You are on page 1of 17

Downstream Manufacturing DBAM Code and Name: MAN.15.

10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

Shell Downstream Manufacturing

Management of Injection Points and Mix Points


Table of Contents
1. General ...................................... 2
1.1 1.2 1.3 1.4 1.5 1.6 Revision Information..................... 2 Purpose ........................................ 2 Scope ........................................... 2 References ................................... 2 Definitions ..................................... 2 Responsibilities ............................ 4

7.

Documentation ......................... 8

Appendix A Identification .......... 10 Appendix B Classification and Inspection Interval ................. 11 Appendix C Inspection Boundaries ............................. 13 Appendix D Example of Circuit CML Set Up for Thickness Data Capture ................................... 14 Appendix E Detection Methods . 15 Appendix F Injection Point Data Sheet ....................................... 17

2. 3. 4.

Background .............................. 5 Identification ............................. 5 Assessment .............................. 6


4.1 Initial Assessment ........................ 6 4.2 Process Safety Concurrence ....... 6 4.3 Re-assessment ............................ 6

5. 6.

Risk Management Strategy...... 6 Inspection ................................. 7


6.1 Inspection Boundaries .................. 7 6.2 Inspection of Piping ...................... 8 6.3 Inspection of Injection Hardware .. 8

Version: 1.0

Date: May 2010

Custodian: DME/4

ECCN: EAR99

Page: 1 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

1.

General

1.1

Revision Information
This is the initial issuance.

1.2

Purpose
1. This Downstream Manufacturing (DSM) Specification (SP) defines requirements and recommendations for managing injection points and mix points. It provides sites with a risk-based methodology for assessment of injection points and mix points. This SP is consistent with DSM-1510002-RP-01, Pressure Equipment Integrity Management, and fulfils the requirements and recommendations for identification, risk assessment, management strategy, inspection and documentation of injection points and mix points. Implementation of a site injection point and mix point risk management program shall be consistent with this specification.

2.

3.

1.3

Scope
1. 2. This SP is applicable to all Downstream manufacturing sites (DSM) under operational control. This SP is in addition to applicable country laws and regulations. If this SP or part(s) of this SP conflict with or are less stringent than applicable country laws or regulations, the laws and regulations shall apply to the extent there is a conflict or more stringent requirements.

1.4

References
DSM-1510002-RP-01 Pressure Equipment Integrity Management recommended practice BPG INSP-02-I API 570 BPG INSP-21-I DEP (new) IDMS Consistent Practices Manual Best Practice Guide In-Service Piping Inspection API Piping Inspection Code Best Practice Guide Cyclic Service Equipment Inspection Design of Water Injection Systems in Process Units Injection Points Section 9C

1.5

Definitions
Condition monitoring locations (CMLs) Specific places on process equipment where the condition is monitored. The nature of the CML varies according to its location. For example,

