Experience Feedback from Bureau Veritas on RBI project at SIR Inspection Meeting 30th and 31st October 2008

Transcription

1 Experience Feedback from Bureau Veritas on RBI project at SIR Inspection Meeting 30th and 31st October 2008 Adama YEO,

2 Definition of RBI RBI stands for Risk Based Inspection. It is a process of optimization of resource allocation and inspection planning according to the level of risk. RBI is: a security management accurate and rigorous method, based on equipments grading according to the level of risk. A tool that permits the control of the residual life cycle RBI is based on the recommendations of a well-known Reference Book, API

3 The challenges of the RBI Approach Identify the most critical equipments so as to draw up priorities within the framework of the strategy inspection implementation: better assess risks for better management. Work out the most appropriate strategy (cost effectiveness) according to risk acceptance criterion, Improve readiness of the installations of the refining company through extension of the operating cycles while maximizing the perimeter of major stops on site. Increase knowledge on the actual condition of equipments. Keep the cardinal principles of existing inspection plans. High compliance with regulatory requirements. Use a high predictive capability risk model (quantitative analysis method). 3

4 Implementation Procedure Project Methodology (Quality procedure) Software RB.Eye DATA COLLECTION General Data Impact on productivity Process Data Design data PROCESS ANALYSIS AND EQUIPMENTS Process Analysis Evaluation of damage mechanisms and calculation of corrosion kinetics CALCULATION OF CRITICALITY Data capture Calculation INSPECTION STRATEGY Frequency and inspection characteristics 4

5 Skeletal Structure of RBI Inspection Plans to be validated Inspection Plans validated A B C D E 5

6 Experience of Bureau Veritas at SIR Bureau Veritas has been intervening in the Ivorian Refining Company (SIR) for many years for inspections and non-destructive testing. In 2007, Bureau Veritas was selected for conducting RBI studies and carrying out its implementation in the refining company. The project officially started in march 2007 with the installation of the RBEYE Software. 6

7 Objectives of the projects 1. Optimizing the inspection activities at each stop in terms of number of equipments to be inspected and the kind of inspection to be carried out. 2. Showing the public authorities our knowledge of risk management capacity so as to extend the time interval between prescribed inspections; 3. Showing the insurers our risk management capacity so as to obtain the reduction of the annual hazard pay. 7

8 Responsibilities of Veritas Bureau : Provide the training of the inspection team of SIR on the RBI methodology Participate in the collection and capture of data Make the study of corrosion loops and establish study reports Assist SIR in process studies Optimization of inspection plans Responsibilities of SIR Acquisition of the software Make all the necessary documentation available Carry out the process study Participate in the collection and capture of data 8

9 Perimeter of study: DHC Complex : conversion by hydrocracking (5 units) HSK 3 Complex : atm distillation, HDT, Reforming and DGO (7 units) HSK 2 Complex : distillation, HDT, Reforming, DGO (6 units) SMB Complex : distillation atm, void distillation (2 units) Central Complex and off site movements : vapor and electric energy production (10 units) In total: 1656 equipments concerned 2368 isometric inspection diagrams (pipes) 9

10 Project team : Project officer: coordination Inspectors (BV + SIR): collection and capture of data Process Engineer : characterization of fluids Corrosion Engineer : definition of corrosion loops Project duration: 2 years (completion expected in December 2008) 10

11 Project stages: Training Collection and capture of data: Design data of equipment pipes Corrosion study: Definition of corrosion loops Analysis and cut-out of equipments according to the corrosion loops Collection and capture of inspection reviews Optimization of inspection plans 11

12 Results obtained up to now : Project being completed: 80 % achievement: Collection and capture of all units data: Data design of equipments and pipes Process data Process study and corrosion of all units Optimization of inspection plans for DHC complex equipments : Current optimization of DHC complex pipe inspection plans 12

13 Examples of difficulties encountered and solutions applied DIFFICULTIES/CONSTRAINTS Absence of certain projects required data : case of thickness calculation of certain equipments Unavailability of certain pipes isometric diagrams Delivery deadline for long process data SOLUTIONS Elaboration of calculation notes for the equipments which do not have some Realization of on-site notes for isometric diagram elaboration Recruitment of additional process engineers 13

14 Benefits of the project: The project allowed to update the documentation of certain equipments; The DHC complex risk equipments were identified and adapted inspection plans were elaborated for future checking. 14

15 Lessons learnt from the project (2/2): The success of a RBI project depends on: The cooperation between all the parties involved in the project (Inspector, Research Department, managers and Bureau Veritas team) The quality of available data in the equipment files -The exhaustiveness of design and exploitation data -The knowledge of the RBI approach in order to better direct process studies. 15

16 A few recommendations to those who might be interested in the RBI Make a sound evaluation of the inventory of fixtures before the planning of the project in order to better assess the resources; Prepare the documentation in advance: Make a review of the documentation in order to ensure its updating (Units operation book, equipment files, ISO ); Appoint to the project inspectors having an acute knowledge of the units. 16

17 THANK YOU FOR YOUR ATTENTION 17