PSM - Refining Damage

Mechanisms “101”
Jim Riley
 DMR Requirements
1. Complete a DMR for all existing and new process where DMR exists.
2. Timeline: 50% DMR’s within 3 years, complete all DMR’s within 5 years
3. Revalidation: At least once every five years
4. DMR’s reviewed as part of major process change prior to the change.
5. Where a DMR is a factor in an incident investigation, review most recent
DMR’s; if no DMR then recommend a DMR be conducted.
6. DMR’s must be available to team performing a PHA for that process
7. DMR’s performed by team with expertise in engineering, equipment and
pipe inspection, damage and failure mechanisms, and operations.
 DMR Requirements (continued)
8. A DMR for each process shall include:
A. Assessment of process flow diagrams;
B. Identification of all potential damage mechanisms;
C. Determination that the materials of construction are appropriate for
their application and are resistant to potential damage mechanisms;
D. Methods to prevent or mitigate damage; and,
E. Review of operating parameters to identify operating conditions that
could accelerate or otherwise worsen damage, or that could minimize
or eliminate damage.
 DMR Requirements (continued)
9. Damage Mechanisms include:
A. Mechanical loading failures, such as ductile fracture, brittle fracture,
mechanical fracture an buckling;
B. Erosion, such as abrasive wear, adhesive wear and fretting,
C. Corrosion, such as uniform corrosion, localized corrosion and pitting;
D. Thermal-related failures, such as creep, metallurgical transformation
and thermal fatigue;
E. Cracking, such as stress-corrosion cracking; and,
F. Embrittlement, such as high-temperature hydrogen attack.
 DMR Requirements (continued)
10. DMRs shall include an assessment of previous experience with the
process, including the inspection history and all damage mechanism
data; a review of industry-wide experience with the process; and all
applicable standards, codes, and practices.
11. At the conclusion of the analysis, the team shall prepare a written DMR
report, which shall include the following:
A. The process unit and damage mechanisms analysed;
B. Results of all analyses conducted, pursuant to subsection (k)(8)
C. Recommendations for temporarily mitigating damage; and,
D. Recommendations for preventing damage.
 DMR Requirements (continued)
12. The report shall be provided to and, upon request, reviewed with
employees whose work assignments are within the process unit
described in the DMR.
13. The employer shall implement all recommendations in accordance with
subsection (x).
14. DMR reports shall be retained for the life of the process unit.
 Industry Aids Available
• API 571 – Damage Mechanisms Affecting Fixed Equipment in the
Refining Industry (2nd Edition 2011)
• NBIC Part 2 Section 3 Corrosion and Failure Mechanisms (2017
Edition)
• API 580/581 Risk Based Inspection/RBI Technology BRD
• API 584 Integrity Operating Window (1st Edition 2014)
• API 970 Corrosion Control Documents (Draft)
 Damage
Mechanisms
 NBIC Part 2
Section 3 Corrosion and Failure Mechanisms
3 .1 Scope
3 .2 General
3.3 Corrosion
3 .3 . 1 Macroscopic Co r rosion Env ironments
3 .3 .2 Microscopic Corr osion Env ironments
3 .3 .3 Control of Corrosion
3 .3 .3 . 1 Process V ariables
3 .3 .3 .2 Protection
3 .3 .3 .3 Material Selection
3 .3 .3 .4 Coa tings
3 .3 .3 .5 Engineering Design
3 .3 .3 .6 Conclusion
3.4 Failure Mechanisms
3.4.1 Fatigue
3 .4 .2 Creep
3 .4 .3 Temperature Effects
3 .4 .4 H y drogen Embrittl ement
3 .4 .5 High-Temperature H y drogen Attack
3 .4 .6 H y drogen Damage
3 .4 .7 Bulges and Blisters
3 .4.8 O v erheating
3 .4.9 Crac k s
 Damage
Mechanisms
of
Equipment
based on
API 571
 Integrity
Operating
Window
API 584
 Corrosion
Control
Documents
•A document that summarizes:
• Unit process description
• Rationale for materials of
construction
• Discusses damage mechanisms
• Defines corrosion circuits
• Defines damage mechanisms in
each circuit:
);;-- Includes critical locations
);;-- Start up and shut down influences
);;-- Includes predicted (or actual) corrosion rates and
environmental cracking tendencies
Courtesy of The Hendrix Group – Corrosion Control Documents Revisited – 2011 API Inspection
Summit - David Hendrix presentation
 Corrosion
Control
Documents

• Process description s
• Hazops
• PFD's
• P&ID's
• Material and Heat Balance (H&MB)
• Equipment design
• Piping specifications
• Inspection and maintenance history

Courtesy of The Hendrix Group – Corrosion Control Documents Revisited – 2011 API Inspection
Summit - David Hendrix presentation
 DMR Review Flow
ID ID
Define Damage Team
Corrosi Written
Process Mechani Review
on Report
Limits sms
Circuits

• Description of • Equipment • API 571 and • Materials • Rationale for DMs

process and and Piping Industry resistance susceptibility in
oper. modes Design, and Experience • Methods to each circuit
• Heat/Material Operating • Corr. & Mat’l prevent or • Recommendations
Balance Conditions Engineer mitigate DM to mitigate or
• PFDs, • CVs, Inj./Mix • Inspection • Conditions prevent damage
P&IDs, MSDs Pts., IOWs, History and that would • Recommendations
• SME Books Bypasses Corrosion accelerate, to adjust
• Corrosion Rates worsen, inspection or PM
Circuits • Operating minimize or plans
Parameters eliminate DM
 Corrosion
Circuit
Diagrams

