Earticle

The likelihood of failure for the stress corrosion cracking (SCC) of caustic cracking, which affect to a risk of facilities, was analyzed through the risk based-inspection using API-581 BRD. We found that SCC of the caustic cracking was occurred above 5 % NaOH concentration, and the technical module subfactor (TMSF) was maximized for above 50 % concentration. The heat traced and monitoring were not sensitive to the TMSF with NaOH concentration and temperature. But the steam out was more of less affect minimum value of the TMSF. Also, the inspection number, the inspection effectiveness, and the year since inspection were very sensitive to the TMSF with NaOH concentration and temperature. Therefore, the plan of next inspection will be established with compositively considering those at once.

The likelihood of failure for the thinning of high temperature sulfide and naphthenic acid corrosion, which affect to a risk of facilities, was analyzed through the risk based inspection using API-581 BRD. We found that the corrosion rate was increased with increasing temperature and total acid number(TAN). And maximum value of the technical module subfactor(TMSF) was not varied with operating condition, but the TMSF was sensitively changed at the range of low temperature, low flow rate, and high TAN. Also, the TMSF was increased as an used year and inspection effectiveness increased, but it was increased as thickness, inspection number, and over design decreased.

The likelihood of failure by the corrosion of high temperature H2S/H2, which affect to a risk of facilities, was analyzed through the risk based-inspection using API-581 BRD. We found that the corrosion rate was increased as temperature and H2S concentration were increased. Also, the technical module subfactor(TMSF) was increased as an used you increased, material thickness decreased, inspection number decreased, and inspection effectiveness increased. In these conditions, the maximum value of TMSF was not varied, but the TMSF was sensitively varied at low temperature for high concentration of H2S.

Likelihood of failure for the external corrosion of carbon and low alloy steels, which affect to a risk of facilities, was analyzed quantitatively through the risk based inspection using API-581 BRD. We found that the technical module subfactor (TMSF) decreased as the inspection number increased and it increased as the Inspection effectiveness and the used year increased. In this condition, the TMSF showed high value for the case of the marine/cooling tower drift area as a corrosion driver, poor quality of coating, no insulation, and low insulation condition.

Likelihood of failure (LOF) for the external corrosion of stainless steel, which affect to a risk of facilities, was analyzed quantitatively through the risk based inspection using API-581 BRD. We found that the technical module subfactor (TMSF) decreased as the inspection number increased and it increased as the inspection effectiveness and the used year increased, and that the TMSF showed high value for the case of the marine/cooling tower drift area as a corrosion driver, In this condition, the LOF for the external corrosion of stainless steel had lower than that for the carbon and low alloy steels

Industrial facilities are becoming more complex and various with rapidly developing technologies. A number of installations and equipments are increased to improve productivity, and they are operated under the condition of high temperature and pressure. They are continuously repaired, replaced or abolished because of the deterioration with time, but their repair and replacement are not easy for economical and environmental concerns. If possible, the deteriorating equipments should be inspected and repaired effectively considering the state of maintenance and preservation, economic efficiency, and safety. That's where RBI(Risk Based Inspection) fits in. Even if RBI technology has been known among specialists, there were no tools readily available and it was hard to practice and apply RBI in industrial inspection and safety management. In the development of the qualitative RBI, the overall algorithm adopted API-581 BRD. The qualitative RBI program was developed to search the appling process.

본 연구는 독성가스 사고의 주요 원인의 하나인 부식에 대해 고압 독성가스시설을 대상으로 필요한 안전기술을 정립하기 위하여 미국석유학회에서 개발한 API-581 절차를 채택하여 사고결과 분석방법에 대한 적용성을 검토하고, 이를 바탕으로 사고결과 분석방법을 제시하였다. 고압 독성가스시설에서 API-581의 8단계 사고결과 분석절차에 따라 단계별 적용성을 검토한 결과, 고압 독성가스시설에 적용할 사고결과 분석방법은 총 6단계로 단순화 할 수 있었다. 즉, Step 1(대표물질 결정), Step 5(누출유형 결정), Step 6(유체상 결정)과 Step 8(사고 피해영역 산출)은 적용하지 않고, Step 3(누출량 산출)은 inventory group 개념만 적용하며, Step 4(누출속도 산출)는 기체 누출속도만을 적용하고, Step 2(누출공 크기 선정)와 Step 7(완화시스템 등급 결정)은 전부 적용한다. 이때, Step 5와 Step 8은 일반적으로 적용이 가능한 CCPS 방법을 대안적인 방법으로 채택한다.

To establish the necessary safety technology in high-pressure toxic gas facilities, especially for the corrosion, which is the main causes of toxic gas accident, this study adopts and investigates the API-581 procedures developed by the American Petroleum Institute (API). And the applicability of the 8-step analytical procedures of consequence analysis in API-581 is discussed, and a method for consequence analysis in high-pressure toxic gas facilities is suggested. Based on the discussion and results, the analytical procedure is simplified as the 6 steps in total for the effective application to high-pressure toxic gas facilities: Step 1 (determination of representative material), Step 5 (determination of release type), Step 6 (determination of phase of fluid), and Step 8 (estimation of damage range) are not applied: Step 3 (estimation of total amount of release) is applied only for the inventory group concept; Step 4 (estimation of release rate) only for the gas release rate; and all of Step 2 (selection of release hole size) and Step 7 (evaluation of post-release response) are applied. In the proposed method, the generally applicable method of CCPS is adopted as alternative method for Steps 5 and 8.

