10 major problems of RBI – Solved!

10 major problems of RBI – Solved!

Uncategorized, Why new RBI?
As an RBI practitioner, you might have experienced ever returning problems in the asset integrity workflow. We have selected 10 major issues originating from the current RBI practices, to exercise with. This article introduces a holistic solution to all of them, through the science based and novel RBI methodology we created. Prepare for novel ideas beyond the traditional thinking and read on. Problems: NDT tools and coverage Firstly, cheaper corrosion inspection tools (manual UT) remain overwhelmingly popular. In return, they produce a false scatter of thickness readings. This scatter often triggers follow-up inspections, can also drive incorrect decisions.More importantly, the choice of UT spots and the extent of inspection coverage is a 'boomerang' problem in every RBI round. One solution is expanding the inspection coverage. Though, it isn't a panacea…
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Freeware CAD and FEA 2020 – Part 1: User friendly  options

Freeware CAD and FEA 2020 – Part 1: User friendly options

FEA and stress analysis, Uncategorized
A familiar commercial software can boost engineers productivity to a maximum. The downside is cost, especially for research and education projects. The good news for 2020: We found that some GNU software evolved to user friendly products, suitable for a variety of problems and user knowledge levels. This article outlines our opinions, hints and conclusions regarding FreeCAD, GMSH and Salome Meca open source suftware. Intro Being involved in any kind of engineering, either by profession or as a hobby, you have probably faced the challenge of choosing a CAD software for: making a drawing, preparing a model for your 3D printer, simulating an object for stress analysis (FEA), solving a fluid-structure simulation using parallel computing maybe, and more... Is there any 'best-of-the-best' software package to do it all? Perhaps yes,…
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5 Levels of Risk Analysis. How many do you have?

5 Levels of Risk Analysis. How many do you have?

Mission Impossible, Why new RBI?
Equipment risk analysis is a core activity in plant risk management. Many spears were broken about prioritizing individual equipment monitoring and risk controls, to ensure its safe and reliable operation. We have arrived to the capability of performing risk assessments at 5 levels of depth. This multi-level approach enables a two-fold cost/benefit optimization: analysis cost is minimized and a risk cost analysis is enabled where required. This article shows applications to pressure equipment inspection planning (RBI). Drivers for multi-level RBI We naturally recognize two levels of approach to engineering problems: First-pass system screening for criticalityIn-depth analysis of critical elements only This sequence of tasks well optimizes time and efforts. The only precaution is not to get locked into the screening step (1) solely. Critical objects require a detailed analysis (2)…
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FEA Nocturne – Time for Change?

FEA Nocturne – Time for Change?

FEA and stress analysis, Uncategorized
Finite Element Analysis (FEA) is indispensable for visualizing a structural response to a wide spectrum of loads and design options. FEA enables plotting a stress/strain field for complex geometries, which is not feasible to do by hand calculations. It appears that FEA services lose popularity in our industry. Here I share my thoughts why this happened, and conclude on how to improve the FEA practicality and to embed it into the plant asset management process. Here we will start from deep technical matters and end up with bright future perspectives. Tips are for FEA practitioners only. Fig. 1. FEA analysis loop, as it should be Introduction - What is FEA at a glance? Structural Mechanics force, displacement and stress calculations are well suitable for simple, idealized objects like beam frames…
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Online IDMS/RBI software made by integrity engineers

Online IDMS/RBI software made by integrity engineers

Mission Impossible
Did you ever wonder whether Integrity engineers can make a good IDMS platform by themselves? Other than just an RBI spreadsheet or MS Access database? Would that be different to the IT market offers? Triple YES! The below text outlines our new concept for a new level of the software user friendliness. It originates from our many years exposure to integrity engineering workflow and from many attempts to automate it. The AIM data® is online and ready to use. The Need for the New In many years of RBI exposure, we observed three major data management gaps: As soon as the number of inspection data grows, spreadsheet based analysis capability becomes limited. Just too many numbers, and too much copy-paste work. Spreadsheets work up to a point.What if we try…
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3 Pressure Relief Devices for Integrity Engineers

