Evaluation of Risks in Monitoring Condition of Fluid Collection and Reinjection Systems in Tongonan, Leyte

Abstract

Risk-based inspection was applied in the evaluation and monitoring of the condition of FCRS plant asset in Tongonan, Leyte. The risk-based evaluation assigns each individual component within the FCRS a risk rating, which allows plant inspection and maintenance to be targeted and prioritized, both during operation and at scheduled shutdowns. Assessment starts with quantifying the likelihood of corrosion and metallurgical damage, which has already, or is likely, to occur. Then the consequence of this damage occurring is quantified in terms of commercial, safety and environmental factors. Combination of these likelihood and consequence ratings gave an overall risk rating for each component in the plant.

In Tongonan, Phase 1 of the Risk Based Inspection program provides a rigorous analysis on which to base an initial prediction of the remaining life of the individual components being assessed. Phase II involved actual inspection of identified components within the FCRS. Finally, Phase III is the continuous monitoring of the identified high-risk and high-consequence components, as well as potential high-risk areas. Of the 461 inspection locations monitored, two were immediately categorized as having extreme risk and requiring mitigating measure, while the others were grouped into requiring on-line to off-line inspection. Other locations (31 in all) were also recommended to forego offline inspection to extended period. The immediate advantages of this method are an ability to predict which items require detailed condition inspection, which are likely to require maintenance or replacement in a given timescale and which are suitable for immediate life extension beyond their design life. This has obvious cost benefit implications for the optimized and prolonged operation of the plant.