LNG플랜트시스템위험도평가기술개발 Development of Smart · PDF...

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LNG plant R&D center

플랜트 조선 Conference 2013주체 : 한국플랜트정보기술협회, 건설기술연구원

LNG플랜트 시스템 위험도 평가기술 개발Development of Smart RBI program

for LNG Plant System

BEXCO Busan, 18 January 2013

Ph.D. Song-Chun Choi (崔松天)

Institute of Gas safety R&D

Korea Gas Safety Corporation

Ⅰ. Research background and

purposes

Ⅱ. Research plan

Ⅲ. Research Promotion System on this Project

Ⅳ The research resultsⅣ. The research results

Ⅴ. The research goal

Ⅵ. Overview on the Smart RBI implementation of LNG plant system

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- Natural gas from gas wells is delivered by pipeline or distribution mains to the liquefaction plant

where it is changed into a liquid.

- The process equipment necessary to make the liquid, the plant also contains equipment to treat

or prepare the gas prior to liquefaction and tankage for storage of the LNG.

- Risk assessment and safety systems are critical to all gas plant. Therefore, the goal of this project ishowhow toto useuse knownknown riskrisk assessmentassessment codescodes (API(API 581581 ISOISO etcetc……)) toto addressaddress suchsuch safetysafety analysisanalysis requirerequire

1. Background and Purposes of this Project

howhow toto useuse knownknown riskrisk assessmentassessment codescodes (API(API 581581,, ISOISO etcetc )) toto addressaddress suchsuch safetysafety analysisanalysis requirerequirementsments forfor riskrisk managementmanagement inin thethe LNGLNG plantplant..

Gas wells Liquid product Transportation Storage

wells treatment liquefactionterminal

LNG carrier

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• Gas wells : confirm of hazard factor in wells

• Treatment : evaluation of piping corrosion , Material degradation and development of the safety index

• Liquid product : Risk analysis of parent metal /welding point from ultra low-temperature materials , unification safety management system

• Storage : Safety assessment mode in gas plant

Cold Box

Liquefaction Plant Block Flow Process Facilities

Institute of Gas Safety R&D가 스 안 전 연 구 원

3


Internet based network Risk Assessment System for LNG Plant Internet based network Risk Assessment System for LNG Plant

ApplicationS

DataWarehouse

• Degradation InformationSystem for Materials

• ASP Application

• Supply Assessment Results

• Risk Analysis SW

• Inspection Scheduling SW

• Repair Scheduling SW

W

InternetInternet

BasedBasedNetworkNetworkSystemSystem

Server

ManagementServer

Server • Inspection Monitoring Data Based on Web

• Cost-Benefit Analysis SW

• Safety Integrity Level (SIL) S/W

• PHA S/W

• Financial Risk Analysis S/W

• Decision Making Tool System

• Management Information System

• GUI Application & User Interface

W b B

Basic Engineering

Engineer & Expert Judgment

• Web Base

• Virtual Reality Based on WEB System

3

4

2. Research plan [2008. 11 ~ 2014. 6]

1st Year 2nd year 3rd 4th 55thth(2012~2013)(2012~2013) 6th(2014.6.17)Code, data survey Standard/code

analysisMaterial DB/

System designRisk assessment

development Inspection Planning Safety management Guide development

S

R i

check the main equipment Reliability Review

M i t i l Inspection point ISO, BS, API ect.

SurveyDesign

Review Pre-reserch

Check the Benchmark ing

Risk check of reuipment , plant module

Compare of Risk asessement technical

Main material survey

Design of material DB destructive

Inspection pointand guideline

Manual Writing

Design of data management In LNG plant system

Safety management Integrated system

Design of NDE signal image viewer

safety index design

Survey of Non destructive of LNG plant

Development of Frameworks in

global code

Research goals

Design of non-destructive history, result

Development of Inspection

Development

Defined of RISK in LNG plant

Web-based

Development of LNG Plant NDE DB

KGS -RBIMFor LNG plant

Development of NDE signalanalysis module

Development of Management tool of LNG NDE

Development of Risk assessment

Reliability confirm NDE system

PlatformDevelopment LNG RBI s/w

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Development of InspectionPlanning module

