TCP external corrosion management share learningTCP外部腐蚀管理分享学习

1、Proprietary - To Be Maintained in Confidence1CAPCO TCP (Taichung Plant)Marine Corrosion management CAPCO TCP (台台中市工厂中市工厂)海洋腐蚀管理海洋腐蚀管理Proprietary - To Be Maintained in Confidence2TCP anti-corrosion progressTCP防腐进度防腐进度lTCP started up in 2003. Performance keeps design expectation. TCP（台中市工厂）于（台中市工厂）于20

2、03年开车。其运行性能维持设计期望值。年开车。其运行性能维持设计期望值。lTCP located at central of Taiwan and inside Taichung harbor. The north side is just beside the coast and has high winds off the ocean. External corrosion is hence severe.TCP（台中市工厂（台中市工厂）位于台湾中部的台中港内。其北面毗邻海岸）位于台湾中部的台中港内。其北面毗邻海岸伴随伴随海洋过来的强风。因此外部腐蚀海洋过来的强风。因此外部腐蚀比较严重。比

3、较严重。lProcess equipment are relatively less externally corroded but structure, carbon steel piping, utility supply station and process accessories in carbon steel are suffered more to high corrosion rate. 虽然工艺设备外部腐蚀程度相对较轻，但是钢结构、碳钢管道、公用工程供应站和碳钢材质的工艺附虽然工艺设备外部腐蚀程度相对较轻，但是钢结构、碳钢管道、公用工程供应站和碳钢材质的工艺附件的腐蚀速率较高

4、。件的腐蚀速率较高。lTCP realized the lesson learned from the local severe incidents (happened around 2007 to 2009 in other company) and reinforcing the mitigation activities and fine-tuned the anti-corrosion plan.TCP（台中市工厂（台中市工厂）从当地严重事件（大约在）从当地严重事件（大约在2007年到年到2009年其他公司发生的严重事件）中认识和学年其他公司发生的严重事件）中认识和学得教训，开始加强减

5、缓措施行动并对防腐方案进行了微调。得教训，开始加强减缓措施行动并对防腐方案进行了微调。lFrom 2012, CAPCO started a series of review processes with support from BP R&T (Research & Technology), CPC- Taiwan (Capco another shareholder) research center and BP E&P (Exploration & Production) to support the corrosion risk and mitigati

6、on action plan review and obtained guidance for improvement. 自自2012年起，年起， 在在BP R&T（研究（研究&技术）、技术）、 CPC- 台湾（台湾（CAPCO的另一股东方）研究中心和的另一股东方）研究中心和BP E&P (探索探索& 生产生产)的支持下，的支持下， CAPCO 开始了一些列的审核流程以支持腐蚀风险和减缓行动方案的审查，并开始了一些列的审核流程以支持腐蚀风险和减缓行动方案的审查，并取得了改进指导性意见。取得了改进指导性意见。Proprietary - To Be Maintain

7、ed in Confidence3Corrosion facts防腐案例防腐案例Distance from seawaterto the TCP site is about 200meters to the north side and20 meter to the west side.海水至海水至TCP工厂现场北侧和西侧距离分别约工厂现场北侧和西侧距离分别约为为200米和米和20米米Failure of the coatingon the CS support structure of PTA product silo.PTA产品料仓碳钢支架结构涂层失效产品料仓碳钢支架结构涂层失效Sever

8、ely corroded coated CS valve actuator diaphragm casing. The corrosion is particularly severe on one side facingthe winter wind.带涂层的碳钢阀门执行结构隔板套带涂层的碳钢阀门执行结构隔板套腐蚀严重。腐蚀严重。朝向冬季风的那一边腐蚀尤其严重。朝向冬季风的那一边腐蚀尤其严重。Severely corrodedpipe support.管道支架腐蚀严重Proprietary - To Be Maintained in Confidence4 TCP improvement p

9、rogramTCP改进方案改进方案lSummarizing inputs from BP R&T, E&P and CPC Taiwan, TCP has systematic revised improvement program based on,结合结合BP R&T, E&P 和和CPC 台湾的投入台湾的投入,TCP已经系统地修订了改进方案（以以已经系统地修订了改进方案（以以下为基础）：下为基础）：Program strategy (objectives, execution methodology, dedicated resources, costs,

10、 schedule, quality, performance management)方案策略（目标、执行方法论、专用资源、费用、计划进度、质量和业绩管方案策略（目标、执行方法论、专用资源、费用、计划进度、质量和业绩管理）理）Program tactics (work scope definition, specifications, materials, design improvements / modifications, technical details)方案手段（工作范围定义、规范、材料、设计改进方案手段（工作范围定义、规范、材料、设计改进/变更和技术细节）变更和技术细节）Prop