Version: 1.0

Date: May 2010

Custodian: DME/4

ECCN: EAR99

Page: 2 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

on straight pipe, a CML is a cross-sectional plane of the pipe at a specific location. If a CML is designated at a fitting such as an elbow, the entire fitting is the CML. Corrosion Metal loss due to exposure to operating or external environments. Synonymous with degradation in this SP. Corrosion Control Document (CCD) Document that identifies 1) the degradation mechanisms that are likely to affect the process equipment in each section of a unit and 2) the controls and limits necessary to maintain integrity. Note: The Corrosion Control Manual (CCM) is sometimes referred to as the generic CCD. Corrosion Control Manual (CCM) Generic document that identifies 1) the degradation mechanisms that are likely to affect the process equipment in each section of a unit and 2) the controls and limits necessary to maintain integrity for a type of unit (e.g. a crude distillation unit). The CCM is used as the basis for their unit specific CCD. Corrosive The mixing of two streams is considered corrosive when the consequence of the blending or the failure of the injection / mix point to function as designed could result in accelerated degradation rates (as compared to the DCR) that may compromise process equipment integrity, including thermal fatigue and brittle fracture considerations. Corrosive mix points also include those where process conditions may result in short-duration, high-rate episodic degradation. Degradation Loss of thickness, loss of material properties (strength), or the creation of defects (cracking) due to exposure to operating or external environments. Synonymous with corrosion in this document. DCR Design corrosion rate. This is either the corrosion rate used when the equipment was designed or the rate suggested by the Materials and Corrosion Engineer. IDMS Inspection Data Management System, the DSM system for PEI data management. Injection Point Locations where relatively small quantities of materials are injected into process streams to control chemistry or other process variables. Examples of injection points are where process chemicals or water wash are introduced into process streams. Inspection Interval The frequency at which a scheduled inspection is to occur. Mitigate Threats to Availability (MTA) A global work process that provides the methodology to identify, prioritise, and take action to mitigate threats to business plan delivery. Mix Point Area in a piping system where two process streams combine. Examples of mix points include compressor recycle tie-ins to the compressor suctions, the mixing of wet and dry hydrocarbon streams at branch connections, hydrogen mixing with hydrocarbon gas streams, and heat exchanger bypass tie-ins to the main header piping. Non-Corrosive The mixing of two streams is considered non-corrosive when the potential for significant interaction is absent or has a low likelihood of compromising the integrity or operability of process equipment. Process Equipment Pressure vessels, heat exchangers, storage tanks, fired heaters, relief devices and pressure piping systems (including valves and piping components) operating in services such as hydrocarbon, amines, acids, high-pressure steam, and sour gas.

Version: 1.0

Date: May 2010

Custodian: DME/4

ECCN: EAR99

Page: 3 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

1.6

Responsibilities
The Pressure Equipment Unit Inspector, Materials and Corrosion Engineer, Process Engineer/Technologist, Production Specialist and Process Safety Engineer shall participate in establishing the injection point/mix point program as described in Section 3 of this document. Some of the key responsibilities of each role are described below. 1.6.1 Unit Inspector 1. 2. 3. 4. 5. Either the unit inspector or the Materials and Corrosion Engineer typically leads the initial implementation of the injection point / mix point program. Verifies completion of non-mandatory fields on Injection Point Data Sheet. Creates inspection schedules for each individual injection point and mix point and leads the inspections. Performs the required documentation and/or updates upon completion of an inspection. Acts as the document owner of the Injection Point Data Sheets, marked up PEFs (process engineering flowschemes) and piping isometrics once risk assessment is complete and is responsible for keeping these documents current.

1.6.2

Materials and Corrosion Engineer (MCE) 1. 2. 3. 4. 5. Either the MCE or the unit inspector typically leads the initial implementation of the injection point / mix point program. Determines if injection points and mix points are corrosive or non-corrosive. Identifies the applicable damage mechanisms. Reviews the inspection plans. Documents injection points and mix points in the unit Corrosion Control Document (CCD) and updates Corrosion & Materials Diagram (C&MD) / Corrosion Loop Drawing (CLD). Participates in the risk assessment of injection points and mix points. Assists the Inspector in selecting CML locations in both Primary and Secondary zones. Assists the Inspector in reviewing and interpreting the inspection NDE results.

6. 7. 8. 1.6.3

Process Engineer/Technologist 1. Supports the completion of the Injection Point Data Sheet and provides specific process information such as process chemical properties and injection rates. Participates in the risk assessment of injection points and mix points.

2.

Version: 1.0

Date: May 2010

Custodian: DME/4

ECCN: EAR99

Page: 4 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

3.

Notifies the Unit Inspector/Materials and Corrosion Engineer if an injection point is removed from service, re-commissioned or is experiencing abnormal operating conditions.

1.6.4

Production Specialist 1. 2. 3. 4. 5. Aids in identifying and locating injection points and mix points in their plant. Provides support information and documentation that pertains specifically to the operation of each piece of process equipment. Validates start up and shut down procedures and actual operating conditions for a given injection point/mix point. Participates in the risk assessment of injection points and mix points. Provides clarity between written procedures and actual field practice, highlighting any discrepancies.

1.6.5

Process Safety Manager/Engineer Concurs with the risk assessment of the injection points and mix points.

2.

Background
Accelerated degradation such as corrosion or thermal fatigue can occur internally where materials are injected into process streams to control chemistry or process variables, or where two process streams of differing composition, phase, and/or temperature join/mix. The degradation rates near these points may be localized and not representative of the degradation characteristics farther downstream where the streams are well mixed. Degradation at injection and mix points has led to loss of containment at DSM sites, resulting in HSE and reliability impacts.