RAMS(Reliability, Availability, Maintainability and Safety)RAMS(Reliability, Availability, Maintainability and Safety)

Intrinsic safety Process design Equipment design Plan layout

Training Organization Procedure Ergonomics

SAFETYSAFETYEngineering reliability

Human reliability in the operations

Process management (control, communication, information)

Plan layout Maintainability

Written procedure Incident investigation Meetings Audits and reviews Permits to work

Ergonomics Design

Responsibility & authority Safety policy Written procedure Emergency planing Internal audits

Organization, Management System

SOCIAL ENVIRONMENTSOCIAL ENVIRONMENT(laws, economic pressure, public opinion)

Figure. Pyramid showing how different aspects of a management system affect the achievementof a safety operation(based on “Jessen, T. K. “Systems for good management practicesin quantified risk analysis.” Process Safety Prog., 12(3), 137) 2

5

5

Component Pakage

1st Stage(2008 ~2009)

RAM based

Interface

2nd Stage(2010~2011)

3rd Stage(2012~2014)

ApplicationServer

DataWarehouse

ServerInternet

Materials DBMaterials information

componentEquipment

components

Leak model Scenario component

Based on Risk Assessment Codes

Ap

plicatio

n P

rog

ramA

pp

lication

Pro

gram

Interface

GUI + VR A li i

ManagementServer

InternetBased

NetworkSystem

Plant design

Consequence model

mm

ing

mm

ing

Application

Database Biz Logic

23

virtualplant

programcording

KICT(Core

Institute)

Institute

SKKU(Sub joint)

Institute Gas Safety

R&D(Joint)

5

JSPS 180th

RBMCommitteein Japan

6

ISO(InternationalISO(International StandardizationStandardization Organization)Organization)

ISO/IEC 15504-4:2004 Process assessment ISO/TS 16732:2005 Guidance on fire risk assessmentISO 17776:2000 Guidelines on tools and techniques

4. The research results

BS(BritishBS(British Standard)Standard)

qfor hazard identification and risk assessment

ISO 15615:2002 Safety requirements in high-pressure devices ISO 21789:2009 Gas turbine applications - SafetyISO 19706:2007 Guidelines for assessing the fire threat to people 외

BS 08/30183974DC, 2008 BS EN 31010. Risk management.BS EN12308:1998 Installations and equipment for LNGBS EN12308:1998 Installations and equipment for LNG.BS EN710:1998 Safety requirements for foundry molding and

coremaking machinery and plant and associated equipment BS ENISO17666:2003 Space systems. Risk management BS PDISO/IECGUIDE73:2002 Risk management. Vocabulary.

Guidelines for use in standards

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APIAPI CodeCode andand ANSIANSI ectect..

• ANSI/AAMI14971:2000 Risk management- Part 1 : Application of risk management

4. The research results

• API RP 581, 2008 Risk-Based Inspection Technology, Second Edition

• IEEE 16085 : 2004(1540-2001), 2006 Software Life Cycle Processes-Risk Management

• CAN/CSA Z276-01, 2003 Liquefied Natural Gas(LNG)- Production, Storage and Handling

• CSAZ276-07, 2007 Liquefied Natural Gas(LNG)- Production, Storage, and Handling, Includes Update

• LNG Preventive Maintenance Guide,1984(AGA)

• Introduction to LNG for Personnel Safety,1986(AGA) ect.

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Identify Risk Areas- Experience and Lessons Learnt from past and similar projects- Logical analysis : Criticality Rating, QRA, RBI, HSE etc.- Project Environment

4. The research results of first year

Inlet Facilities- Uncertainty of feed stock property- Slug design basis- Insufficient separation of gas & liquid- Fouling

Acid Gas Treatment- Foaming

Vibration d e to t o phase flo


- Vibration due to two phase flow- Sudden vaporization

Dehydration & Mercury Removal- Batch process- Replacement of Molecular sieve- Disposal of activated carbon

4. The research results of first year

Liquefaction- High temperature around gas turbine- Large bore piping & piping support- Vibration of large rotating machine- Large liquid inventory- Cracking of cryogenic component

Storage & Loading- Jetty head : Connect & disconnect operation


- Spillage- Maneuvering operation- Leakage from LNG Tank

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Damage, Damage, RiskRisk, Hazard…… , Hazard……

reason, Cause,Factor?