11、rietary - To Be Maintained in Confidence5Program Strategy & Tactics方案策略和手段方案策略和手段lProgram strategy (all followed) 方案策略（全部已落实）方案策略（全部已落实）Completion in 5 years as execution objective.5年内完成做为执行目标Risk based prioritization of 6 areas to be improved in sequence.按顺序对6个待改进区域按风险进行级别划分。Appointed project t

12、eam of required specialty to implement the refurbishment work and maintaining fabric.指定所需专业项目组来落实翻新工作和维护保养。Setup touch-up workforce to implement fabric repair of painting defects.成立修补人力来落实油漆缺陷的修复工作。Systematic review to find out cost effective approach through field implementation. 系统审查并通过现场落实的方式找到有成

13、本效益的途径。lProgram tactics 方案手段方案手段Design modification (spec. changed?, check Phoenix by KYT?)设计变更（规范变更？通过KTY与Phoenix核对）。Sand blasting to Sa 3 whenever possible. (over 80%)只要可能，要对Sa 3进行喷砂处理（超过80%）。Wet grit blasting (slurry blasting) is the allowed alternative. (none)湿喷砂处理（淤浆喷砂）是许可的替代方案（无）。Remove piping

14、 insulation for inspection and repainting for those operating under 150C. (follow and on going)拆除运行温度处于150摄氏度以下管线的保温层便于检查和重新刷漆（落实并正在进展中）。Adopt Hot spun zinc galvanized or zinc-nickel plated bolts. (Apply localized Galvanized bolts with thicker coating and 304SS bolts)使用热镀锌或锌镍合金大帽螺栓。（使用带较厚涂层的局部镀锌螺栓和3

15、04SS螺栓）Wax-based mastic and tape protection for critical area flanges, valves, fittings. (Some are replaced by TSZ)对关键区域法兰、阀门和管件，要用蜡基玛脂和胶带保护。（使用TSZ对某些进行替换）Control of work in refurbishment projects similar to TAR, except working in operating plant. (Followed TCP process and similar to TAR)翻修项目作业控制与大修

16、类似，在运行装置作业除外。（遵守TCP流程，与大修类似）Proprietary - To Be Maintained in Confidence6Quality Assurance 质量保证质量保证lQuality Control质量控制质量控制Develop or modify required technical specifications. (Done)编制或修改必要的技术规范。（已完成）Strength internal quality assurance competition. (Followed)加强内部质量保证竞赛。（已落实）Qualified vendor survey a

17、nd approval of contractors. (Done)合格供应商调查和承包商审批。（已完成）Certified contractor personnel for site work. (Followed)参与现场工作的承包商人员资质。（已落实）Contractor quality control plan review and implementation audit (Followed)承包商质量控制方案审查和落实审计。（已落实）Quality assurance reporting by contractor (By contracted NACE coating inspe

18、ctor)承包商质量保证报告（由BACE涂层检查人员出具）lAssessment评估评估Internal performance management (Followed) 内部业绩管理（已落实） Setup KPIs (including safety, quality, progress, cost) 设立关键业绩指标（包括安全、质量、进度和成本） Monthly KPI review 月度关键业绩指标审查External audit 内部审计 Review in the BP reliability network (Finished in July 2014) BP可靠性网络中审查 （

19、2014年7月完成） Invite expert to conduct confirmation check (Finished in July 2014 Reliability peer review) 邀请专家进行确认核查（2014年7月完成可靠性同行审查）Proprietary - To Be Maintained in Confidence7Team activities highlight团队工作亮点lTeam members discussed Mr. David Rays report and setup plan based on Mr. Rays strategy and t

20、actics for the refurbishing execution work.团队成员讨论了David Ray先生的报告并根据David Ray先生的策略和手段为翻修实施工作设立了计划。lTeam was set up on Oct. 1, 2013 and held kick-off meeting on 10/8.团队与2013年10月1日组建并与10月8日举行了开工会。lFor safety reason, begun to plan handrail replacement work for whole plant.为安全起见，开始计划全厂栏杆替换工作。lField surve

21、y to define where and how to do refurbishment work in the defined area.现场调查以确定哪些地方需要翻新作业以及划定区域里如何进行翻新作业。lDiscussed the TSZ dual coating applicability with Mr. Ray. Found two qualified TSZ dual coating contractors for speeding up the project.与David Ray先生讨论TSZ双涂层适用性。发现有两家合格的TSZ双涂层承包商可推进该项目。lDeveloped

22、Specifications for paining, sand blasting and insulation. 编制刷漆、喷砂处理和保温规范。lHire NACE coating inspector to carry out the paining QA/QC work.聘请NACE涂层检查人员开展刷漆QA/QC工作。Proprietary - To Be Maintained in Confidence8Refurbishing Area in 20142014年翻修区域 Proprietary - To Be Maintained in Confidence9Anti-corrosion Schedule for 20142014年防腐进度计划表Proprietary - To Be Maintained in Confidence10Field work progress现场工作进度lTotal 1200 meters cable trays will be replaced with SS304. Completion rate YTD: 80%.总计1200米电缆