Dealing with Aging Process Facilities and Infrastructure

By CCPS (Center for Chemical Process Safety)

Examines the concept of aging process facilities and infrastructure in high hazard industries and highlights options for dealing with the problem while addressing safety issues

This book explores the many ways in which process facilities, equipment, and infrastructure might deteriorate upon continuous exposure to operating and climatic conditions. It covers the functional and physical failure modes for various categories of equipment and discusses the many warning signs of deterioration. Dealing with Aging Process Facilities and Infrastructure also explains how to deal with equipment that may not be safe to operate. The book describes a risk-based strategy in which plant leaders and supervisors can make more informed decisions on aging situations and then communicate them to upper management effectively. Additionally, it discusses the dismantling and safe removal of facilities that are approaching their intended lifecycle or have passed it altogether.

Filled with numerous case studies featuring photographs to illustrate the positive and negative experiences of others who have dealt with aging facilities, Dealing with Aging Process Facilities and Infrastructure covers the causes of equipment failures due to aging and their consequences; plant management commitment and responsibility; inspection and maintenance practices for managing life cycle; specific aging asset integrity management practices; and more.

• Describes symptoms and causal mechanisms of aging in various categories of process equipment
• Presents key considerations for making informed risk-based decisions regarding the repair or replacement of aging process facilities and infrastructure
• Discusses practices for managing process facility and infrastructure life cycle
• Includes examples and case histories of failures related to aging 

Dealing with Aging Process Facilities and Infrastructure is an important book for industrial practitioners who are often faced with the challenge of managing process facilities and infrastructure as they approach the end of their useful lifecycle.

• Language: English
• Publisher: Wiley
• Release date: Apr 3, 2018
• ISBN: 9781119430759

Book preview

This book is one in a series of process safety guidelines and concept books published by the Center for Chemical Process Safety (CCPS). Please go to www.wiley.com/go/ccps for a full list of titles in this series.

It is sincerely hoped that the information presented in this document will lead to an even more impressive safety record for the entire industry. However, the American Institute of Chemical Engineers, its consultants, the CCPS Technical Steering Committee and Subcommittee members, their employers, their employers’ officers and directors, and AcuTech Consulting Group, Inc., and its employees do not warrant or represent, expressly or by implication, the correctness or accuracy of the content of the information presented in this document. As between (1) American Institute of Chemical Engineers, its consultants, CCPS Technical Steering Committee and Subcommittee members, their employers, their employers’ officers and directors, and AcuTech Consulting Group, Inc., and its employees and (2) the user of this document, the user accepts any legal liability or responsibility whatsoever for the consequences of its use or misuse.

Dealing with Aging Process Facilities and Infrastructure

CENTER FOR CHEMICAL PROCESS SAFETY of the AMERICAN INSTITUTE OF CHEMICAL ENGINEERS New York, NY

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This edition first published 2018

© 2018 the American Instiute of Chemical Engineers

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Library of Congress Cataloging-in-Publication Data

Names: American Institute of Chemical Engineers. Center for Chemical Process Safety, author.

Title: Dealing with aging process facilities and infrastructure / Center for Chemical Process

Safety of the American Institute of Chemical Engineers. Description: New York, NY :

Wiley, 2018. | Includes bibliographical references and index. |

Identifiers: LCCN 2018010560 (print) | LCCN 2018012416 (ebook) |

ISBN 9781119430766 (pdf) | ISBN 9781119430759 (epub) | ISBN 9781119430834 (cloth)

Subjects: LCSH: Chemical plants--Maintenance and repair. | Chemical

plants--Equipment and supplies--Deterioration. | Service life (Engineering)

Classification: LCC TP155.5 (ebook) | LCC TP155.5 .D425 2018 (print) | DDC 660--dc23

