the need for ndt, rca & rbi
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The need for NDT
During their service lives, many industrial componentsneed regular non-destructive tests to detect damage thatmay be difficult or expensive to find by everydaymethods. For example:
o Aircraft skins need regular checking to detect cracks;
o Underground pipelines are subject to corrosion andstress corrosion cracking;
o Pipes in industrial plants may be subject to erosion and
corrosion from the products they carry;
o Reinforced concrete structures may be weakened if the
inner reinforcing steel is corroded;o Pressure vessels may develop cracks in welds;
o The wire ropes in suspension bridges are subject to
weather, vibration, and high loads, so testing for broken
wires and other damage is important.
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Applications
Automotive
Engine parts
Frame
Aviation / Aerospace
Airframes
Spaceframes
Powerplants
Propellers Reciprocating Engines
Gas Turbine Engines
Rocketry Construction
Structures
Bridges
Maintenance
Bridges
Manufacturing Machine parts
Castings and Forgings
Industrial plants such as Nuclear, Petrochemical,Power, Refineries, Pulp and Paper, Fabricationshops, Mine processing and their Risk BasedInspection programmes.
NDT is used in a variety of settings that covers
a wide range of industrial activity.
Pressure vessels
Storage tanks
Welds
Boilers
Heat exchangers
Turbine bores In-plant Piping
Miscellaneous
Pipelines
In-line Inspection using "pigs"
Pipeline integrity
Leak Detection
Railways
Rail Inspection
Wheel Inspection
Tubular NDT, for Tubing material
Corrosion Under Insulation (CUI)
Amusement park rides
Submarines and other Naval warships
Medical imaging applications
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Methods and techniques
Liquid penetrant testing (PT or LPI)
Radiographic testing (RT)
Digital radiography (real-time)
Computed radiography
SCAR (Small Confined Area Radiography)
Neutron radiographic testing (NR)
Computed tomography (CT)
Impulse excitation technique (IET)
Ultrasonic testing (UT)
Phased array ultrasonics
Time of flight diffraction ultrasonics (TOFD)
Time of Flight Ultrasonic Determination of 3D Elastic Constants (TOF)
Internal Rotary Inspection System (IRIS) ultrasonics for tubes
EMAT Electromagnetic Acoustic Transducer (non-contact)
laser ultrasonics (LUT) Electromagnetic testing (ET)
Alternating Current Field Measurement (ACFM)
Alternating Current potential drop measurement (ACPD)
Direct Current potential drop measurement (DCPD)
Eddy-Current Testing (ECT)
Remote field testing (RFT)
Magnetic-particle inspection (MT or MPI)
Magnetic flux leakage testing (MFL) for pipelines, tank floors, and wire rope
NDT is divided into various methods of nondestructive testing,
each based on a particular scientific principle.
These methods may be further subdivided into various techniques.
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Methods and techniques (cont.)
Acoustic emission testing (AE)
Positive Material Identification (PMI) Hardness testing (Brinell) (HT)
Infrared and thermal testing (IR) Thermographic inspection
Laser testing Profilometry
Holographic interferometry
Electronic Speckle Pattern Interferometry
Shearography
Leak testing or Leak detection (LT) Tracer-gas method testing Helium, Hydrogen and refrigerant gases
Bubble testing
Absolute pressure leak testing (pressure change)
Halogen diode leak testing
Mass spectrometer leak testing
Magnetic resonance imaging and NMR spectroscopy Visual inspection (VT)
Pipeline video inspection
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Root Cause Analysis
Root cause analysis (RCA) is a class of problem solving methodsaimed at identifying the root causes of problems or events.
The practice ofRCA is predicated on the belief that problems are bestsolved by attempting to correct or eliminate root causes, as opposed
to merely addressing the immediately obvious symptoms.
By directing corrective measures at root causes, it is hoped that thelikelihood of problem recurrence will be minimized.
However, it is recognized that complete prevention of recurrence by a
single intervention is not always possible. Thus, RCA is oftenconsidered to be an iterative process, and is frequently viewed as atool of continuous improvement.
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General principles of root cause analysis
Aiming performance improvement measures atroot causes is more effective than merelytreating the symptoms of a problem.
To be effective, RCA must be performedsystematically, with conclusions and causesbacked up by documented evidence.
There is usually more than one root cause forany given problem.
To be effective the analysis must establish allknown causal relationships between the rootcause(s) and the defined problem.
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General process for performing and
documenting an RCA-based Corrective Action
Define the problem.
Gather data/evidence.
Ask why and identify the causal relationships
associated with the defined problem. Identify which causes if removed or changed will
prevent recurrence.
Identify effective solutions that prevent recurrence, arewithin your control, meet your goals and objectives and
do not cause other problems. Implement the recommendations.
Observe the recommended solutions to ensureeffectiveness.
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Basic elements of root cause
Materials Defective raw material
Wrong type for job
Lack of raw material
Machine/Equipment Incorrect tool selection
Poor maintenance or design
Poor equipment or tool placement
Defective equipment or tool
Environment Orderly workplace
Job design or layout of work
Surfaces poorly maintained
Physical demands of the task
Forces of nature
Management No or poor management involvement
Inattention to task
Task hazards not guarded properly
Other(horseplay, inattention....)
Stress demands
Lack ofProcess
Methods
No or poor procedures
Practices are not the same as written
procedures
Poor communication
Management system
Training or education lacking
Poor employee involvement
Poor recognition of hazard
Previously identified hazards were not
eliminated
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Risk based inspection
Risk based Inspection (orRBI) is a risk-
based approach to inspection in the Oil
and Gas industries. This type of inspection
analyzes the likelihood of failure and the
consequences of the same, often in
industrial pipework. It is also called Risk
Based Asset Management (RBAM), RiskBased Integrity Management (RBIM) or
simply Risk Based Management (RBM).
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RBI objectives
RBI will assist a company to select cost
effective and appropriate maintenance and
inspection tasks and techniques, to
optimize such efforts and cost, to shift
from a reactive to a proactive maintenance
regime, to produce an auditable system, to
give an agreed Operating window, topromotes Team work and to create a Risk
Management Tool.
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RBI purposes
To move away from time based inspectiongoverned by minimum compliance with rules,regulations and standards for inspection.
To apply a strategy of doing what is needed forsafeguarding integrity and improving reliability
and availability of the unit by planning andexecuting those inspections that are needed.
To provide economic benefits such as fewerinspections, shorter shutdowns, longer runlength, and less frequent shutdowns.
To safeguard integrity.
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Sample ofRBI process
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