Ri kRi kRiskRisk can be formally defined

as the potential of loss(e.g., material, human, or environment, losses) resulting from exposure to a hazardhazard.


정유 및 석유화학설비 주요 사고발생 설비(해외)정유 및 석유화학설비 주요 사고발생 설비(해외)

Piping systems

Tanks

Reactors

Drums

Pumps/Comp.

H/E


00 2020 2525 3030 35351515101055

/Towers

Heaters/Boilers

Others/Unknown

건수건수

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What is the definition of ~~~~~~ ?What is the definition of ~~~~~~ ? HazardHazard : is considered as “a source of dangera source of danger””

but the concept does not contain any notionof the likelihood with which that dangerwill actually impact on people or

HazardHazard : is considered as “a source of dangera source of danger””but the concept does not contain any notionof the likelihood with which that dangerwill actually impact on people oron the environment.

Risk Risk : a set of scenarios SSii each of which hasa probability PPii and a consequences XXi.

RR = < SSii , PPii , XXi > i=1, 2, ……, n,SSii = (ⅰ) What What can go wrong that could lead to an outcome of hazard exposurePPii = (ⅱ) How likelyHow likely is it to happen ?XXi = (ⅲ) Given that it occurs, what are the consequencesthe consequences ?

on the environment.

Risk Risk : a set of scenarios SSii each of which hasa probability PPii and a consequences XXi.

RR = < SSii , PPii , XXi > i=1, 2, ……, n,SSii = (ⅰ) What What can go wrong that could lead to an outcome of hazard exposurePPii = (ⅱ) How likelyHow likely is it to happen ?XXi = (ⅲ) Given that it occurs, what are the consequencesthe consequences ?


Kaplan S. and Garrick, B.J., “On the quantitative definition of risk”Risk Analysis, 1, 11-27, 1981.Kaplan S. and Garrick, B.J., “On the quantitative definition of risk”Risk Analysis, 1, 11-27, 1981.

What is the definition of ~~~~~~ ?What is the definition of ~~~~~~ ? ReliabilityReliability : The probability that an item will perform

a required function, under stated conditions,

for a stated period of time.

~~~ “The probability of nonThe probability of non--failure in given periodfailure in given period.”

ReliabilityReliability : The probability that an item will perform

a required function, under stated conditions,

for a stated period of time.

~~~ “The probability of nonThe probability of non--failure in given periodfailure in given period.”

MaintainabilityMaintainability : The probability that a failed item will be

restored to operational effectiveness within

a given period of time when the repair action

is performed in accordance with prescribed

procedures.

~~~ “The probability of repair in a given timeThe probability of repair in a given time.”

MaintainabilityMaintainability : The probability that a failed item will be

restored to operational effectiveness within

a given period of time when the repair action

is performed in accordance with prescribed

procedures.

~~~ “The probability of repair in a given timeThe probability of repair in a given time.”


David J. Smith “Reliability, Maintainability and Risk” Practical methods for engineers, sixth edition, 2001, Butterworth-Heinemann.David J. Smith “Reliability, Maintainability and Risk” Practical methods for engineers, sixth edition, 2001, Butterworth-Heinemann.

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Risk Ranking of EquipmentRisk Ranking of Equipment% of Total Risk Vs % of Equipment Items

Plant Unit, ~500 Total Items100%

10%

20%

30%

40%

50%

60%

70%

80%

90%

% o

f To

tal Ris

k

~80% of all equipment items yielding ~20% of total risk

Most of the total inspectable plant risk is concentrated in a small percentage of the equipment items


0%

10%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

% of Equipment

~20% of equipment items yielding ~80% of total risk

risk

What is the definition of RISK ?