3.

Identification
1. 2. Injection points and mix points shall be identified by a review of each unit. The review shall: a. b. c. Identify all injection points and mix points. (See Appendix A for guidance.) Characterize each point as corrosive or non-corrosive, identifying the degradation mechanism and degradation mode such as pitting or cracking. Be completed by a team consisting of the Unit Inspector, Materials and Corrosion Engineer, Process Engineer/Technologist and Production Specialist. Other positions may be identified for the team as necessary. Be performed as part of the Corrosion Control Document (CCD) development/review but may be performed as a dedicated, separate activity. Be completed through a thorough review of unit Process & Instrument Diagrams (P&IDs), Process Engineering Flowschemes (PEFs) or equivalent and field walk downs, if required.
Date: May 2010 Custodian: DME/4 ECCN: EAR99 Page: 5 of 17

d. e.

Version: 1.0

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

4.

Assessment

4.1

Initial Assessment
The review team shall perform the initial assessment as described below: 1. 2. 3. 4. 5. 6. Classify injection points and mix points using the matrix in Appendix B. Estimate the potential consequence from a loss of containment based on the mode of failure (pinhole leak, rupture, etc). Estimate the likelihood of failure due to corrosion and/or cracking under steady state and upset conditions. Use the consequence and likelihood with Appendix B to determine classification and inspection interval. Consider both age-related and non-age-related mechanisms. The classification should consider worst credible conditions, such as failure of the injection point or mix point to operate as designed.

4.2

Process Safety Concurrence


The site Process Safety Engineer shall review the potential consequence defined during the initial assessment and either concur with the assessment or, if they do not concur, consult with the Unit Inspector and/or Materials and Corrosion Engineer to resolve any differences.

4.3

Re-assessment
1. Injection points and mix points shall be reassessed by the Inspector and the Materials and Corrosion Engineer (at a minimum) after each inspection or after a significant change in hardware, operation or process conditions. These reassessments should take place as part of the CCD or Risk Based Inspection reviews. The risk assessment results and any changes to the inspection strategy shall be formally documented in the Inspection Data Management System (IDMS). Local legal requirements may require reassessment of injection points and mix points on a fixed interval.

2. 3.

5.

Risk Management Strategy


1. For injection points and mix points with a classification of A or B, an inspection interval not exceeding those shown in Appendix B shall be applied, the threat shall be entered into the site Threats Database, and prioritised consistent with the Mitigate Threats to Availability (MTA) work process. Additionally, the Hazards and Effects Management Process (HEMP) shall be utilised to determine 1) if additional risk mitigation measures (barriers) are needed, 2) what elements are needed to create an effective barrier, and 3) the timing associated with implementing the barrier.
Date: May 2010 Custodian: DME/4 ECCN: EAR99 Page: 6 of 17

Version: 1.0

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

The Threats Database should be updated with the pertinent HEMP information (e.g. timing, mitigation plans, HEMP critical barrier indicator). a. For hydroprocessing reactor effluent water washes, the DEP titled Design of Water Wash Injection Systems Process Units (not currently numbered), shall be applied. This document offers guidance on water wash injection point design and can be used as a reference during the review of the injection points and mix points. Other injection point or mix point types (such as water washes into crude, delayed coker or catalytic cracker overhead systems or delayed coker and catalytic cracker wet gas compression systems) shall be evaluated by a Shell mix point specialist

b.

c. A vibration analysis shall be a part of the design review if not considered during the original design. 2. 3. Injection points and mix points with a classification of C, D or E shall be inspected on a frequent enough basis to monitor their condition and operation within the timing specified in Appendix B. Injection points and mix points with a classification of F should be inspected with the piping system they are in. No special measures are needed since the injection point/mix point can be considered as having no increased risk. An alternative inspection interval may be assigned if a rigorous engineering analysis has been completed and documented and all other requirements within this Specification have been satisfied.

4.

6.

