally applicable
For any upset condition, the effect

on the RBI analysis has to be
re-evaluated. The inspection
interval or scope may need to be
changed
Experiences with Boiler Inspections at
ARC
Large Boilers (>20T/hr):
Good condition found. Internal

surfaces show classical Fe3O4
film, no pitting
No measurable wall loss
No hot surface damage to
tubes/components
Little creep life consumed
Water treatment very effective
Experiences with Boiler Inspections at ARC
Small Boilers (<20T/hr):
WHBs attached to SRU (High Sulphur

in combusting gases)
Boiler drum and piping show no
deterioration internally
Not operated in creep range
Fire-side deterioration during shutdown
Repeated annual shutdown damages
refractory
Cracks in ferrules protecting tubesheet
High T. sulphidation attack of tubesheet
SRU WHB Ferrule and Refractory on
Tubesheet
75
40
2.0 mm
22.8
18.8
31.75
16.8
25

Small boilers (<20 T/hr) at ARC:
Have the same water quality as the large

boilers
Have the same deterioration mechanisms
Are subjected to the same inspection scopes
Do not operate in the creep range
Are run at low P and T compared with design
Are subjected to annual thermal cycles that
cause damage to refractory and increased
corrosion
Shutting down small boilers for annual inspection

causes more damage than operating for longer
periods
In other countries, small boilers are treated no differently

from large boilers, so inspection periods can be extended
if justified

Conclusions
RBI Methodology can be used to prioritise
inspection requirements, based on Criticality
When applied to boilers, statutory inspection periods

are shown to be conservative for boilers with:
- Good water quality
- Carefully fired within the Op.Window
- Correctly inspected and maintained
Small boilers (<20T/hr) should not be treated

differently from large boilers - the same potential
for extending statutory inspection periods should
apply
Full Criticality Matrix

