Case Studies for Non-Metallic Materials in the CPI
Michael Ye, RTConsults
Nonmetallic materials use in industrial plants pertaining to piping and tanks can perform well in a corrosive environment with proper oversight. The design, fabrication, inspection, and maintenance of nonmetallic construction are important key requirements. Furthermore, qualification of materials and testing is necessary to complement the specification and material selection for optimum performance. In addition, the paper will go into case studies and lessons learned from successful projects covering the importance of inspection and quality assurance for reliable service life.
The Green Scorecard – Measuring ROI in Sustainability Initiatives
Dr. Jack J. Phillips, ROI Institute
When global warming first made headlines in the 1980s, it stirred up concern and public debate throughout the world. Still, business leaders resisted the issue, expecting a high price tag to address the problem. While most agreed that climate change was occurring, views differed regarding its origins, and finding solutions was not a priority to many business leaders. Today, however, most (if not all) organizational leaders recognize that climate change must be addressed. Some are making great strides to solve it, resulting in a wave of sustainability and environmental projects. From an organizational perspective, going green offers employees, contractors, volunteers, and citizens the opportunity to influence this green movement through involvement and contribution. The challenge is to create the correct approach to involve stakeholders, including teaching, persuading, communicating, enabling, supporting, and encouraging participation in the process. And, most of all, a process must be in place to measure success with impact and ROI.
How to Reduce Hydrogen Embrittlement in Titanium Alloys
Elise Deloye, Neotiss
High hydrogen content in titanium alloys induces a modification of the mechanical properties, which can generate a premature rupture of the material. The study carried out within NEOTISS, in collaboration with two French university laboratories (ICB and UTINAM) aims to reduce the phenomenon of hydrogen embrittlement by applying different industrial processes as cold rolling, shot peening, anodization, and thermal treatment. Main targeted application is to protect titanium grade 2 tubes in specific heat exchanger environment, like in high conductivity brackish water conditions. Based on results, scenarios about hydrogen move and/or hydrogen preferred location will be proposed and discussed.
Improving the Performance, Reliability and Safety of Process Facilities through the Use of Aerogel Based Insulations
Mark Krajewski, Aerogel
For decades the industrial insulation materials available relegated thermal insulation to design purgatory, necessary but little more than a box checking exercise. Designers understand these materials have a profound impact on the installed cost, construction schedule, performance & safety of the facilities they design and operate, but with scant alternatives the same materials were specified and used. With the introduction of Aerogel based insulations designers can specify products that install faster, have greater durability and significantly reduce the instance of corrosion under insulation (CUI) – a major industry reliability problem. These conclusions are shown by the test data and experience included in this presentation. The reduced insulation thicknesses with equal thermal performance are also beneficial in reducing the required clearances which can be critical on revamp projects with spacing limitations or in reducing the required size of pipe racks. These next generation thermal, acoustic and passive fire protection materials provide bottom line value and unique design capabilities to the hydrocarbon process facility engineer, owner and operator.
Integrity Operating Windows API584
Clay White, Becht
This presentation will cover an outline and discussion of the key principals from the document in establishing an Integrity Operating Windows (IOW) program, and cover the changes from the recently updated 2nd Edition. RP 584 represents a significant departure from the traditional inspection program approach by proactively focusing on, and trending, the operating conditions that can produce equipment damage. Originally released in 2014, RP 584 has been significantly improved and now includes multiple appendices covering examples of process variables by unit (most of which are Refinery units, but it does include one example of a chemical process units). In addition, are examples are provided for specific utilities services and equipment types which will be reviewed. In addition, a list of common mistakes or “pitfalls” that have been found during the implementation of IOW programs, has been included and will be covered in this presentation. One of the conclusions from this presentation will be to highlight the need for additional development of examples for typical process units in the chemicals industry for a potential MTI project.
Using Life Cycle Cost Analysis to Increase Operational Sustainability
Chuck Young and Dennis Lamberth, Tricor Metals
When analyzing expenditures for process equipment, CPI companies have the opportunity to use accounting tools to determine which of the various options can make the most sense – in terms of long-term profitability and sustainability of a particular plant.
Companies can use “Life Cycle Costing” to develop the real impact of the decision on the sustainability of the chemical plant by comparing initial capital outlay with the actual total cost of a decision over the life of the plant. This presentation will briefly discuss what is involved in “Life Cycle Costing” for CPI equipment. This includes the initial cost of equipment, the cost of money or anticipated rate of return for capital, and the cost of maintenance in terms of actual labor, as well as the cost of planned or un-planned downtime. Company executive management, engineering and operations must agree on how often maintenance has to occur, and to what degree it has to be done. A projection of the rate of inflation is also required. Finally, the company must develop an anticipated life for each piece of equipment. Specific examples of how “Life Cycle Costing” can be used to make an informed decision, will be shown and a spreadsheet showing how to do the “Life Cycle Costing” analysis will also be presented for attendees going forward.