Inspection

6.1

Inspection Boundaries
1. There are two adjoining areas or zones in the injection point or mix point circuits that require inspection. The following general rules apply to the physical limits of these zones: a. Primary Zone Equivalent to the zone requiring more extensive inspection in API570. This is a minimum of 3 pipe diameters or 300 mm (12 inches) upstream of the injection point nozzle (whichever is greater) or mix point tee and at least 10 pipe diameters or past the first change in flow direction downstream of the injection point / mix point (whichever is greater). For counter current injection points, the primary zone should be extended to a minimum of 2 meters (6 feet) upstream of the injection point. Secondary Zone The outer boundary of the injection point / mix point circuit as defined in API-570. This is a minimum of 3 pipe diameters or 300 mm (12 inches) upstream of the Primary Zone (whichever is greater) and 8 meters (25 feet) or past the second flow directional change (whichever is greater) downstream of the Primary Zone.

b.

2. 3.

Inspection shall occur in both the Primary and Secondary zones. If equipment such as a pressure vessel or heat exchanger is reached within the limits described above, the boundary of the injection point or mix point ends at the equipment.
Date: May 2010 Custodian: DME/4 ECCN: EAR99 Page: 7 of 17

Version: 1.0

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

4. 5.

A Materials and Corrosion Engineer shall be consulted to aid in determining the physical limits of the injection point or mix point circuit. Appendix C depicts typical inspection boundaries.

6.2

Inspection of Piping
1. The Pressure Equipment Inspector shall use the output from the review of each unit and additional input from the Materials and Corrosion Engineer to establish condition monitoring locations (CMLs) for each injection point and mix point. Appendix D depicts a typical circuit layout and CML locations. Appendix E provides guidance for inspection detection methods.

2. 3.

6.3

Inspection of Injection Hardware


1. Injection points with spray nozzles shall be removed and visually tested on an interval determined by risk assessment to verify that the nozzle is delivering the proper spray pattern at the designed pressure drop. a. b. c. Remove the quill from the piping system at least every other turnaround. Flow test to verify the spray nozzle is working properly and the spray pattern is complete and as listed on the injection point data sheet. Inspect the quill for corrosion, thermal or vibration fatigue cracking and environmental cracking. If degradation damage due to fatigue or erosion is found, the injection point should be evaluated for potential redesign.

2.

Injection points associated with hydrotreater reactor effluent water washes shall be verified to be operating per design on an interval determined by risk assessment and periodically reviewed to verify their effectiveness. For injection quills and spray nozzles, the direction of the quill shall be clearly marked on the assembly so that the quill can be oriented properly (such as facing upstream or downstream) and verified while the unit is in operation. The optimum direction shall be established by the Process Engineer/Technologist and the Materials and Corrosion Engineer and listed on the injection point datasheet. Static mixers, thermal sleeves, skin temperature measurement devices, and other related hardware necessary to verify the proper delivery and intended mixing efficiencies shall be inspected for degradation and functionality at frequencies similar to the injection point or mix point circuit associated with this equipment.

3.

4.

7.

Documentation
1. Injection points and mix points shall be documented in: a. b.
Version: 1.0

Corrosion Control Documents (CCDs) in the stand-alone document or in S-RBI tool, Piping isometrics,
Date: May 2010 Custodian: DME/4 ECCN: EAR99 Page: 8 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

c. d. e. 2.

Corrosion and Materials Diagrams or corrosion loop drawings, Injection Point Data Sheets, and IDMS (Inspection Data Management System).

