shell risk based inspection approach

Topic or Session or Module Name

Copyright: Shell Brands International AG 2008

THE SHELL RISK BASED INSPECTION AND SAFETY APPROACH OF PETROCHEMICAL AND GAS INTALLATIONS

1st CEOC International Safety Seminar 3rd Feb 2010 Brussels

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1st CEOC International Safety Seminar, 3 Feb. 2010, Brussels

Paul Slangen

Shell Projects & Technology

Netherlands

Contents

About Shell

Process safety - Asset management

h ll k dShell Risk Based Inspection (S-RBI)*

Deliverables

Implementation experience

2*S-RBI is a Shell trade mark



SHELL

GROUP ACTIVITIES

App. 50 manufacturing & gas sites

UPSTREAM BUSINESSES

DOWNSTREAM BUSINESSES

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SHELL PROJECTS & TECHNOLOGY

CORPORATE


SHELLPROJECTS & TECHNOLOGY

Unit created in 2009, merging:

• Global Solutions

• Technology directorate of Exploration &

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• Technology directorate of Exploration & Production

• Safety and environment function

• Contracting and procurement function


Safety is No Harm - Goal Zero - within Shell

Work with a valid work

permit when required

Conduct gas tests when required

Verify isolation before work

begins and use the specified life

protecting equipment

Obtain authorisation

before entering a confined

space

Obtain authorisation

before overriding or disabling safety critical equipment

Protect yourself against a fall

when working at heightrequired required equipment space critical equipment height

1

7

2

8

3 5

11

6

129 10

4

Do not walk under a

suspended load

Do not smoke outside

designated smoking areas

No alcohol or drugs while working or

driving

Wear your seat belt

While driving, do not use your phone and do not exceed

speed limits

Follow prescribed Journey

Management Plan

5

Managing Process SafetyBow-Ties are used for:

• the identification and risk assessment of HSE hazards

• the evaluation and implementation of control and recovery measures and

• to document that major HSE risks have been reduced to as low as reasonably practicable (ALARP).

Threat

Corrosion Barrier

Material

Barrier

Inspection

Barrier

OperatingWindow

Hazard

Hydrocarbons

Barrier

EmergencyResponseBarrier

Gas detection

Barrier

ESD

Consequence

Small fire

Top Event

E l i /FiCause Effect

Scenario

Loss of containment

Threat

Degradation

Barrier

Material

Barrier

MOCBarrier

OperatingWindow

Barrier

EmergencyResponse

Barrier

Gas detection

Barrier

ESD

Consequence

Small fire

Explosion/Fire

6


Link to Manufacturing Work Processes

Bow-Tie

ESPME

Proactive Processes Execution Processes

RRM*RCMBow-Tie

ESPRBI

IPF

Barriers needed

TARRM

Critical Activities needed to maintain barriers

RCM

EI

ESP

Emergency Response, MOC, Competency Mgt., Permit to Work, Document Management, HSE Compliance, Contractor Mgt., PPE

Critical activities needed to maintain barriers

The linkages between the other work processes is also very important!!

*RRM is a Shell trade mark: Risk & Reliability Management ; ME: maintenance execution; TA: turn around; EI: equipment integrity; ESP: ensure safe production

7

Shell RBI has a strict definition

Is a risk-based decision support process

structured and multidisciplinary

to determine and document, cost-effectively,

The optimum inspection requirements

of pressure containing equipment in its operating context

and safeguards integrity

8


S-RBI requires regular updating (evergreening)

Asset IntegrityDatabase

Asset IntegrityDatabase

Corrosion Loop Assessment

Corrosion Loop Assessment

Including IOW*Including IOW*

Remnant Life CalculationRemnant Life Calculation

Criticality (Risk) Assessment

Criticality (Risk) Assessment

Analyse results & Document

Analyse results & Document

Initiate Corrective

Actions

Initiate Corrective

Actions

9

AssessmentAssessment

ConfidenceRating

ConfidenceRating

InspectionInterval & Tasks

InspectionInterval & Tasks

Task ExecutionTask Execution

*IOW: Integrity Operating Window

Assessment of the Criticality (RAM)

H L MH H E E

Criticality

CLA

SS

Very susceptible todegradation

Susceptible to degradation

Susceptibility to Failure

M L M MH H E

L N L M MH H

N N N L M MH

no/slight damage

minor damage local damage major damage extensivedamage

no/slight injury minor injury major injury single fatality multiple fatalities

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

PRO

BABI

LITY

C Susceptible to degradationunder normal conditions

Susceptible to degradationunder upset conditions

Not susceptible under anyforseen conditions

CON

SEQ

UEN

CECA

TEG

ORY

ECONOMICS (US$)

HEALTH & SAFETY

ENVIRONMENT

10

RAM = Risk Assessment MatrixN = Negligible L = Low M = MediumMH = Medium High H = High E = Extreme

NEGLIGIBLE LOW MEDIUM HIGH EXTREMECONSEQUENCE CLASS


S-RBI is documented & managed

Methodology Process Toolpeoplegy p p

11RRM = process : people : tools = 40 : 40 : 20

Deliverables S-RBI

Corrosion Control Document per Unit

— Corrosion loops (systems)

– potential degradation mechanismpotential degradation mechanism

– integrity operating parameters

– RBI study validity window

Summary S-RBI analyses

— Criticality distribution

– Focus on critical equipment and piping

– Optimised Inspection Interval

– Summary of equipment with intervals < TA interval

– High level inspection plan

– Follow-up actions and recommendations

Shared knowledge and buy-in by stakeholders

Auditable process (transparency)12


Implementation experience [1/2]

Study based on present knowledge and experience

• Evergreen RBI in the run and maintain phase

• Progressing insights – failure (degradation) modes – during

– inspections and turnarounds

– failure and incident investigations

• Need for knowledgeable team members and shared i f h i d ( d d d d )experience from the industry (standards and procedures)

13

Implementation experience [2/2]

Actions and recommendations

• Interaction with other work processes, i.e EI, ME, TA,Interaction with other work processes, i.e EI, ME, TA, ESP, MOC…..

Competence of RBI facilitators

• RBI knowledge (i.e. API 580, CEN)

• Facilitation skills

• Project management skills

• Methodology skills

14


How can CEOC play a role?

Inspection and certification bodies

• Standardisation and guidelines

• Certification

– knowledge (i.e. API 580, CEN etc.)

– facilitation skills

– project management skills

15


THANK YOU

Discover more at www.shell.com or contact:

[email protected]

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shell risk based inspection approach

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