LC record available at https://lccn.loc.gov/2018010560

Cover images : Courtesy of CCPS

Cover design by Wiley

CONTENTS

LIST OF TABLES

LIST OF FIGURES

ACKNOWLEDGMENTS

PREFACE

1 INTRODUCTION

1.1 OVERVIEW

1.2 PURPOSE

1.3 AGING: CONCERNS, CAUSE AND CONSEQUENCES

1.4 HOW AGING OCCURS

2 AGING EQUIPMENT FAILURES, CAUSES AND CONSEQUENCES

2.1 AGING EQUIPMENT FAILURE AND MECHANISMS

2.2 CONSEQUENCES OF AGING EQUIPMENT INCIDENTS

2.3 MECHANICAL FAILURE OF METAL

2.4 SYSTEM FUNCTIONAL AGING

2.5 AGING STRUCTURES

3 PLANT MANAGEMENT COMMITMENT AND RESPONSIBILITY

3.1 PROMOTING SITE SAFETY CULTURE

3.2 MANAGEMENT CHALLENGES

3.3 MONITORING AGING PROCESS AND MEASURING PERFORMANCE

3.4 HUMAN RESOURCES REQUIREMENTS

3.5 PLANNING FOR EQUIPMENT RETIREMENT AND REPLACEMENT

3.6 APPRECIATING THE IMPORTANCE OF AGING INFRASTRUCTURE TO THE BUSINESS ENTERPRISE

3.7 ADDRESSING AGING INFRASTRUCTURE IN DECISION PROCESS

4 RISK BASED DECISIONS

4.1 RISK MANAGEMENT BASICS

4.2 RISK BASED DECISIONS

4.3 HOW TO APPLY RISKED BASED DECISIONS

4.4 EMBRACING RISK BASED MANAGEMENT

4.5 DEALING WITH UNEXPECTED EVENTS

4.6 RISK BASED DECISIONS SUCCESS METRICS

5 MANAGING PROCESS EQUIPMENT AND INFRASTRUCTURE LIFECYCLE

5.1 LIFECYCLE STAGES

5.2 ASSET LIFECYCLE MANAGEMENT

5.3 GENERAL TOPICS

5.4 PREDICTING ASSET SERVICE LIFE

5.5 INFRASTRUCTURE SPECIFIC TOPICS

6 INSPECTION AND MAINTENANCE PRACTICES FOR MANAGING LIFE CYCLE

6.1 INSPECTION AND MAINTENANCE GOALS

6.2 INSPECTION AND MAINTENANCE PROGRAM ELEMENTS

6.3 INSPECTION AND MAINTENANCE PROGRAM RESOURCES

6.4 ADDRESSING INFRASTRUCTURE DEFICIENCIES

7 SPECIFIC AGING ASSET INTEGRITY MANAGEMENT PRACTICES

7.1 STRUCTURAL ASSETS

7.2 ELECTRICAL DISTRIBUTION AND CONTROLS

7.3 EARTHWORKS: ROADS, IMPOUNDMENTS, AND RAILWAYS

7.4 MARINE FACILITIES: TERMINALS AND JETTIES

7.5 UNDERGROUND UTILITY SYSTEMS

8 DECOMMISSIONING, DISMANTLEMENT AND REMOVAL OF REDUNDANT EQUIPMENT

8.1 INTRODUCTION

8.2 EQUIPMENT HAZARDS

8.3 FINAL DECOMMISSIONING PRACTICES

8.4 DISMANTLING AND DISPOSAL

9 ONWARD AND BEYOND

ACRONYMS

REFERENCES

APPENDIX A AGING ASSET CASE STUDIES

CASE STUDY 1: GAS DISTRIBUTION PIPELINE EXPLOSION

CASE STUDY 2: MISSISSIPPI BRIDGE COLLAPSE

CASE STUDY 3: SINKING BUILDING FOUNDATION

CASE STUDY 4: TAILINGS DAM FAILURE

CASE STUDY 5: SINKING OF THE BETELGEUSE

CASE STUDY 6: ALEXANDER KIELLAND DRILLING RIG DISASTER

CASE STUDY 7: ROOF COLLAPSE AT ORE PROCESSING FACILITY

INDEX

EULA

List of Tables

Table 2.2-1. Deaths and Injuries Statistics for MARS Reportable Major Accident Hazard Incidents