CCDs shall include descriptions for all injection points and mix points along with the purpose, all applicable degradation mechanisms and their likelihood of occurrence (including the technical basis for arriving at the likelihood), and any integrity operating windows (IOWs) associated with these points. Piping isometrics shall be developed to document the actual configuration and the physical boundaries of the injection point or mix point. An example generic CML layout drawing, which identifies the primary and secondary zones and shows an example of how to layout CMLs within each zone, can be found in Appendix D. Sites should also utilize a photograph of the injection point showing the piping configuration and process flow direction to aid with the proper installation of quills. The Corrosion and Materials Diagrams (C&MDs) or Corrosion Loop Diagrams (CLDs) shall uniquely identify locations of injection points and corrosive mix points. Injection point data sheets shall be completed and/or revised jointly by the Pressure Equipment Inspector, Process Engineer/Technologist, Production Specialist, and the Materials and Corrosion Engineer for injection points. The datasheet shall include information on process conditions, operating procedures, physical requirements such as the type of injection quill, spray nozzle, orientation, etc. An example injection point data sheet is included in Appendix F. This data should be stored as MSWord files or as hard copy in binders until IDMS has the capability to store all the necessary information as specifications and retrieved as a custom report. Mixing points do not require a datasheet and should be documented in the CCD. Injection points and mix points shall be identified and tracked in the Inspection Data Management System (IDMS) as separate circuits. Inspection schedules, inspection strategies and the results of the inspections shall also be documented in IDMS along with any applicable risk mitigation or prevention measures. The inspection interval developed using this SP shall be documented in IDMS and indicated that it is based upon RBI. The piping system for an injected material, up to the injection point or mix point nozzle flange or isolation valve, shall be a separate circuit from the injection point.

3.

4. 5.

6. 7.

8. 9.

Version: 1.0

Date: May 2010

Custodian: DME/4

ECCN: EAR99

Page: 9 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

Appendix A Identification
Piping Systems
1. Examples of injection points and mix points include but are not limited to the list below. They may have an injection system (spray nozzle, quill, etc.) or may be a simple tee or weldolet with no injection device, may be aqueous or non-aqueous, and may be continuous or intermittent flow. The Materials and Corrosion Engineer and Pressure Equipment Inspector should use these as examples during the Identification phase. a. Streams injected with: i. Utilities (water, steam, air and nitrogen)

ii. Acids, such as sulphuric or hydrochloric iii. Oxygen iv. Hydrogen or syngas v. Chemical additives such as filmer, neutralizer, anti-foulant, anti-foaming, scavenger, or passivator

vi. Any alkaline chemical such as caustic or ammonia vii. Any chemical containing halides viii. Catalysts b. c. d. e. f. g. 2. Wet hydrocarbon streams mixing with dry hydrocarbon streams. Hydrocarbon streams mixing with hydrocarbon streams containing halides. Hydrocarbon vapour streams mixing with liquid streams. Hotter streams mixing with cooler streams. Injection streams used only during regeneration, sulfiding, decoking, etc. Attemporator quills for steam desuperheaters.

Due to their inherently non-corrosive nature, some injection points or mix points may be excluded, such as: a. b. c. d. e. Water occasionally injected into level bridles for the purpose of flushing. The mixing of two process streams of similar composition, contaminants and temperature. Utility purges (e.g. nitrogen, air, fuel gas, etc.) injected into valves, pumps, instruments, etc. where there is no significant temperature difference between the streams. Temporary non-corrosive decontamination facilities (e.g. steam-out connections, etc.). Finished products mixing such as in a tank farm.

Vessels and Process Equipment


The following process is recommended when materials are injected into vessels and other process equipment: 1. 2. 3. Review the areas of potential degradation, Identify specific tasks to inspect these areas and the injection hardware, if any, and, Include these tasks as part of the equipment inspection plan.

Version: 1.0

Date: May 2010

Custodian: DME/4

ECCN: EAR99

Page: 10 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

Appendix B Classification and Inspection Interval


Consequences A
Potential internal corrosion rates <0.5 DCR or 0.05 mm/y (2 mpy). Thermal fatigue unlikely during all conditions.

Increasing Likelihood / Susceptibility to Failure B


Potential internal corrosion rates <0.5 DCR or <0.05 mm/y (2 mpy). Thermal fatigue differential temperature between streams <165C (app 300F) for ferritic materials of construction or <80C (app 150F) for stainless steel; and quill or sleeve installed and cycles < 1/day. Environmental cracking likely during upset conditions. Likelihood <1/100,000.

C
Potential internal corrosion rates 0.5 -1 DCR or 0.05 - 0.25 mm/y (2 - 10 mpy). Thermal fatigue differential temperature between streams <165C (app 300F) for ferritic materials of construction or <80C (app 150F) for stainless steel; and no quill or sleeve and cycles < 1/day. Environmental cracking likely during normal conditions. Likelihood < 1/1000 but 1/100,000

D
Potential internal corrosion rates 1- 4 DCR or 0.25 - 0.5 mm/y (10 20 mpy). Thermal fatigue differential temperature between streams >165C (app 300F) for ferritic materials of construction or >80C (app 150F) for stainless steel; and quill or sleeve installed and cycles > 3/day.

