Friday, 18 May 2018

Risk Based Inspection (RBI) Programme

OLD MAILS REGARDING DEVELOPMENT IN 2010



With best regards,
BEAT PLASTIC POLLUTION , the theme for World Environment Day 2018, 
Dr. AMAR NATH GIRI                       
EHSQ , NFCL 
M.Sc. -Environmental Science,Ph.D -Environmental Science law & DIPLOMA AS - P.G.D.E.P.L,CES, DCA,
EX IIM LUCKNOW FELLOW, EX RESEARCH SCIENTIST
IGIDR-MUMBAI 
9912511918
amarnathgiri@nagarjunagroup.com
http://www.nagarjunafertilizers.com 

---------- Forwarded message ----------
From: Dr Amarnath Giri <AmarnathGiri@nagarjunagroup.com>
Date: Fri, May 18, 2018 at 3:59 PM
Subject: Fw: Risk Based Inspection (RBI) Programme
To: goswami248@gmail.com


----- Forwarded by Dr Amarnath Giri/TS/KKD/NFCL/NAGARJUNA on 05/18/2018 03:54 PM -----
From:Dr Amarnath Giri/TS/KKD/NFCL/NAGARJUNA
To:Raghavan R/PROD/KKD/NFCL/NAGARJUNA@NAGARJUNA, P Chandra mohan/TS/KKD/NFCL/NAGARJUNA@NAGARJUNA, Ramachandra Rao K/TS/KKD/NFCL/NAGARJUNA@NAGARJUNA,
Date:05/31/2011 02:28 PM
Subject: Risk Based Inspection (RBI) Programme




Dear Sir ,
Wish You a very good afternoon , we are continuously approaching sustainable development in all around the plant  , we must have to inculcate as much as possible Qualities Under Your  innovative ideas & guidance , Sir, Some Information cane be helpful to make the best Production with all Systems Performance as we as EHSQ & Systems Up garadtion as objective in OHSAS ,RCMS & EMS .
 Modern Process Plants, especially fertilizer plants are designed for flexible production and maximum recovery of energy. Provision of a Distributed Control System (DCS) along with an Advanced Process Control (APC) philosophy can serve this purpose. The objectives of APC implementation in a Gas based Ammonia Plant are as follows:
Minimization of specific energy consumption. 
Stabilization of plant load even during fluctuations in variables such as Natural gas pressure, flow or quality.  
Precise control of “Steam to Carbon” ratio in the Primary Reformer for steam economy.
Optimum control of Oxygen in the Flue Gas.
Control of Synthesis gas quality i.e. the Hydrogen to Nitrogen Ratio.
Accurate control of Methane slippage from the Primary and Secondary Reformers
..
Risk Based Inspection (RBI) Programme

The main aim of the Risk Based Inspection programme is to;Maximize safety by evaluating risks for individual equipments/accessories and recommend methods to reduce risks.
- Optimize productivity by optimizing plant shut down timings
- Optimize inspections, testing and maintenance to improve plant reliability.
- Improve the understanding of the condition of plant hardware and its management for long term plant operation.
- Make optimal use of resources through a risk based approach.
Equipment that should be covered in the RBI programme are;
- Furnaces
- Reaction vessels
- Heat exchangers
- Boilers
- Storage tanks/Vessels
- Piping and Pressure Relief valves
Preparation of comprehensive lists of pressure equipment based on criticality in terms of services and set up inspection programme accordingly
- Prioritize the pressure equipment so that the assessments to be carried out enable the major outcomes from the critical plant to be reported as early as possible.
- Develop process loops for piping such that each process loop has the same environment and similar risk exposure.
- Complete a risk-based assessment so that meaningful profiles of failure risk, failure
likelihood and failure consequence can be established for each “nominated” pressure item or process loop in the ammonia plant.
- Prepare inspection programmes for pressure equipment and piping to ensure these items
 of plant are effectively operated, maintained and their condition assessed.
- Recommend actions, which will be needed to be carried out to ensure safe & reliable operation of the plant prior to and after planned shutdown.
- Use of proprietary Reliability Management System (RMS) software of the Vendor who will be entrusted to carryout the study.
- Recommend preliminary scope of work and period of the planned upcoming shutdown
.
A Risk based Inspection study helps to standardize the inspection procedures to optimize production and time span for planned shutdown.
b. Improving Plant Reliability through Corrosion Monitoring
Corrosion attacks can reduce equipment performance and lead to unexpected failures and plant shut downs. Corrosion attack of process equipments may be external or internal. External attack is by ambient environment whereas internal attack is caused by process fluid handled inside. Corrosion monitoring is an essential input in Residual Life Assessment and Aging Management Programme.
Corrosion monitoring techniques are;
- Methods that indirectly measure parameters related to corrosion and inter corrosion
behavior from some model of corrosion process, e.g. electrochemical potential, pH and temperature.
- Methods that directly measure corrosion behavior, e.g., Non-destructive Inspection,
Material Test Coupons, Galvanic Currents etc.
-- Corrosion Monitoring Techniques:
Direct Measurements
• Non Destructive Inspection (NDI)
• Electrical Resistance (ER) Probes
• Material Test Coupons
• Galvanic Currents
• Cyclic Potentiodynamic Polarization (CPP)
• Linear Polarization Resistance
• Electro Chemical Noise (EN)
• Electrochemical Impedance Spectroscopy (EIS)
Indirect Measurements
• Potential
• Biological Count
• Hydrogen
• pH
• Temperature
• Conductivity
• Specific Ions
Periodic assessment is the most common method of corrosion monitoring and can help to:
• Evaluate materials performance under specific service conditions
• Aid in proper material selection
• Evaluate and control the production process
• Provide necessary data for Residential Life Assessment
Improving Plant Reliability by Conducting Regular Safety Audits

Dr. Amar Nath Giri
Environment


("Many Species: One Planet ,One Future)
"Biodiversity -Ecosystems Management & the Green Economy " 2010-International Biodiversity Year.








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