Table 2.2-2. Total Losses (Million € Equivalent) for MARS Reportable Major Accident Hazard Incidents

Table 2.3-1. Examples of Corrosion Mechanisms

Table 2.3-1. Examples of Corrosion Mechanisms, continued

Table 2.3-2. Typical Refinery Elements Contributing to Elevated Corrosion Rates

Table 3.2-1. Component Condition Health Metrics

Table 3.2-1. Component Condition Health Metrics, continued

Table 4.2-1. Guidelines for Risk Based Decisions

Table 4.3-1. RBD Documentation Guidelines

Table 4.6-1. Corrective and Preventive Metrics Definitions

Table 4.6-1. Corrective and Preventive Metrics Definitions, continued

Table 5.4-1. Estimated Mean Life for the 500-kV Reactors (IEEE, 2006)

Table 6.1-1. Budgeting Guidelines for Various Types of Infrastructure to be maintained

Table 7.1-1. Analogous Inspection Practices for Structures

Table 7.1-1. Analogous Inspection Practices for Structures, continued

Table 7.1-2. Example Checklist for Structural Assets

Table 7.2-1. Inspection Practices for Electrical Infrastructure

Table 7.2-2. Example Checklist for Electrical Systems

Table 7.2-3. Inspection Practices for Control Systems Infrastructure

Table 7.2-4. List of UPS Disturbance Causes

Table 7.3-1. Inspection Practices for Road Infrastructure

Table 7.3-2. Example Checklist for Roads Maintenance and Inspection

Table 7.3-2. Example Checklist for Roads Maintenance and Inspection, continued

Table 7.3-3. Inspection Practices for Earthwork Infrastructure

Table 7.3-4. Example Checklist for Earthworks Infrastructure Maintenance and Inspection

Table 7.3-5. Example Checklist of Inspection Practices for Rail Spur Infrastructure

Table 7.4-1. Inspection Practices for Marine Infrastructure

Table 7.4-2. Example Checklist for Marine Infrastructure

Table 7.5-1. Inspection Practices for Underground Cable Systems

Table 7.5-2. Example Checklist for Maintenance and Inspection of Underground Cable Systems

Table 7.5-3. Inspection Practices for Underground Utility Piping Infrastructure

Table 7.5-3. Inspection Practices for Underground Utility Piping Infrastructure, continued

Table 7.5-4. Example Checklist for Underground Utility Piping Infrastructure

List of Illustrations

Figure 1.1-1. Image of an Aging Facility Containing Silos

Figure 1.1-2. Vintage Vessels Fastened with Rivets

Figure 1.4-1. Suggested Spectrum for Aging Facilities

Figure 1.4-2. External Corrosion of a Pipe Due to Leakage of Steam Tracing (Sastry, 2015)

Figure 1.4-3. Image Showing Scoring on a Shaft

Figure 2.2-1. High Level Categorization of MARS Incidents

Figure 2.2-2. Causes of Technical Integrity Incidents in MARS Data

Figure 2.3-1. Typical Stress vs. Strain Diagram Indicating the Various Stages of Deformation

Figure 2.3-2. Catastrophic Failure of Electrical Generator Rotor

Figure 2.3-3. Rotted Railway Ties Providing Weakened Support

Figure 2.5-1. Grain Loading Conveyor Collapse in Ama, Louisianna

Figure 2.5-2. Image of Corroded Oil Recovery Vessels

Figure 2.5-3. Image of Aging Iron Making Facility

Figure 2.5-4. Image of Aging Gas Plant

Figure 2.5-5. Image of Aging Process at Marine Facility

Figure 2.5-6. Image of Aging Process Facility

Figure 2.5-7. 1911 Vintage 3-Cylinder Internal Combustion Engine

Figure 4.1-1. Dimensions of Choice

Figure 4.1-2. Example of a Risk Matrix

Figure 4.3-1. Aging Assets RBD Logic Diagram

Figure 5.2-1. Asset Lifecycle Management

Figure 5.3-1. Codes and Standards Applied to Facility Assets

Figure 5.3-2. Probability of Failure vs. Time for a Safety Instrumented System (Dräger, 2007)