3 Pressure Relief Devices for Integrity Engineers

Mission Impossible, Uncategorized
Caring about plant integrity is a busy and stressful work. Human psychology is such that maintaining current environment is confused with staying in a comfort zone. Albeit this zone may not be comfortable at all (same outcomes from same contractors, same burden of responsibility and document management, same questionable risk management confidence). If you wish to change this environment, consider the holistic improvement of integrity tasks: 1. Know your Risk Cost and Safety Implications One thing in the back of your mind might be: 'How confident are we about what we do for the equipment integrity and safety'? - an obsessive question. Consider all those people going on site and doing the hard work there. And also - all the resources being spend over a facility life. Looking at the…
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What is Gigacycle Fatigue importance for pant operators?

What is Gigacycle Fatigue importance for pant operators?

Away from a collision course, Mission Impossible, Uncategorized
It is known that the 1st fatigue curve was created in XIX century by German engineer August Woehler. He investigated why railroad carriage axles fail in a delayed manner. The Woehler's phenomenological fatigue model was correct and remains generally valid now. However, there are some additional limitations and improvement ideas, which are necessary for practical vibration fatigue predictions. Misconceptions first Consider the above graph meaning: The Number of stress cycles to failure (N) is a function of the Stress amplitude in each cycle (S). More stress means less life, as shown by the red line. The yellow line simulates a constant amplitude fatigue limit. Finally, the green line is the variable amplitude stress cut-off, e.g. no fatigue damage is assumed in design for lower stresses. The historical reason for the…
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Why immediate savings impair plant safety?

Why immediate savings impair plant safety?

Away from a collision course
We can help you to develop an optimal plant integrity management strategy, which will comply with budget goals safely. A step change in integrity data assessment methods is involved. While there is so much talk about the Oil&Gas industry competitiveness, why don't upgrade the asset management confidence level? Mentioning 'safety', what comes into the mind of plant workers? PPE, JHA, KPI and more well recognized abbreviations. What is the prominent message from a typical safety induction session? 'If you don't commit unsafe actions in workplace, you will be fine out there!' This message is well memorized by workers, safety rules are followed, the clock is ticking, but this is only one side of the medal - these procedural health and safety measures in place. The other side of the medal…
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Why new RBI?

Why new RBI?

Why new RBI?
Here we start a new series of posts which explain what exactly is offered by our New Generation Asset Integrity strategy and tactics. Please don't hesitate to communicate your thoughts or critics. Welcome aboard our rocket ship! Issues with traditional RBI? Risk Based Inspection planning (RBI) is on the scene for decades. Its rightful concept of proportioning integrity budgets to failure risks is a great common-sense solution for cost optimization. The ever increasing budget savings pressure highlighted one major inability of the published RBI methodologies though. Financial management of industrial plants has set a question, which integrity management personnel can't reply: 'How much budget saving results from integrity management costs?' What happens is that both parties - integrity responsible and finance responsible - are striving to adopt a correct decision,…
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Let’s make the New Year positively different !

Let’s make the New Year positively different !

Away from a collision course
HAPPY FESTIVE SEASON TO EVERYONE ! Welcome the New Year of opportunities. Our preceding posts addressed major quality gaps of integrity engineering. Is there a panacea solution? We believe: Yes! This article encompasses all we have presented earlier in this blog series and bonds these topics together, at a higher consideration level. This is our engineering philosophy for a new, better year coming.   A Christmas tree is an amazing sight: So beautiful! The lights are blinking, running here and there. Everything is shiny. Looks like an action, but no, these are rather visual effects with no other use. Certainly, our organizations aren't created for visual effects , but still, there can be internal spectators judging the work process entirely by its appearance. For example, someone responsible for safe and…
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