Courtesy of The Hendrix Group – Corrosion Control Documents Revisited – 2011 API Inspection
Summit - David Hendrix presentation
 Corrosion
Circuit
Diagrams

• Fixed equipment and piping in a

process with:
• Same stream composition
• Similar operating pressure and
temperature
< 25F (-13C) difference
<50 (-4 Barg) psig difference
• Same materials of construction
• Same phase, (liquid, vapor, etc.)
Courtesy of The Hendrix Group – Corrosion Control Documents Revisited – 2011 API Inspection
Summit - David Hendrix presentation
 Corrosion
Circuit
Attributes

• Circuit numbering system (legend)

• Circuit description
• Materials of construction
• Stream composition
• OP/OT/P hase information
• Corrosion precursors
• Operational upsets influencing
corrosion
Courtesy of The Hendrix Group – Corrosion Control Documents Revisited – 2011 API Inspection
Summit - David Hendrix presentation
 Corrosion
Circuit
Attributes

• Damage mechani sms

• Corrosion rates (predicted or
actual)
• Critical areas
• Operating envelope s
• Startup and shutdown
considerations
Courtesy of The Hendrix Group – Corrosion Control Documents Revisited – 2011 API Inspection
Summit - David Hendrix presentation
 Process
Stream
Composition
• Typically obtained from H&MB
• Difficult to obtain in refining units
• Small amounts of corrosives might
not be listed:
• Chlorides
• Injected chemicals
• Process contaminants or upset OP
• Should review with owner process
eng.
Courtesy of The Hendrix Group – Corrosion Control Documents Revisited – 2011 API Inspection
Summit - David Hendrix presentation
 Process
Stream
Composition

• Examples of stream constituents

that can influence or accelerate
.
corrosion:
• C0 2
• H2 S
• Chlorides
• Acids
• Oxygen
• cyanides
Courtesy of The Hendrix Group – Corrosion Control Documents Revisited – 2011 API Inspection
Summit - David Hendrix presentation
 Critical
Locations

• Location depends on damage

mechanism
• C02 - High velocity lines, elbows, etc.
• Chlorides - Condensing, wet-dry,
stagnant area, dead legs, etc.
• Amine SCC - weld HAZ's
• Up to unit inspector to locate
specific areas in circuit on P&ID
Courtesy of The Hendrix Group – Corrosion Control Documents Revisited – 2011 API Inspection
Summit - David Hendrix presentation
 Report
Formatting –
Process
Description
1. Process Description
The Crude Unit separates diluted crude feed into the following products:
• diluent naphtha
• colJlb.i.n.e.g distillate (mixture of light distillate, heavy distillate, light
vacuum gas oil (LVGO), and purge naphtha).
• medium vacuum gas oil (MVGO)
• heavy vacuum gas oil (HVGO)
• vacuum residue

FEED PREHEAT
The feed is preheated by heat exchange with the following streams:
• diluent naphtha
• overhead vapor from the Atmospheric Tower
• light distillate PJJJIIPJlcru.JUO.and product
• heavy distillate R1llilPfilQ!Jll and product
• medium vacuum gas oil QJJmQaCQUaP.and product
• heavy vacuum gas oil QumQacouoo and product
• vacuum residue
 Report
Formatting –
Circuit Assets
 Report
Formatting –
Specific Circuit
DM Concerns
Specific Corrosion Concerns:
• Possible accelerated corrosion at the injection points where d.emulsifiec
chemical, .desa]le_r water and stripped sour water are injected into the
crude oil feed. Consider the development of an injection point inspection
program, using ultrasonic scanning and radiographic techniques, as
discussed in AP I 570 and Inspection Strategy #20.
• Possible corrosion under insulation, for insulated piping and exchanger
vessels with a process temperature less than 300°F. Consider a program
for CU I inspection, as described in API 570 and Inspection Strategy #19 .
• Possible wet Hi S cracking of heat exchanger shells and carbon steel
piping In general, none of the equipment has been PWHT. Exchanger
and piping components are at low risk for sulfide stress cracking; however,
other forms of long term cracking such as HIC and SOH IC would still
apply. Consider prioritization and ultrasonic inspection strategies, as
described in Inspection Strategy #17.
 Report
Formatting –
IOWs and
Operating
Parameters
3. Process Control Monitoring and the development of Key
Critical Operating Parameters
Process Control Monitoring is important to pressure equipment integrity,
as well as product quality and production rates. The Key Critical
Operating Parameters are those process operating limits that will
significantly influence corrosion and other material degradation
mechanisms in the Unit They are listed in this Risk Assessment for
guidance only. These operating limits should be established after the Unit
is in operation as a joint exercise between the Corrosion Engineer, Unit
Operations and the Unit Process Engineer. Where limits apply to the
injection of chemicals, (i.e. neutraliz.ing amine or corrosion inhibitor), then
the chemical treating specialist should also be included in determining
these parameters. Where appropriate, typical limits used in industry have
been provided, for reference.

3.1. Crude Preheat Exchangers to the Desalter Inlet

Monitor for:
Salt content of crude oil (measured by double extraction)
Sulfur content of crude oil
Acid content of cru de oil
Damage Mechanism Reviews
The Damage Mechanism Review will become an
important part of a mechanical integrity program.
Results can be incorporated into validation of Integrity
Operating Window programs, Ciruitization of equipment
and piping for corrosion monitoring and locations for
CMLs.
DMRs may be useful with RBI programs and special
emphasis inspections.
There are many ways that DMRs can be formatted to
accomplish the end goal of defining damage
mechanisms and presenting the rational for active DMs,
capturing the review by the DMR Team, and the final
improvement plans for inspection and PMs.