Extension of plant service life

Summary

Based on its comprehensive range of engineering expertise, Toyo Engineering offers the means of extending the service life of aged facilities from the viewpoint of minimizing lifecycle costs.

Background of a plant life extension project

Objectives

Working to extend the service life of a plant beyond its initial service life of 20 years, which will soon expire.

  • Achieving the process performance and maintaining reliable operation

  • Obtaining the greatest benefits within a limited budget and time constraints

Understanding how the plant was designed and operated

In addition to reviews of design documents, operation history and conservation/inspection by expert engineers, we conduct on-site surveys and interviews with operators.

Estimating the remaining plant service life

  • A nondestructive inspection of the equipment is conducted to collect the latest data, thereby precisely determining the plant situation
  • The concept of risk analysis is introduced when selecting the locations for conducting nondestructive inspection, which is conducted based on the categorization according to degree of importance
  • The remaining service life of the equipment and piping are estimated based on the design and inspection data. Plans for repairs are prepared taking into consideration the need for replacement and repair

Example of equipment renewal plan

The results of diagnosing the remaining service life revealed that it, in the case of a significant number of items of equipment and piping, replacement was not necessary.

Results of the plant life extension project

Safely extended the plant service life at minimal cost and in a short period

  • Narrowing down the equipment for which the thickness is to be measured; about 30% of the all equipment and piping in the plant are selected

  • The remaining service life is estimated and a basic plan for extending the plant service life is prepared

  • In the basic plan, there was no tower or tank equipment requiring immediate replacement. However, it was recommended that about 10% of all piping, by volume, be replaced

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