Figure 5.4-1. Basin Curve for Failure Rate of Equipment

Figure 5.4-2. Relationship Between Failure Rate and Age for a Normal Probability Distribution

Figure 5.4-3. Relationship Between Failure Rate and Age for a Weibull Probability Distribution

Figure 5.4-4. Relationship Between the Value, Time, and Preventive Maintenance for Aged Equipment

Figure 5.5-1. Aged Conveyor System in Backup Service

Figure 6.1-1. Vintage Steel Mill Retired from Active Service

Figure 6.1-2. Vintage Chemical Plant Dust Reduction Facility

Figure 6.1-3. Cable Failure Rates

Figure 6.4-1. Vintage Grain Elevator Awaiting Renewal (or Refurbishment)

Figure 6.4-2. Expected Uniform Annual Cost

Figure 7.1-1. Image of a Building That Developed a Crumbling Crack

Figure 7.1-2. Photo of Primitive Structural Supports

Figure 7.1-3. Liquefied Petroleum Gas (LPG) Storage Sphere Collapsed While Being Filled for a Hydrostatic Pressure Test

Figure 7.1-4. Chemical Plant Shelter Showing Signs of Severe Deterioration

Figure 7.1-5. Building Presenting Aging Signs

Figure 7.1-6. Photo of Aged Chemical Silos

Figure 7.2-1. Motor Control Center (MCC) Thermal Scan of a Phenol Unit – Photo

Figure 7.2-2. Motor Control Center (MCC) Thermal Scan of a Phenol Unit – Photo

Figure 7.2-3. Thermography Image Showing Hot Terminals

Figure 7.2-4. Damaged Contacts in Lighting Panel Circuit Breaker

Figure 7.2-5. Loose A Phase on 3 Phase Circuit Breaker and Possible Unbalanced Load

Figure 7.2-6. Loose Connection on A Phase in a 2 Speed Motor Contactor

Figure 7.2-7. Medium Voltage (15kV) Indoor Open-Air Switchgear

Figure 7.3-1. Picture of Vintage Tank Car Fastened with Rivets

Figure 8.1-1. Image of Building Awaiting Demolition

Figure AP.1-1. Example of an Old Facility Presenting Aging Signs

Figure AP.1-2. Sketch Showing Bending Moment as a Result Unbalanced Buoyancy Forces

LIST OF TABLES

Table 2.2-1. Deaths and Injuries Statistics for MARS Reportable Major Accident Hazard Incidents

Table 2.2-2. Total Losses (Million € Equivalent) for MARS Reportable Major Accident Hazard Incidents

Table 2.3-1. Examples of Corrosion Mechanisms

Table 2.3-1. Examples of Corrosion Mechanisms, continued

Table 2.3-2. Typical Refinery Elements Contributing to Elevated Corrosion Rates

Table 3.2-1. Component Condition Health Metrics

Table 3.2-1. Component Condition Health Metrics, continued

Table 4.2-1. Guidelines for Risk Based Decisions

Table 4.3-1. RBD Documentation Guidelines

Table 4.6-1. Corrective and Preventive Metrics Definitions

Table 4.6-1. Corrective and Preventive Metrics Definitions, continued

Table 5.4-1. Estimated Mean Life for the 500-kV Reactors (IEEE, 2006)

Table 6.1-1. Budgeting Guidelines for Various Types of Infrastructure to be maintained