Se l e c t e d os i / N ext
F a i l ur e c al c A c tC or R e mna nt c a l c i nt e r v c a l c i ns p
T a g numbe r A s s e t D e s c r i pt i o n C o r r o s i o n l o o p na me c a l c c o nf C o r r os i o n F r e q c o de I ns pe c t i o n M e t ho d I nt r us i I ns pe c t i o c o mme nt s
M o de I D C r i tA s s es A l l ow Li f e f ac t i nt e r v
R ate ve n D ate
C ombined P i pi ng C L-022-211 P i pi ng Uti l i ty Water 1 M N 3 0.1 30 0.6 18 I NV UT T M OS/ NI 7/ 1/ 03
C ombined P i pi ng C L-024-211 I H M P / HP / HHP Steam P i pi ng M P / HP / HHP s team 1 M M 1 0.1 10 0.4 4 I NV UT T M OS/ NI 7/ 1/ 03
E -1112 I H Hd C ond/ Feed P r eheater M P / HP / HHP s team 1 VH N 3 0.1 30 0.8 24 6Y UT T M OS/ NI 7/ 1/ 08
E -1112 I H Hd C ond/ Feed P r eheater M P / HP / HHP s team 1 VH N 3 0.1 30 0.8 24 12Y V I , UT T M & HT SD/ I 8/ 1/ 14
E -1112 T i C ond/ Feed P r eheater M P / HP / HHP s team 1 H N 1.05 0.1 10. 55 0.7 7.35 6Y V I & HT SD/ I 5/ 1/ 07
C ombined P i pi ng C L-021-212 Demi n Water P i pi ng Demi ner al i s ed Water 1 M N 0.25 0.01 25 0.6 15 6Y UT T M OS/ NI 1/ 1/ 04
F-4101 T o GT Gener ati ng tubes Fl ue Gas 1 VH H 0.25 0.01 25 0.5 12.5 3Y V I , UT T M & HT SD/ I 12/ 1/ 06 Legal r equi r ement
F-4101 T o ST Super heater tubes Fl ue Gas 1 VH H 0.25 0.01 25 0.5 12.5 3Y V I & HT SD/ I 12/ 1/ 06 Legal r equi r ement
F-4102 T o GT Gener ati ng T ubes Fl ue Gas 1 VH H 0.25 0.01 25 0.5 12.5 3Y V I , UT T M & HT SD/ I 11/ 1/ 06 Legal r equi r ement
F-4103 T o GT Gener ati ng T ubes Fl ue Gas 1 VH H 0.25 0.01 25 0.5 12.5 3Y V I , UT T M & HT SD/ I 1/ 1/ 06 Legal r equi r ement
V -4102 Fuel Gas K .O Dr um Fuel Gas 1 M M 3 0.1 30 0.4 12 6Y V I & UT T M SD/ I 7/ 1/ 08
V -4102 Fuel Gas K .O Dr um Fuel Gas 1 M M 3 0.1 30 0.4 12 3Y UT T M OS/ NI 7/ 1/ 05
V -4901A Fuel Gas K O Dr um Fuel Gas 1 H M 3 0.1 30 0.5 15 6Y V I & UT T M SD/ I 7/ 1/ 08
V -4901B Fuel Gas K O Dr um Fuel Gas 1 H H 2.35 0.16 14. 69 0.4 5.88 3Y V I & UT T M SD/ I 7/ 1/ 05
C ombined P i pi ng C L-021-(241-249) C ombi ned P i pi ng For Demi n Water Demi n Water 1 M N 0.25 0.01 25 0.6 15 6Y UT T M OS/ NI 1/ 1/ 04
C ombined P i pi ng C L-022-(241-249) Uti l i ty Water P i pi ng Uti l i ty Water 1 M N 1 0.1 10 0.6 6 I NV UT T M OS/ NI 7/ 1/ 03
V -4103 C onti nous B l owdown Dr um M P ,HP ,HHP Steam 1 VH L 3 0.1 30 0.7 21 12Y V I & UT T M SD/ I 8/ 1/ 14
V -4103 C onti nous B l owdown Dr um M P ,HP ,HHP Steam 1 VH L 3 0.1 30 0.7 21 6Y UT T M SD/ NI 7/ 1/ 08
V -4201 M P C ondens ate Fl as h Dr um M P ,HP ,HHP Steam 1 VH L 3 0.1 30 0.7 21 12Y V I & UT T M SD/ I 8/ 1/ 14
V -4201 M P C ondens ate Fl as h Dr um M P ,HP ,HHP Steam 1 VH L 3 0.1 30 0.7 21 6Y UT T M SD/ NI 7/ 1/ 08
V -4202 LP Condens ate Fl as h Dr um M P ,HP ,HHP Steam 1 VH L 3 0.1 30 0.7 21 12Y V I & UT T M SD/ I 8/ 1/ 14
V -4202 LP Condens ate Fl as h Dr um M P ,HP ,HHP Steam 1 VH L 3 0.1 30 0.7 21 6Y UT T M SD/ NI 7/ 1/ 08
E -4101 T f B l owdown C ool er Steam C ondens ate B ef or e Deoi l er 1 M N 1.2 0.1 12. 05 0.6 7.26 6Y V I & HT SD/ I 5/ 1/ 07
E -4101 T f Hd B l owdown C ool er Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 12Y V I , UT T M & HT SD/ I 8/ 1/ 14
E -4101 T f Hd B l owdown C ool er Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 6Y UT T M SD/ NI 7/ 1/ 08
E -4202 T f C ondens ate T r i m C ool er Steam C ondens ate B ef or e Deoi l er 1 M N 1.2 0.1 12. 05 0.6 7.26 6Y V I & HT SD/ I 2/ 1/ 09
E -4202 T f Hd C ondens ate T r i m C ool er Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 12Y V I , UT T M & HT SD/ I 8/ 1/ 14
E -4202 T f Hd C ondens ate T r i m C ool er Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 6Y UT T M SD/ NI 7/ 1/ 08
