Developing Effective Inspection Plans for Fixed Equipment Programs

Developing Effective Inspection Plans
for Fixed Equipment Programs
by Lynne Kaley & John Conway
Lynne Kaley, PE
 Materials/Corrosion and Risk Management Engineer
 30+ Years Refining, Petrochemical and Midstream Gas
Processing Experience
 10 years owner/user plant metallurgist/corrosion and
corporate engineer
 20+ years consulting with plant management,
engineering and inspection departments:
• Risk-Based technology (RBI) development leader
• Development of implementation work process for plant
• Member of API committees for development of API 580 and API
581 recommended practices
 Project Manager of API RBI Project from 1996-2009
John Conway
 33 years Inspection/Reliability Experience
• Owner/User
• Inspection/Reliability Management
• Inspection and RBI Consulting
 Certifications/Training/Education
• National Board
• API 510 with 571 endorsement API 570, API 653
• NACE-Senior Corrosion Technologist
• BS- University of Texas at Austin
 Affiliations
• API Codes and Standards Participant
• Development of recommended practices for Corrosion Under
Insulation (CUI) and Integrity Operating Windows (IOW)
 Purpose of Presentation
• Development of effective inspection programs with or without
• Proper documentation of inspection to achieve full credit for
inspection performed
• Development of acceptance/rejection criteria prior to
conducting inspection
• Show examples to demonstrate potential challenges and how
to handle exceptions during inspection
 Sources/References
• API 510, 570, 653
• API 580, 581
• API 571
 Introduction
 Inspection Program Goals
 Inspection Planning Process
 Fixed Interval vs. Risk-Based
 Cost Benefit for Risk-Based
 Today’s Inspection Responsibilities
 Future Inspection Programs
 Industry Examples (4)
 Conclusions
 Flood of technology and regulatory requirements since
1990 has changed inspection program management
work flow
 Outsourcing inspection and engineering services has
provided additional resources and expertise but has
created a fractured work flow and introduced multiple
• Can introduce errors at each hand-off point
• May not achieve the same level of ownership by each party
• May not take advantage of synergy potential between parties
 Inspection data analysis required to:
• Develop, evaluate and interpret inspection findings
• Provide recommendation for next inspection required
 Multiple software products add complexity as well as
time consuming manual methods for combining results
Inspection Program Goals
 Assure regulatory and corporate compliance
 Identify program improvements by streamlining the
workflow and eliminating, to the extent possible, time-
consuming manual activities or duplicate efforts
• Provide improved inspection data quality by being more
involved and aware of the working process
• Provide suggestions for improvements as well as better analysis
and information from the field
• Help define/design the streamlined workflow including
procedure, decision-making points, analysis and reporting
 Provide added-value services for budgeted inspection
 Develop multi-year inspection plan for scheduling and
 Provide data management and analysis, scorecard
metrics and dashboard reporting
Inspection Plan Development
Reliability & Risk Compliance
Interval Based Program
Safety & Environmental
Baseline Inspection
TML/CML Inspection Program
Optimized Inspection Program
Risk Based Program
Inspection Plan Development
 Critical to develop credible inspection plan
• Collect quality data, evaluate, validate and manage fixed
equipment data
• Historical inspection and maintenance records
• Damage assessment, damage rate and key operating variable
driving damage (integrity operating window, IOW)
• Develop specific inspection requirements based on operation
of plant and complexity of operation
 Prioritize Equipment inspection
• Inspection due dates versus internal accessibility and expected
 Define criteria for inspection
• Acceptable damage for continued operation
• Fitness for service assessments, as required
• Repair/Replacement criteria