Risk-Based Inspection of a Fish Feed Factory.
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Production equipment is always subject to corrosion and material degradation, e.g. wear and fatigue, when in operation. The extent of deterioration depends on several parameters such as material selection, operating conditions and environmental exposure. Operational conditions are likely to change during a factory s lifetime and may affect the deterioration positively or negatively. Inspection is, therefore, an integral part of the maintenance activity at a factory. Risk-based inspection (RBI) is a decision-making technique for inspection planning based on risk. The RBI methodology has been used in the refinery and processing industry for decades, and this thesis examines its potential for use on Cargill Aqua Nutrition (CQN) s fish feed factory in Florø. The primary objectives of this thesis are to develop a procedure to implement an RBI system at CQN s fish feed factory in Florø, use the procedure to implement the RBI methodology and based on the findings from the implementation propose an inspection program, a monitoring program or alternative material selection to part of the factory. The RBI procedure is based on best practices from the oil and gas industry and adapted, primarily by reducing the level of detail, to the fish feed factory. During the work, CQN indicated that corrosion under insulation (CUI) is one of the main problems they face for one system, in particular, the oil system. The oil system was the perfect candidate to be subject to a detailed RBI analysis, having uncoated carbon steel piping insulated with polyurethane foam and covered in polyethene jacketing. The resulting plan of action was to uncover and apply a coating to the carbon steel surface of the field joints, based on the condition of the weatherproofing. Also part of the plan is an inspection program of yearly visual inspections of the outdoor weatherproofing together with a non-destructive examination of 10% of the field joints every 4 years. The implementation of a corrosion management system (CMS) through the use of the proposed RBI procedure resulted in a significant lowering of the risk related to the factory s insulated oil system. The biggest challenge for implementing the CMS is retrieving the data required as input to the RBI process. The solution to overcoming this challenge is to integrate the CMS with a pre-existing computerised maintenance management system and to ensure that all material, operational and maintenance data is stored in the database.