E -4203 T f SteamC ondens er Steam C ondens ate B ef or e Deoi l er 1 M N 1.2 0.1 12. 05 0.6 7.26 6Y V I & HT SD/ I 5/ 1/ 07
E -4203 T f Hd SteamC ondens er Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 12Y V I , UT T M & HT SD/ I 8/ 1/ 14
E -4203 T f Hd SteamC ondens er Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 6Y UT T M SD/ NI 7/ 1/ 08
V -4103 C onti nous B l owdown Dr um Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 12Y V I & UT T M SD/ I 8/ 1/ 14
V -4103 C onti nous B l owdown Dr um Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 6Y UT T M OS/ NI 7/ 1/ 08
V -4104 I nter mi ttent Bl owdown Dr um Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 6Y V I & UT T M SD/ I 7/ 1/ 08
V -4104 I nter mi ttent Bl owdown Dr um Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 6Y UT T M OS/ NI 7/ 1/ 08
V -4201 M P C ondens ate Fl as h Dr um Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 6Y UT T M OS/ NI 7/ 1/ 08
V -4201 M P C ondens ate Fl as h Dr um Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 12Y V I & UT T M SD/ I 8/ 1/ 14
V -4202 LP Condens ate Fl as h Dr um Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 6Y UT T M OS/ NI 7/ 1/ 08
V -4202 LP Condens ate Fl as h Dr um Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 12Y V I & UT T M SD/ I 8/ 1/ 14
V -4203 SteamC ondens ate Dr um Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 6Y UT T M OS/ NI 7/ 1/ 08
V -4203 SteamC ondens ate Dr um Steam C ondens ate B ef or e Deoi l er 1 VH N 3 0.1 30 0.8 24 12Y V I & UT T M SD/ I 8/ 1/ 14
C ombined P i pi ng C L-030-(241-249) I H C ombi ned P i pi ng For B oi l er Feed Water B oi l er Feed Water (B FW) 1 M H 1 0.1 10 0.3 3 I NV UT T M OS/ NI 7/ 1/ 03
C ombined P i pi ng C L-030-(241-249) I H C ombi ned P i pi ng For B oi l er Feed Water B oi l er Feed Water (B FW) 2 M H 1 0.1 I NV UT T M OS/ NI 7/ 1/ 03
C ombined P i pi ng C L-030-(241-249) I H C ombi ned P i pi ng For B oi l er Feed Water B oi l er Feed Water (B FW) 5 VL H 1 0.1 6Y V I & WFM P T SD/ NI 7/ 1/ 08
C ombined P i pi ng C L-030-(241-249) I H C ombi ned P i pi ng For B oi l er Feed Water B oi l er Feed Water (B FW) 5 VL H 1 0.1 1Y VI OS/ NI 7/ 1/ 03
V -4101A Dear ator s B oi l er Feed Water (B FW) 1 VH N 3 0.1 30 0.8 24 12Y V I & UT T M SD/ I 8/ 1/ 14
V -4101A Dear ator s B oi l er Feed Water (B FW) 2 H N 3 0.1 24Y Sel ecti ve del aggi ng SD/ NI 5/ 1/ 26
V -4101A Dear ator s B oi l er Feed Water (B FW) 2 H N 3 0.1 12Y V I &I R OS/ NI 8/ 1/ 14
V -4101A Dear ator s B oi l er Feed Water (B FW) 5 VL N 3 0.1 6Y V I & WFM P T SD/ I 7/ 1/ 08
V -4101B Dear ator s B oi l er Feed Water (B FW) 1 VH N 3 0.1 30 0.8 24 12Y V I & UT T M SD/ NI 8/ 1/ 14
V -4101B Dear ator s B oi l er Feed Water (B FW) 1 VH N 3 0.1 30 0.8 24 6Y UT T M OS/ NI 7/ 1/ 08
V -4101B Dear ator s B oi l er Feed Water (B FW) 2 H N 3 0.1 12Y V I &I R OS/ NI 8/ 1/ 14
V -4101B Dear ator s B oi l er Feed Water (B FW) 2 H N 3 0.1 24Y Sel ecti ve del aggi ng SD/ NI 5/ 1/ 26
V -4101B Dear ator s B oi l er Feed Water (B FW) 5 VL N 3 0.1 6Y V I & WFM P T SD/ I 7/ 1/ 08
C ombined P i pi ng C L-046-(241-249) C ombi ned P i pi ng For Steam C ondens ate Steam C ondens ate to Stor age
1 M H 1 0.1 10 0.3 3 I NV UT T M OS/ NI 7/ 1/ 03
T o Stor age
F-4101 T i GT Gener ati ng T ubes B oi l er T ube 1 VH L 0.25 0.01 25 0.7 17.5 3Y V I , UT T M & HT SD/ I 12/ 1/ 06 Legal r equi r ement
F-4101 T i ST Super heater tubes B oi l er T ube 1 VH L 0.25 0.01 25 0.7 17.5 3Y V I & HT SD/ I 12/ 1/ 06 Legal r equi r ement
F-4102 T i GT Gener ati ng T ubes B oi l er T ube 1 VH L 0.25 0.01 25 0.7 17.5 3Y V I , UT T M & HT SD/ I 11/ 1/ 06 Legal r equi r ement
F-4102 T i ST Super heater tubes B oi l er T ube 1 VH L 0.25 0.01 25 0.7 17.5 3Y V I & HT SD/ I 11/ 1/ 06 Legal r equi r ement