Table 7.1-1. Analogous Inspection Practices for Structures

Table 7.1-1. Analogous Inspection Practices for Structures, continued

Table 7.1-2. Example Checklist for Structural Assets

Table 7.2-1. Inspection Practices for Electrical Infrastructure

Table 7.2-2. Example Checklist for Electrical Systems

Table 7.2-3. Inspection Practices for Control Systems Infrastructure

Table 7.2-4. List of UPS Disturbance Causes

Table 7.3-1. Inspection Practices for Road Infrastructure

Table 7.3-2. Example Checklist for Roads Maintenance and Inspection

Table 7.3-2. Example Checklist for Roads Maintenance and Inspection, continued

Table 7.3-3. Inspection Practices for Earthwork Infrastructure

Table 7.3-4. Example Checklist for Earthworks Infrastructure Maintenance and Inspection

Table 7.3-5. Example Checklist of Inspection Practices for Rail Spur Infrastructure

Table 7.4-1. Inspection Practices for Marine Infrastructure

Table 7.4-2. Example Checklist for Marine Infrastructure

Table 7.5-1. Inspection Practices for Underground Cable Systems

Table 7.5-2. Example Checklist for Maintenance and Inspection of Underground Cable Systems

Table 7.5-3. Inspection Practices for Underground Utility Piping Infrastructure

Table 7.5-3. Inspection Practices for Underground Utility Piping Infrastructure, continued

Table 7.5-4. Example Checklist for Underground Utility Piping Infrastructure

LIST OF FIGURES

Figure 1.1-1. Image of an Aging Facility Containing Silos

Figure 1.1-2. Vintage Vessels Fastened with Rivets

Figure 1.4-1. Suggested Spectrum for Aging Facilities

Figure 1.4-2. External Corrosion of a Pipe Due to Leakage of Steam Tracing (Sastry, 2015)

Figure 1.4-3. Image Showing Scoring on a Shaft

Figure 2.2-1. High Level Categorization of MARS Incidents

Figure 2.2-2. Causes of Technical Integrity Incidents in MARS Data

Figure 2.3-1. Typical Stress vs. Strain Diagram Indicating the Various Stages of Deformation

Figure 2.3-2. Catastrophic Failure of Electrical Generator Rotor

Figure 2.3-3. Rotted Railway Ties Providing Weakened Support

Figure 2.5-1. Grain Loading Conveyor Collapse in Ama, Louisianna

Figure 2.5-2. Image of Corroded Oil Recovery Vessels

Figure 2.5-3. Image of Aging Iron Making Facility

Figure 2.5-4. Image of Aging Gas Plant

Figure 2.5-5. Image of Aging Process at Marine Facility

Figure 2.5-6. Image of Aging Process Facility

Figure 2.5-7. 1911 Vintage 3-Cylinder Internal Combustion Engine

Figure 4.1-1. Dimensions of Choice

Figure 4.1-2. Example of a Risk Matrix

Figure 4.3-1. Aging Assets RBD Logic Diagram

Figure 5.2-1. Asset Lifecycle Management

Figure 5.3-1. Codes and Standards Applied to Facility Assets

Figure 5.3-2. Probability of Failure vs. Time for a Safety Instrumented System (Dräger, 2007)

Figure 5.4-1. Basin Curve for Failure Rate of Equipment

Figure 5.4-2. Relationship Between Failure Rate and Age for a Normal Probability Distribution

Figure 5.4-3. Relationship Between Failure Rate and Age for a Weibull Probability Distribution

Figure 5.4-4. Relationship Between the Value, Time, and Preventive Maintenance for Aged Equipment

Figure 5.5-1. Aged Conveyor System in Backup Service

Figure 6.1-1. Vintage Steel Mill Retired from Active Service

Figure 6.1-2. Vintage Chemical Plant Dust Reduction Facility

Figure 6.1-3. Cable Failure Rates

Figure 6.4-1. Vintage Grain Elevator Awaiting Renewal (or Refurbishment)