E
Potential internal corrosion > 4 DCR or >0.5 mm/y (20 mpy) (whichever is less). Thermal fatigue differential temperature between streams >165C (app 300F) for ferritic materials of construction or >80C (app 150F) for stainless steel; and no quill or sleeve and cycles > 3/day. Environmental cracking highly likely (likelihood 1/10).

Consequence Severity

Environment

Reputation

Assets

People

Environmental cracking unlikely during all conditions. No injury or health effect Slight injury or health effect Minor injury or health effect Major injury or health effect PTD or up to 3 fatalities More than 3 fatalities No damage Slight damage Minor damage Moderate damage Major damage Massive damage No impact Slight impact Minor impact Moderate impact Major impact Massive impact

Environmental cracking moderately likely during normal conditions (likelihood < 1/10 but 1/1000).

0 1 2 3 4 5

No effect Slight effect Minor effect Moderate effect Major effect Massive effect

F F F F F F E

F F F
8 yrs RAM 3 10 yrs RAM 2

F F E
8 yrs RAM 3 10 yrs RAM 2

F F D (3 6 yrs) C (3 yrs) B ( 3 yrs) A ( 1 yrs)


ECCN: EAR99

F F C (3 yrs) B ( 3 yrs) A ( 1 yrs) A ( 1 yrs)


Page: 11 of 17

D (3 6 yrs) C (3 yrs) B ( 3 yrs)

D (3 6 yrs) C (3 yr)
Custodian: DME/4

Version: 1.0

Date: May 2010

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

Notes for Appendix B: 1) For purposes of this SP, likelihood is the susceptibility of a material to a type of damage mechanism, such as thermal fatigue or vibration-induced fatigue, combined with the severity of the process environment on that material. Susceptibility to Failure is the same concept defined as the vulnerability to actual degradation as compared to the degradation expected per design. 2) Highly variable process conditions with the potential to significantly affect damage rates should be modelled in the table by increasing the likelihood by two levels. 3) Variable process conditions with the potential to have some changes significantly affect damage rates should be modelled in the table by increasing the likelihood by one level. 4) Normally stable process conditions with the potential for occasional upsets and/or low magnitude variations should be reviewed to determine if the likelihood should be increased. 5) Steady state process conditions with low potential of significantly changing damage rates will not change the likelihood. 6) Thermal fatigue likelihoods in the table are based on liquid injection into a gas stream. Liquid into liquid and gas into gas injections can be modelled as lower likelihoods for thin walled piping components. 7) The likelihood of failure of the quill due to vibration-induced fatigue is covered in Module S8 of the Degradation Library. 8) Reassessment intervals specified by the jurisdiction (e.g. 3 years in regions following API 570 requirements) take precedence if they are shorter than the intervals specified above. 9) The inspection intervals above are maximum inspection intervals independent of the corrosion calculations. The corrosion circuit calculations may result in shorter intervals based on the corrosion rate and interval factor used.

Version: 1.0

Date: May 2010

Custodian: DME/4

ECCN: EAR99

Page: 12 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

Appendix C Inspection Boundaries


The following sketch and table illustrate the primary and secondary zones for inspection coverage.

Injection Point

The secondary zone is a minimum of 3 pipe diameters or 300 mm (12 inches) upstream of the primary zone (whichever is greater) and past the second flow directional change or 8 meters (25 feet) downstream of the primary zone (whichever is greater)

Secondary

Primary

Primary

Secondary

The primary zone is a minimum 3 pipe diameters or 300 mm (12 inches) upstream of the injection point (whichever is greater) and past the first flow directional change or 10 pipe diameters downstream of the injection point (whichever is greater)

Version: 1.0

Date: May 2010

Custodian: DME/4

ECCN: EAR99

Page: 13 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

Appendix D Example of Circuit CML Set Up for Thickness Data Capture


The following illustrates how to capture the primary and secondary zones can be documented for circuit set up and CML thickness data capture.