LIKELIHOOD OF EVENTLoF

X CONSEQUENCECoF

=RISK

Generic Failure

FrequencyGFF

Damage FactorDF

ADamage Inspection

Injury ($)

Item repair ($)

Env. clean up ($)

Adjacent repairs ($)

X


Age Mechanism(s)& Rates

pEffectiveness Downtime ($)

TOTAL ($)

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Managing Riska. Human error

b. Natural disasters

c. External events(e.g., collisions or falling objects)

d. Secondary effects from nearby units

e. Deliberate acts(e.g., sabotage)

f. Fundamental limitations of the inspection method

D i

a. Human error

b. Natural disasters

c. External events(e.g., collisions or falling objects)

d. Secondary effects from nearby units

e. Deliberate acts(e.g., sabotage)

f. Fundamental limitations of the inspection method

D i

Risk using RBI

Risk with a “typical”inspection programRisk

g. Design error

h. Previous unknown mechanisms of deterioration

g. Design error

h. Previous unknown mechanisms of deterioration


Uninspectable risk

Inspection Activity

RBI Program for InRBI Program for In--Service EquipmentService EquipmentPlant Database

Risk Based Inspection

Inspection Planning

Fitness For Service

Inspection Result

QIP(Quality ImprovementProcess)


Inspection Updating

System Audit

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Qualitative RBI processQualitative RBI process

Plant DatabasePlant DatabasePlant DatabasePlant Database

User Level

SemiSemi--Quantitative RBI Quantitative RBI processprocess

Quantitative RBI processQuantitative RBI process

Likelihood Category

Damage Consequence

Health Consequence

Release Calculation

Likelihood AnalysisTechnical Module Subfactor

Inspection Effectiveness

Flammable Area

Toxic Area

Inventory Group

Release calculation

Likelihood AnalysisTechnical Module Subfactor

Equipment Modification FactorManagement system Evaluation

Equipment Damage Cost

Business Interruption


Potential Injury Cost

Environmental Cleanup

Risk AreaRisk AreaFinancial RisksFinancial Risks

Inspection PlanningInspection Planning

Risk Ranking Matrix Risk Ranking MatrixInspection Planning

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LNG RBI Middle Ware

Results of research(2008.11~2012.12)

Presentation Layer Algorism

Smart-RBI Business Logic

Data Broker

LNG-RBI Middle WareJoint to (VR SystemVR System)

Modules of Risk Assessment of Components

Materials DB for Critical LNG Facilities

NDE monitoring system and Inspection Planning

Equipment DataCommand


External ERP System (SAP, Maximo. Etc…)

SAP Data Provider

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Example of Presentation Layer with Risk Assessment Model by using VR


Selection of the Risk

assessment method for LNG plant

• Qualitative, quantitative, semi-quantitative

• Survey Survey hazard factor hazard factor feedback in LNG plant feedback in LNG plant

• ISO, BS, ANSI act. (Confirm ofRisk analysis method

• API 581 (Risk based inspection)

• Survey of NDE tech. from the international and local codes

• System framework •• Detailed Design of RBI s/w Detailed Design of RBI s/w

algorism algorism

Reliability Verification

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6. Possibility of implementation

IT Solution RBM IT Solution RBM (Risk(Risk--Based Management) Based Based Management) Based on ERP & VR on ERP & VR SystemSystem

IT Solution RBM IT Solution RBM (Risk(Risk--Based Management) Based Based Management) Based on ERP & VR on ERP & VR SystemSystem

Monitoring

LNG plant blazing information system

RBMRBM• Links to

each module• Decision Making

Tool

g• Condition

Monitoring System• TroubleMonitoring

• Virtual Reality

Material DB

RBIRBI• Risk Based

Inspectionscheduling andmanagement

NDENDE• Integrity Inspection

• IntelligentDiagnosis

◆ Currently Available PM Package

- SAP, MAXIMO, MP5, MLS, IFS

◆ Currently Available PM Package

- SAP, MAXIMO, MP5, MLS, IFSApplication of Engineering Knowledge Based

LNG Plant Management System

LNG plant blazing information systemMaterial DB• Degradation

InformationSystem

for Materials

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LNG Plant Management ProgramLNG Plant Management ProgramLNG Plant Management System(LPMS)LNG Plant Management System(LPMS)

Conceptual design of LPMSConceptual design of LPMS

Recent Research for the Governmental Project[2008. 11 ~ 2012. 12] - Smart RBI for LNG Plant -

