INTEGRATED REFINERY

BUSINESS IMPROVEMENT PROGRAM

HPCL Mumbai–
Best Practice:-
Shell Risk Based Inspection

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Operational Reliability Management System (ORMS)

PUBLICISE,
RELIABILITY STEERING COMMITTEE COMMUNICATE
CHAMPION EM OM TM

ACTION PLANS

OPTIMUM
RECOMMEND
MAINTENANCE
PROGRAMME
FEEDBACK

IMPLEMENT
Area Focal
S-RCM
Point(s)
S-RBI RRM Defect
SIFpro Elimination

Multidiscipline
Team(s)
PROACTIVE REACTIVE MONITOR,
KPIs

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 METHODOLOGIES, PRINCIPLES, SCOPES,
DELIVERABLES, BENEFITS
Risk & Reliability Management (RRM)

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PART OF RISK & RELIABILITY MANAGEMENT

Methodology
&
Software

S-RBI S-RCM SIFpro Tank RRM

roof

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SCOPE

Methodology Scope
S-RBI integrity, envelope, pressure containment,

Verify
Test
Rectify
Modify

avoiding leaks
Tank RRM containment in storage tanks
SRV-RBI safety relief valves
SIFpro automatic systems to avoid hazards
Civil RCM civil infrastructures
S-RCM rotating equipment, static equipment (internals,
fouling), instrumentation, electrical equipment
Defect Elimination incidents

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DELIVERABLES

Methodology Deliverables
S-RBI optimised inspection tasks and agreed integrity
Verify
Test
Rectify
Modify

operating windows
Tank RRM optimised inspection and maintenance tasks
SRV-RBI optimised test frequencies and overhauls
SIFpro optimised levels of safeguarding
Civil RCM optimised inspection and maintenance tasks
S-RCM cost effective maintenance plan to ensure facility
produces as intended
Defect Elimination optimal solutions to eliminate root causes

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 RRM & S-RBI IN THE WORLD

S-RBI up to 1999
2002 onwards
Fredericia
Gothenburg Harburg
Cominco NAM Godorf
Paper & pulp BP Grangemouth 2 x
Carrington Orlen SEIC
Pernis CRC Omsk Cosmo Sakaide 2 x
Berre BayernOil Kawasaki Ref.
Yokkaichi
API 580 Saras KNPC
Cosmo Yokkaichi 2 x
Abu Dhabi 3 x
API 581 Saudi Arabia
Oman LNG
PDO Hazira Port Dickson 2 x
Petronas Gas Petronas Melakka 5 x
Nigeria LNG
Bintulu-MLNG Brunei LNG
Mombassa Sarawak EP

Durban
Geelong
Buenos Aires Woodside

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SHELL RISK BASED INSPECTION

Is a risk-based decision support process …

which is structured and multidisciplinary
to determine and document cost-effectively
the optimum inspection requirements
in terms of reliability and availability
of pressure containing equipment
in its operating context
and which safeguards integrity

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S-RBI – Multidisciplinary Team

probability × exposure × consequence

inspector maintenance

corrosion engineer operation

process engineer

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S-RBI – COMPETENCES REQUIRED

time 2h 3d 2w 3m 3y

level 1 2 3 4 5
planner x
maintenance x
process engineer x x
operation x x
inspector x x x
corrosion engineer x x x
champion / guru / facilitator / reviewer x x x x
management / sponsor x

Shell Global Solutions x x x x x

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Competency levels

Level
 
Capability Experience Theory

Practice Test

1 Awareness Hours Appreciate 75 : 25 Try Listen

2 Knowledge Days Understand 50 : 50 Participate Exam

3 Skill Weeks Explain 25 : 75 Implement Show

4 Mastery Months Teach 20 : 80 Optimise Prove

Develop
5 new
Years Innovate 10 : 90 Improve Justify

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Multiple “root causes” (simultaneously)

E.g. Technical Integrity Barriers

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Right balance legislation

verify S-RBI
test SIFpro
procedures
rectify S-RCM
Process improve RCA

software RRM
team

Tools People
equipment
training

competence
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RRM = process : people : tools = 40 : 40 : 20

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DETAILED DELIVERABLES S-RBI

Hard
 Integrity Operating Windows

 Tasks

 Recommendations (long term)

 Actions (short term)

Soft
 better understanding (of risk and influencing factors)

 better ownership (of information and assumptions)

 team building (to enable multidisciplinary work)

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 RISK, PREVENTION, MITIGATION
RISK ASSESSMENT MATRIX
Shell Risk Based Inspection

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“Bow-tie” diagram

“prevention” cause effect

“mitigation”

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Risk Assessment Matrix (RAM)

Risk can be semi-quantified

allows assessment with factor 10 margin
a N × M matrix can still have (N+M-1) levels of risk

High Risk
Probability ?