IP
1 dia.

Primary CMLs - place approx. 1 diameter apart Secondary CMLs

Place Secondary CMLs as needed

3 dia. (Sec.)

3 dia.(Pri.)

10 dia.(Pri.)

8 meters total (Sec.)

Version: 1.0

Date: May 2010

Custodian: DME/4

ECCN: EAR99

Page: 14 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

Appendix E Detection Methods

Primary Zone
Localized Corrosion Target Percent Coverage Class A, B, C or D Class E or F Recommended Detection Methods Profile Radiography [1] [2] EMAT Lamb-wave [1] [3] Automated Digital RT [1] B-Scan Ultrasonics Visual C-Scan Ultrasonics Hand scanning [6] Confirmation / Follow-Up Methods Manual Straight-Beam Ultrasonics with None necessary. Flaw Detector (hand-scanning) [1] [2] [3] [4] None necessary. A Scan Ultrasonics [1] Profile Radiography [1] [2] Automated Digital RT [1] Pulsed Eddy Current Straight Beam EMAT Digital Thickness Ultrasonics Manual Angle Beam UT [1] Automated UT Radiography 100% of primary zone Can be less than 100% with input from the Materials and Corrosion Engineer. 100% of CMLs 100% of CMLs 100% of Susceptible Areas [5] Can be less than 100% with input from the Materials and Corrosion Engineer. Damage Mechanism General Corrosion [4] Cracking

Preferred methods Piping diameter greater than or equal to 250 mm (10 inches) requires multiple contact-density radiography shots for 100% coverage. Not effective for grooving type corrosion along long axis of pipe. When general corrosion is suspected and has not been confirmed, the user should inspect, as a minimum, during the next two inspection intervals, using methods for localized corrosion before changing to the general corrosion damage mechanism. [5] The Corrosion/Materials Engineer should be consulted to determine which areas would be considered "susceptible". Areas where stresses tend to concentrate, such as welds and formed elbows, should be considered. [6] Acceptable for small diameter piping where it is difficult to apply automated UT methods.
Version: 1.0 Date: May 2010 Custodian: DME/4 ECCN: EAR99 Page: 15 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

Appendix E Detection Methods (continued)

Secondary Zone
Damage Mechanism Localized Corrosion Target Percent Coverage Class A, B, C or D Class E or F General Corrosion [4] Cracking 100% of Susceptible Areas [5] Can be less than 100% with input from the Materials and Corrosion Engineer.

100% of CMLs 100% of CMLs Can be less than 100% with input from 100% of CMLs the Materials and Corrosion Engineer.

Recommended Detection Methods Same as Primary Zone. Ultrasonic hand Same as Primary Zone. scanning is acceptable for secondary zone. Confirmation / Follow-Up Methods Same as Primary Zone. None necessary

Same as Primary Zone.

None necessary

[1] [2] [3] [4]

Preferred methods Piping diameter greater than or equal to 250 mm (10 inches) requires multiple contact-density radiography shots for 100% coverage. Not effective for grooving type corrosion along long axis of pipe. When general corrosion is suspected and has not been confirmed, the user should inspect, as a minimum, during the next two inspection intervals, using methods for localized corrosion before changing to the general corrosion damage mechanism. [5] The Corrosion/Materials Engineer should be consulted to determine which areas would be considered "susceptible". Areas where stresses tend to concentrate, such as welds and formed elbows, should be considered. [6] Acceptable for small diameter piping where it is difficult to apply automated UT methods.

Version: 1.0

Date: May 2010

Custodian: DME/4

ECCN: EAR99

Page: 16 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

Downstream Manufacturing DBAM Code and Name: MAN.15.10 Provide Asset Availability Ensure Equipment Integrity

Restricted

Management of Injection Points and Mix Points

DSM-1510002-SP-30

Appendix F Injection Point Data Sheet


The following is an example of an injection point data sheet that can be used to document each injection point.

Version: 1.0

Date: May 2010

Custodian: DME/4

ECCN: EAR99

Page: 17 of 17

Feb 23, 2012 Printed _______________ Printed copies are uncontrolled Printed copy should not be used more than 1 month after printed date

You might also like