As one of promising solutions to overcome high oil price and energy crisis, the construction market of high value-added LNG plants is spotlighted world widely. The purpose of this study is to introduce LNG-RBI system to develop risk assessment technology with RAM(Reliability, Availability, Maintainability) modules against overseas monopolization. After analyzing relevant specific features and their technical levels, risk assessment program, non-destructive reliability evaluation strategy and safety criteria unification class are derived as core technologies. These IT-based convergence technologies can be used for enhancement of LNG plant efficiency, in which the modular parts are related to a system with artificial optimized algorithms as well as diverse databases of facility inspection and diagnosis fields.

본 연구에서는 압력설비의 위험 원인분석 방법을 제시하기 위하여 API-581 절차에 의한 위험기반검사(RBI)에서 염산부식의 두께감소로 인한 사고발생 가능성을 해석하였다. 이를 위해 사고발생 가능성의 주요 인자인 기술종속계수(TMSF)를 산출하고, TMSF에 미치는 매개변수의 영향을 정량적으로 해석하였다. 그 결과, TMSF는 염화이온 농도와 온도가 증가할수록 증가하였으나, 설비두께, 검사횟수 및 검사유효성이 증가할수록 감소하였으며, 모니터링이 있는 경우와 과설계계수가 1.5배 이상인 경우에는 상당히 적은 값을 나타내었다. 이때, 검사횟수, 검사유효성 등급 및 과설계 계수의 크기에 따라 TMSF가 민감하게 변화하였으며, 모니터링은 TMSF의 크기만 변화시켰다.

To propose a cause analysis method of pressurized facilities, a likelihood of failure (LOF) for the thinning module by hydrochloric acid corrosion was analyzed through the risk-based inspection (RBI) using API-581 BRD. For this investigation, the technical module subfactor (TMSF), as a main factor of the LOF, was estimated, and the effects of parameters on the TMSF were analyzed quantitatively. As a result, we found that the TMSF increased with increasing chloride ion concentration and temperature, but it decreased with increasing thickness of the facilities, inspection number and inspection effectiveness. Also, the TMSF showed a relatively low value for the monitoring system implemented and the overdesign factor>1.5. In this condition, the TMSF changed sensitively with the inspection number, the inspection effectiveness and the overdesign factor, and its magnitude varied with the monitoring system.

압력설비를 안전하고 효율적으로 사용하기 위하여 본 연구에서는 API-581 절차에 의한 위험기반검사에서 취성파괴에 의한 사고발생 가능성을 정량적으로 해석하였다. 그 결과, 낮은 온도/낮은 인성파괴와 뜨임취성에서는 A 충격곡선이고. 낮은 온도와 열처리 전인 상태에서 기술종속계수(TMSF)가 큰 값을 나타내었고, $855^{\circ}F$ 취성에서는 위험도가 무시할 수 있었으나, 시그마상 취성에서는 낮은 온도의 고 시그마인 경우에 TMSF가 큰 값을 나타내어 사고발생 가능성이 매우 높았다.

To use pressurized facilities safely and effectively, a likelihood of failure (LOF) for the brittle fracture was analyzed quantitatively through the risk based inspection using API-581 BRD. We found that for the case of the low temperature/low toughness and the temper embrittlement, the technical module subfactor (TMSF) showed high value for the A impact curve, low temperature, and the no post weld heat treatment. But the risk didn't significantly change at the $855^{\circ}F$ embrittlement, and the LOF far the sigma phase embrittlement showed high value at low temperature of the high sigma.

독성가스의 누출은 공정설비의 위험도에 크게 영향을 미친다. 본 연구에서는 API-581에 의한 위험기반검사에서 매개변수의 변화에 따른 독성가스(암모니아 및 염소 가스)의 누출사고 결과를 분석하였다. 그 결과, 독성물질의 누출에 의한 사고결과, 즉 독성 피해영역은 온도가 증가할수록, 그리고 압력과 파이프 직경이 감소할수록 감소하였으며, 동일한 누출조건에서 암모니아 보다 염소가스인 경우에 큰 값을 나타내었다.

Accidental releases of toxic gases heavily affect to the risk of process facilities. In this research, consequence analysis for accidental releases of ammonia and chlorine gases was studied using the risk based inspection, based on API-581 BRD. It was found out that consequence areas (toxic areas) decrease as temperature increases and as the pipe diameter and pressure decrease. For the same release condition, the toxic area by the release of chlorine gas was larger than that by the release of ammonia gas.

Consequence analysis of flammable materials that affect to a risk of facilities was studied at the risk based inspection using API-581. We found that consequence areas (damage area of equipment and fatality area) by release accident of flammable materials showed high value for the case of liquid phase and auto-ignition likely, and that consequence areas of flammable gases decreased as temperature increased and the pipe diameter and pressure decreased at continuous release.

용기누출로 인한 가스 폭발사고의 영향을 분석하기 위해 API-581 절차에서 제시된 누출 시나리오를 사용하여 누출물질, 온도, 압력 및 용기의 종류 등을 변화시키면서 누출속도, 장치피해영역 및 상해영역을 산출하였다. 그 결과, 용기누출에서 누출속도, 장치피해영역 및 상해영역은 배관누출에서보다 상당히 큰 값을 가지며, 그 크기는 탱크>반응기>드럼>탑의 순서로 나타났다.

For consequence analysis at a gas explosion by vessel release, release rates, demage areas of facilities, and fatality areas were estimated and analyzed at various conditions(release materials, temperatures, pressures, and vessel types) by using the release scenario of API-581 BRD. Simulation results showed that release rates and consequences in the vessel release were higher than those in the pipe release, and the order of release rates and damage areas was as follows; tank>reactor>drum> column.