F-4103 T i GT Gener ati ng T ubes B oi l er T ube 1 H L 0.25 0.01 25 0.6 15 3Y V I , UT T M & HT SD/ I 1/ 1/ 06 Legal r equi r ement
F-4103 T i ST Super heater tubes B oi l er T ube 1 H L 0.25 0.01 25 0.6 15 3Y V I & HT SD/ I 1/ 1/ 06 Legal r equi r ement
Se l e c t e d
C or r os i on F a i l ur e c al c A c tC or A l l o I ns pe c t i o n os i / N e x t I ns pe c t i o n
T a g numbe r A s s e t D e s c r i pt i o n c a l c c o nf C or r os i on R e mna nt L i f e c a l c i nt e r v f a c t c a l c i ns p i nt e r v F r e q c o de c o mme nt s
l oo p na me M o de I D C r i tA s s es w M e t ho d I nt r u s i v e D ate
R ate
P 200018 / P 205018 Sour f eed gas f r om A DIP 1 & 2 1 L H 3 0.05 60 0.3 6 UT M 2008
P 210001 Sour f eed gas f r om A DIP 1 & 2 1 L H 3 0.05 60 0,3 6 UT M 2008
V 2106 Feed gas K O dr um 1 L H 3 0.05 60 0.3 6 VI 2008
P 210002 Sour gas to E 2107 1 L H 3 0.05 60 0.3 6 UT M 2008
E 2107 Feed gas heater 1 L H 3 0.05 60 0.3 6 VI 2008
P 210003 / 006 / 210101 Sour gas l i ne to F2101 / F2201 1 L H 1 0.05 20 0.3 6
P 240043 Sour f eed gas f r om SWS 1 L H 4 0.05 80 0.3 6 UT M 2008
V 2107 Feed gas K O dr um 1 L H 3 0.05 60 0.3 6 VI 2008
P 210005 Sour gas to P 210006 1 L H 4 0.05 80 0.3 6
F2101 C l aus bur ner 1 L M 0 0 na 0.4 8 VI 2003 R ef r actor y
M 2101 C ombus ti on chamber 1 L M 0 0 na 0.4 8 VI 2003 R ef r actor y
E 2101 (tube s ide) Waste heat boi l er 1 L M 0 0 na 0.4 8 VI 2003 R ef r actor y
P 210102 P r ocess gas to E 2102 1 L M 3 0.02 150 0.4 8
E 2102 1 st Sul phur condens er 1 L M 1.5 0.05 30 0.4 8 VI 2004
P 210103 P r ocess gas to M 2102 1 L M 1.5 0.05 30 0.4 8
F2102 1s t Li ne bur ner 1 L M 0 0 na 0.4 8 VI 2003 R ef r actor y
M 2102 1s t M i xi ng chamber 1 L M 0 0 na 0.4 8 VI 2003 R ef r actor y
P 210104 P r ocess gas to R 2101 1 L M 3 0.05 60 0.4 8
R 2101 1s t C l aus r eactor 1 L M 0 0 na 0.4 8 VI 2003 R ef r actor y
E 2103 2nd Sul phur condens er 1 L M 1 0.05 20 0.4 8 VI 2004
P 210106 P r ocess gas to M 2103 1 L M 1 0.05 20 0.4 8
F2103 2nd Li ne bur ner 1 L M 0 0 na 0.4 8 VI 2003 R ef r actor y
M 2103 2nd M i xi ng chamber 1 L M 0 0 na 0.4 8 VI 2003 R ef r actor y
P 210107 P r ocess gas to R 2102 1 L M 3 0.05 60 0.4 8
R 2102 2nd C l aus r eactor 1 L M 0 0 na 0.4 8 VI 2003 R ef r actor y
E 2104 3r d Sul phur condens er 1 L M 1 0.05 20 0.4 8 VI 2004
P 210109 P r ocess gas to V 2105 1 L M 1 0.05 20 0.4 8
V 2105 Sul phur coal es cer 1 L M 3 0.05 60 0.4 8 V I / UT M 2004
P 210110 T ai l gas to i nci ner ator s 1 L M 1 0.05 20 0.4 8
P 210111/ P 220111 T ai l gas to M 2150 / M 2250 1 L M 1 0.05 20 0.4 8
F2150 I nci ner ator bur ner 1 L M 0 0 na 0.4 8 VI 2004 R ef r actor y
M 2150 I nci ner ator mi xi ng chamber 1 L M 0 0 na 0.4 8 VI 2004 R ef r actor y
P i pi ng 48" T ai l gas 1 L M 0 0 na 0.4 8 R ef r actor y
R 2150 I nci ner ator r eactor 1 L M 0 0 na 0.4 8 VI 2004 R ef r actor y
Fl ue gas duct T ai l gas to stack 1 L M 0 0 na 0.4 8 R ef r actor y
P 210121 Li qui d s ul phur to V 2101 1 L M 4 0 na 0.4 8 R ef r actor y
P 210122 Li qui d s ul phur to V 2102 1 L M 4 0.05 80 0.4 8
V 2111 / 12 / 13 / 14 Sul phur f unnel s 1 L M 4 0.05 80 0.4 8 VI 2004
V 2101 / 02 / 03 / 04 Sul phur l ocks 1 L M 4 0.05 80 0.4 8 VI 2004
P 210125 Li qui d s ul phur to stor age 1 L H 4 0.05 80 0.3 6
V 2108 Sul phur degass i ng vessel 1 L H 3 0.05 80 0.3 6 VI 2008
W210003 B FW to V 2110 1 H M 1 0.05 100 0.7 14
V 2110 Steam dr um 1 H M 3 0.01 300 0.7 14 VI 2003 T hai Lei gi sl ati on
S210001 I P s teamoutl et 1 H M 1 0.01 100 0.7 14
W210018 B FW to E 2102 1 H M 1 0.01 100 0.6 12
E 2101 (shel l si de) WHB 1 H M 1.5 0.01 150 0.7 14 VI 2003 T hai Legi s l ati on
E 2102 (shel l si de) Sul phur condens er 1 H M 1.5 0.01 150 0.7 14
S210021 LP steam outl et 1 H M 1 0.01 100 0.7 14