Figure 6.4-2. Expected Uniform Annual Cost

Figure 7.1-1. Image of a Building That Developed a Crumbling Crack

Figure 7.1-2. Photo of Primitive Structural Supports

Figure 7.1-3. Liquefied Petroleum Gas (LPG) Storage Sphere Collapsed While Being Filled for a Hydrostatic Pressure Test

Figure 7.1-4. Chemical Plant Shelter Showing Signs of Severe Deterioration

Figure 7.1-5. Building Presenting Aging Signs

Figure 7.1-6. Photo of Aged Chemical Silos

Figure 7.2-1. Motor Control Center (MCC) Thermal Scan of a Phenol Unit – Photo

Figure 7.2-2. Motor Control Center (MCC) Thermal Scan of a Phenol Unit – Photo

Figure 7.2-3. Thermography Image Showing Hot Terminals

Figure 7.2-4. Damaged Contacts in Lighting Panel Circuit Breaker

Figure 7.2-5. Loose A Phase on 3 Phase Circuit Breaker and Possible Unbalanced Load

Figure 7.2-6. Loose Connection on A Phase in a 2 Speed Motor Contactor

Figure 7.2-7. Medium Voltage (15kV) Indoor Open-Air Switchgear

Figure 7.3-1. Picture of Vintage Tank Car Fastened with Rivets

Figure 8.1-1. Image of Building Awaiting Demolition

Figure AP.1-1. Example of an Old Facility Presenting Aging Signs

Figure AP.1-2. Sketch Showing Bending Moment as a Result Unbalanced Buoyancy Forces

ACKNOWLEDGMENTS

The American Institute of Chemical Engineers (AIChE) and the Center for Chemical Process Safety (CCPS) express their appreciation and gratitude to all members of the Aging Process Facilities and Infrastructure Subcommittee for their generous efforts in the development and preparation of this important concept book. CCPS also wishes to thank the subcommittee members’ respective companies for supporting their involvement in this project.

We appreciate the involvement and writing contributions of Brian Kelly and Terry White. Special thanks are extended to the team of technical writers from ioMosaic Corporation who coordinated inputs and developed the manuscript. The ioMosaic team consisted of Elena Prats, Peter Stickles and Kathy Anderson.

The members of the CCPS project subcommittee were:

All CCPS books are subjected to a rigorous peer review prior to publication. CCPS gratefully acknowledges the thoughtful comments and suggestions of the following peer reviewers:

PREFACE

The process safety community, through professional and industry associations, has focused considerable attention on Asset Integrity Management (AIM) of equipment directly involved in process operations. The purpose of this book is to address integrity management of assets that often fall outside the traditional process safety management asset integrity program, because they are not ranked high as "safety critical’’ and have long lifecycles. In particular, such assets include process supporting infrastructure like pipe racks and bridges, equipment supporting structures, sewer and drain lines, rail spurs, and process buildings to name a few. Failure of these types of assets can be contributing factors to process safety incidents and should not be ignored.

Aging process equipment, facilities and infrastructure are common in industry today. The developed world has expanded at an ever increasing rate placing high demands on our existing infrastructure. In many instances, equipment is now required to operate at conditions well beyond those anticipated in the original design. Service life may also have been extended. The option to retire and replace aging equipment is often not practical or economical. In fact, sometimes decisions are made to run equipment to failure.

Industry needs to better manage what it has built and acquired over the past several decades. There is no established set of rules for doing this. Each company or operating facility must examine its own business practices and goals and determine a strategy that meets its own risk criteria.

Aging equipment presents a challenge to managing the integrity of plants and associated infrastructure. This book examines the concept of aging equipment and infrastructure in high hazard industries. It specifically looks at the causes and effects of aging in many types of facilities. Possible options for dealing with the problem are highlighted without providing prescriptive advice. Related publications from the Center for Chemical Process Safety (CCPS) and others are cross referenced to provide the reader with a better understanding of the problems encountered by others and some of the