Low Risk
Consequence ?

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Reducing risk by Prevention and Mitigation

Base Risk without maintenance, inspection, testing

Residual Risk after maintenance, inspection, testing

Mitigation

High Risk
Probability ?

Prevention

Low Risk
Consequence ?

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EXAMPLE RAM FOR RISK BASED INSPECTION

Any observations ?
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METHODOLOGY
(IN A NUTSHELL)
Shell Risk Based Inspection

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S-RBI PROCESS

Equipment
Data List
Analysis/Review
Design- and Feedback
Inspection Data

Asset Integrity
Task Execution
Database

Corrosion Loop Inspection/Monitoring

Definition Planning

Criticality Confidence
Assessment Assessment

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FAILURE MODE CHARACTERISTIC

Corrosion Under Insulation

LT Embrittlement
Cooling Water Corrosion
Sulphuric acid corrosion
Caustic Cracking
Atmospheric Corrosion
Caustic Corrosion

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 S-RBI PROCESS
Asset
Integrity
Database

Corrosion Loop Investigative

1 definition Inspection

(Tag) criticality Feed back &

Criticality = N
assessment 2 Analyse

StF
Criticality Mitigate
H CR > 4*CRd L MH H E E
Risk
PROBABILITY CLASS

M CR = 1 - 4*CRd L M MH H E

No inspection L CR = 0,5 - 1 CRd N L M MH H Detailed

Analysis Execute
periodic review N CR < 0,5*CRd N N L M MH

no/slight damage minor damage local damage major damage extensive Inspection Plan
only ECONOMICS (US$)
CONSEQUENCE

(<10k) (10-100k) (0.1-1m) (1-10m) damage (> 10m)

CATEGORY

HEALTH & SAFETY no/slight injury minor injury major injury single fatality multiple fatalities

ENVIRONMENT no/slight effect minor effect local effect major effect massive effect

CONSEQUENCE CLASS NEGLIGIBLE LOW MEDIUM HIGH EXTREME

3
Remnant Life
Confidence Inspection &
(Age Related
Rating Monitoring Plan
only)

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MATERIAL AND ENVIRONMENT

degradation

What type of degradation

can occur and where ?
material
+
environment
Which (process) controls
Are needed ?

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WHAT IS A CORROSION LOOP?
“A practical way to understand and describe Failure Modes in a Unit”

Part of a unit subjected to:

-similar process conditions Corrosion Loop
-similar materials selection
=> resulting in similar Failure Modes Loop
2

Loop 3

One “Operating Window”

- control of Failure Modes via
process control Loop 1

- values agreed by team

(boundary conditions for RBI)
- deviation should be reported • similar process conditions
• similar Failure Modes

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CORROSION LOOP BOUNDARIES

Inert vapour
Some “rules”
4 Vapour
Change in Construction Material E-1
2 Liquid
Change in Process Conditions
“Battery Limit” V-1
Equipment in severest CL Susceptible
3
Feed material 1
Corrosive liquid
Merge very small CL’s Restistant
material
Split very large CL’s
Inert vapour 5

C-1
E-2

3
Inert liquid

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CORROSION LOOP EXAMPLE

5Cr 0.5Mo

ss
1.25Cr 0.5Mo

CS

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will not occur

Corrosion Loop
Will not
occur if
Tag 3

Tag 2
Will FM 2
occur AR
Tag 1
NAR

FM 1

% Management
% X of Change
% X

IOW X $
$
$
Monitor Task
IOW Task

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Age Related, Non-Age Related &
Strategy Based
Condition ?

Rejection Strategy Based

Age Related
Non-Age Related
e.g. SCC
Time ?

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INTEGRITY OPERATING WINDOW

Provides further operating limits to prevent pre-mature

integrity failures due to degradation of the material

The Operating Window

Design Window
Process & Economical Window
Integrity Operating Window

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 S-RBI Risk Assessment Matrix
premature failure

StF
Criticality
H CR > 4*CRd L MH H E E
PROBABILITY CLASS

M CR = 1 - 4*CRd L M MH H E

L CR = 0,5 - 1 CRd N L M MH H
within design

N CR < 0,5*CRd N N L M MH

no/slight damage minor damage local damage major damage extensive

ECONOMICS (US$)
CONSEQUENCE

(<10k) (10-100k) (0.1-1m) (1-10m) damage (>10m)

CATEGORY

HEALTH & SAFETY no/slight injury minor injury major injury single fatality multiple fatalities

ENVIRONMENT no/slight effect minor effect local effect major effect massive effect

CONSEQUENCE CLASS NEGLIGIBLE LOW MEDIUM HIGH EXTREME

N = Negligible L = Low M = Medium MH = Medium High H = High E = Extreme

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CONFIDENCE

? ?