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ALLIANCE REFINING COMPANY LIMITED

ALLIANCE REFINING COMPANY LIMITED

ALLIANCE REFINING COMPANY LIMITED

Shell PTT ChevronTexaco

64% 36% 36% 64%

Rayong Refinery Star Petroleum

Alliance Refining Co., Ltd.

Everyone takes risks already

Benefits can be realised by

ALLIANCE REFINING COMPANY LIMITED

Balances tasks against CRITICALITY

ALLIANCE REFINING COMPANY LIMITED

An optimised inspection plan

ALLIANCE REFINING COMPANY LIMITED

ALLIANCE REFINING COMPANY LIMITED

CRITICALITY = PROBABILITY x CONSEQUENCES

Non Age Related Mechanisms

ALLIANCE REFINING COMPANY LIMITED

ALLIANCE REFINING COMPANY LIMITED

ALLIANCE REFINING COMPANY LIMITED

ALLIANCE REFINING COMPANY LIMITED

ALLIANCE REFINING COMPANY LIMITED

Rating VERY LOW to VERY HIGH

Better Confidence yields LONGER

ALLIANCE REFINING COMPANY LIMITED

Maximum Inspection Interval

TECHNIQUES, LOCATION and SCOPE

Deviations to be reviewed and

Revise Inspection Plans if needed

ALLIANCE REFINING COMPANY LIMITED

Actual condition and fitness for service

ARC has a number of package- and WH

ALLIANCE REFINING COMPANY LIMITED

Package and Co-gen. boilers that have steam

Package and Co-gen. boilers that have steam

ALLIANCE REFINING COMPANY LIMITED

ALLIANCE REFINING COMPANY LIMITED

Superheater - Carry out fibrescope inspection of tubes.

Furnace Header - Carry out fibrescope inspection of tubes.

Economizer - Open flanges on inspection nozzles at inlet and outlet header.

ALLIANCE REFINING COMPANY LIMITED

Air and Gas ducting - Inspection of all Expansion Joints.

Stack - Open manway for visual inspection.

Relief valve calibration - Remove to workshop for overhaul

Water drum - Carry out fibrescope inspection of tubes

Blowdown line - Spot UT gauging or X-Ray will be applied to monitor for

Hydrostatic Testing - Apply hydrotest to boiler at 1.5 x D.P.

ALLIANCE REFINING COMPANY LIMITED

BFW, boiler water, steam and

ARC has a water treatment programme

ALLIANCE REFINING COMPANY LIMITED

Test Required Target 40F101 40F102 40F103 40F104

pH 9.5 - 11.5 10.83 10.5 10.5 10.49

Conductivity (uS/cm) < 500 266 142 127.6 125.2

S-Phosphate (mg PO43-/l) 5-10 7.3 7.07 6.31 5.8

Silica (mg/l) <30 21.4 19.83 20.56 19.54

T-Iron (mg Fe/l) <1 0.13 0.14 0.12 0.21