Conceptual design of LPMSConceptual design of LPMSLNG Plant Design Management System(LPDMS)LNG Plant Design Management System(LPDMS)LNG Plant Operation & Management System(LPOMS)LNG Plant Operation & Management System(LPOMS)

2828

<Concept and main window of LPMS><Concept and main window of LPMS>

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Main window

Linked in P&IDLinked in P&ID

2929

Material Balance Table (artificial neural network)

1

2

3

13

1

4

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❖Quantitative RBI (API RP 581)

Equipment Data Likelihood Analysis Consequence Analysis Financial RiskEquipment Data Likelihood Analysis Consequence Analysis Financial Risk

Key Data for Key Data for Damage MechanismDamage Mechanism AssessmentAssessment

•• Equipment Fabrication DataEquipment Fabrication Data– Material specification (including heat treatment, chemistry,

strength level etc )strength level, etc.)

– Material production flaws: laps, laminations, voids, segregation, shrinks, cracks

– Welding related flaws: lack of penetration and fusion, delayed hydrogen cracking, slag, undercut, porosity

– Construction related flaws: out-of-roundness, forming cracks

– Heat treatment related flaws or embrittlement: reheat crackingHeat treatment related flaws or embrittlement: reheat cracking, sensitization, sigma phase embrittlement, 885℉/430℃embrittlement

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•• Process Operations DataProcess Operations Data– Service exposure, normal and upset, typical data includes


Pressure, temperature (normal, max/min, design)

Corrosive concentration (S, etc.)

Existence of trace amounts of contaminants (CN, Hg)

Carryover, leaking valves, and in particular, human factors

– Mitigating factors (coking, crack closure, residual stresses, coatings, chemical additives, water wash)

– Timing: How often and how quickly does damage potentially occur? Is it continuous or episodic? (e.g., process cycle times, unit rate fluctuations, unit run length effects)

•• Equipment InEquipment In--Service Inspection DataService Inspection Data– Morphology and rate of known/existing damage


– Previous inspections techniques – Effectiveness at targeting the particular mechanisms (pits vs. Cracks vs. general thinning)

– Supplementary monitoring or other warning system data (probes)

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•• Professional / Technical SocietiesProfessional / Technical Societies– American Petroleum Institute (API)

– National Association of Corrosion Engineers (NACE)

Information on Information on Damage MechanismsDamage Mechanisms OverviewOverview

g ( )

– Welding Research Council (WRC)

– American Society of Metals (ASM)

– American Society of Mechanical Engineers (ASME)

• Company Guidelines and internal publications such as research and development reports

• General Publications (e.g. AICHE, Hydrocarbon Processing, Oil & Gas Journal, etc.)

• Material Properties Council’s (MPC) Joint Industry Projects (JIPs); MPE FFS, MPC HIC, MPC HPV, MPC Omega, MPC HEP

• Personal Experience

•• API PublicationsAPI Publications– API 571 – Damage Mechanisms

– API 572 – Inspection of Pressure Vessels

Information on Information on Damage MechanismsDamage Mechanisms in APIin API

– API 573 – Inspection of Fired Heaters and Boilers

– API 574 – Inspection Piping Systems

– API 575 – Inspection of Atmospheric and Low Pressure Storage Tanks

– API 581 – RBI Base Resource

– API 751 – Sate Operations of HF Units

– API 939A – Wet H2S Cracking

– API 939C – Sulfidic Corrosion in Refineries

– API 941 – Hydrogen Attack

– API 945 – Environmental Cracking in Amine Units

– Guide for Inspection of Refinery Equipment, Chapter 2 (old)

• API Meeting Summaries

– CRE Subcommittee on Corrosion & Materials and/or Inspection

– Operating Practices Presentations

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• STG 34 Minutes (RefinCor)

• NACE Annual Corrosion Papers

• Materials Performance (NACE Publications) Articles

Information on Information on Damage MechanismsDamage Mechanisms in NACEin NACE

• Materials Performance (NACE Publications) Articles

• Standards and Publications

– Pub 34101 Refinery Injection and Precess Mix Points

– RP 0170 Polythionic Stress Corrosion Cracking (SCC)