? ?

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 Why Confidence Rating?
Statistical variations
influence short term Risk

There are many factors:

High confidence

Low confidence

now tx time

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MAXIMUM INSPECTION INTERVAL

inspections

t new remnant life

X X
maximum
X inspection interval

minimum allowable thickness

t (min)

Time →

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INTERVAL FACTORS FOR AGE RELATED FAILURE MODES

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PROCESS MONITORING REGIMES

FOR NON-AGE RELATED FAILURE MODES

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 LIMITATIONS,
CRITICAL SUCCESS FACTORS
Shell Risk Based Inspection

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SPARC
Limitations of S-RBI

(too slow)
N
StF
Criticality
H CR > 4*CRd L MH H E E
PROBABILITY CLASS

M CR = 1 - 4*CRd L M MH H E

CR = CRd L CR = 0,5 - 1 CRd N L M MH H

N CR < 0,5*CRd N N L M MH

no/slight damage minor damage local damage major damage extensive

ECONOMICS (US$)
CONSEQUENCE

(<10k) (10-100k) (0.1-1m) (1-10m) damage (>10m)

CATEGORY

L HEALTH & SAFETY no/slight injury minor injury major injury single fatality multiple fatalities

ENVIRONMENT no/slight effect minor effect local effect major effect massive effect

CONSEQUENCE CLASS NEGLIGIBLE LOW MEDIUM HIGH EXTREME

Fit for Purpose Analysis min

(too fast)

Time

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Critical Success Factors for S-RBI
Asset Owner to establish design premises and review when necessary
Corrosion Engineer to structure knowledge, incl
map Failure Modes and associated Integrity Operating Windows onto the assets
use clear language and clarify the distinctions between the Corrosion Loops
Inspector to summarise raw inspection "data" into "information“, incl
select the most effective inspection technique
Process Engineer to participate and quantify operating conditions
Operations to implement Integrity Operating Windows and report excursions
Everyone to be trained to the appropriate competence level to contribute, incl
record assumptions so studies are repeatable and can be improved (
learning)
link to existing documents and avoid duplication
-------------------------------------------------------------------------------------------------------
Management to trust the process and to accept the outcomes, incl
provide resources and endorse policies to cater for extreme situations
Authorities to be engaged and work in partnership with the industry
Key Performance Indicators to demonstrate benefits and pro-activeness 55

Review
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SOFTWARE WALKTHROUGH

Shell Risk Based Inspection

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C Confidence Rating
CoF Consequence of Failure
Cr Criticality
CRd Corrosion Rate (Design)
Ec Economics
Ev Environment
HS Health & Safety
IF Interval Factor
MII Maximum Inspection Interval
Qx Question x (for Confidence Rating)
RCA Remnant Corrosion Allowance
RL Remnant Life
SCR Selected Corrosion Rate
StF Susceptibility to Failure

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Q1
Q2

Q3

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 C Confidence Rating
CoF Consequence of Failure
Cr Criticality
CRd Corrosion Rate (Design)
Ec Economics
Ev Environment
HS Health & Safety
IF Interval Factor
MII Maximum Inspection Interval
Qx Question x (for Confidence Rating)
RCA Remnant Corrosion Allowance
RL Remnant Life
SCR Selected Corrosion Rate
StF Susceptibility to Failure

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SCC etc Monitoring plan

C Confidence Rating
CoF Consequence of Failure
Cr Criticality
CRd Corrosion Rate (Design)
Ec Economics
Ev Environment
HS Health & Safety
IF Interval Factor
MII Maximum Inspection Interval
Qx Question x (for Confidence Rating)
RCA Remnant Corrosion Allowance
RL Remnant Life
SCR Selected Corrosion Rate
StF Susceptibility to Failure

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CUI INSPECTION/MAINTENANCE STRATEGIES

FOR CS/LOW ALLOY STEEL

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CUI INSPECTION/MAINTENANCE STRATEGIES
FOR STAINLESS STEEL (CL-SCC)

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Sustainability

Commitment Quality
contribute ensure ownership
implement the results hand over roles

Efficiency Input & Communication

balance detail vs insight be structured and clear
leverage commonalities celebrate success

Ever greening Repeatability & Learning

refresh content & competences document assumptions
adopt (external) best practices have a logic audit trail

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History ? Analysis ? Plan must always stay connected !!

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