– RP 0296 Wet H2S Inspection

– RP 0205/0294/0391 H2SO4 Handling

– SP 0403 Caustic SCC

– SP 0472 SCC of Carbon steel in Refineries

– SP 0590 Deaerator SCC

Smart RBI Program Result for Damage Factor module(RBI) based on API RP 581

3838

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LNG Plant Operation & Management System

Inspection Planning

API RP 580, 581, 571,ASME Document

Qualitative, Quantitative Interface

3939

LNG Plant Inspection Management System

Inspection Planning with Inspection Planning with Target RiskTarget Riskfor for Web based Web based SmartSmart--RBIRBI

Inspection Planning with Inspection Planning with Target RiskTarget Riskfor for Web based Web based SmartSmart--RBIRBI

Target Risk

Target Date.InspectionPerformed

Next Inspection Date2014 09 12

4040

2014. 09. 12

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NDE Reliability System

s

dsssP sD )()(

Probability of Detection for UTProbability of Detection for UT Equation of PODEquation of POD

)(s : The rate of detection: The rate of detection

POD Grade

1 Less than 0.6

2 0.6~0.7

3 0.7~0.75

4 0.75~0.82

5 Over 0.82

Inspection Method Inspection Effectiveness

Base on API 581 Code

Inspection

Category

Inspection Eff

ectiveness Cat

egory

NDE Inspection Example

AHighly

Effective

Shear wave ultrasonic testing of 25-

100% of weld/cold bend; or Radiogr

aphic testing of 50-100% of weld/co

ld bends

U ll

Shear wave ultrasonic testing of 10-

24% f ld/ ld b d R di

Reliability Matrix Reliability Matrix

Inspection effectiveness(API581)Inspection effectiveness(API581))(s : probability density function: probability density function

RT UT MT

ECT PT AE

Five Effectiveness categories

Damage type

POD

General Examination System Requirements

Procedure Requirements

Qualification Requirements

NDE InspectionDiagnosisReliability

⊙

Probability of detection(POD)54321

A

B

C

D

EInsp

ecti

on

Effe

ctiv

enes

s

Low

Medium

Medium High

High

BUsually

Effective

24% of weld/cold bend; or Radiogra

phic testing of 25-49% of weld/cold

bends

CFairly

Effective

Shear wave ultrasonic testing of less

than 10% of weld/cold bend; or Rad

iographic testing of less than 25% of

weld/cold bends

DPoorly

EffectiveVisual inspection for leaks

E Ineffective No inspection

4141

NDE Data Management System

Equipment ID

Equipment Type

NDE Diagnosis Record NDE Diagnosis Signal

Result

Inspector

Inspection date

Equipment Type

P&ID No.

Network

Equipment ID Equipment Type P&ID No. PFD No. Inspection

date Inspector Result of Inspection

Damage type

NDE Reliability

Diagnosis Signal

LNG-E-XX1 Steel pipe(2’’) E6358-XX1 E6001-XX1 2010/11/15 WJ KIM PASS *** HIGH DS101

LNG-E-XX2 Steel pipe(6’’) E6358-XX2 E6001-XX2 2010/11/16 WJ KIM FAIL *** MIDDLE DS102

LNG-E-XX3 Steel pipe(18’’) E6358-XX3 E6001-XX3 2010/11/17 WJ KIM REPAIR *** LOW DS103

4242

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ERPServer

FILEServer

ProductionServer

PDISPDIS(Plant Data Information System

Virtual LNG Plant Prototype

Risk Assessment

RBI Server

Design(3D)DocumentationServer

Admin.User

DB Server

RDBMS

Admin.User

PDIS

InspectionUser

WebServer

ProcurementProcurementUserUser

Civil/Tech.User

Admin

EditUser

Assistance

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DCS PLC Analyzer

RTDB

DCS PLC Analyzer

MaintenanceRCM/ CMMS

Server

Scanner Printer Plotter

Admin.User

AssistanceUser

RTDB : Real-Time DataBase

RDBMS : Relational DataBase Management System

DCS : Distributed Control System

PLC : Programmable Logic Controller

CMMS: Computerized Maintenance Management System

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Thank you very muchThank you very muchfor your attention !

LNG플랜트시스템위험도평가기술개발 Development of Smart · PDF...

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