Shell Risk Based Inspection Approach
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(2) Topic or Session or Module Name. Copyright: Shell Brands International AG 2008. SHELL. UPSTREAM BUSINESSES. GROUP ACTIVITIES App. 50 manufacturing & gas sites. DOWNSTREAM BUSINESSES. CORPORATE. SHELL PROJECTS & TECHNOLOGY. Sub-Brand zone. Copyright: Shell Brands International AG 2008. SHELL PROJECTS & TECHNOLOGY Unit created in 2009, merging: • Global Solutions • Technology directorate of Exploration &. Production. • Safety and environment function • Contracting and procurement function. Sub-Brand zone. Page 2.
(3) Topic or Session or Module Name. 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. 1. 2. 3. 4. 5. 7. 8. 9. 10. 11. Do not walk under a suspended load. Do not smoke outside designated smoking areas. No alcohol or drugs while working or driving. While driving, do not use your phone and do not exceed speed limits. Protect yourself against a fall when working at height. 6. 12. Wear your seat belt. Follow prescribed Journey Management Plan. 5. Managing Process Safety Bow-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). Hazard Hydrocarbons. Threat. Consequence. Barrier. Corrosion. Material. Barrier Barrier Operating Window. Barrier Barrier. Barrier. Inspection. Gas detection. Top Event. Cause Barrier. Threat. Material. Emergency Response. Effect. E l i /Fi Explosion/Fire. Barrier Barrier. ESD. Small fire. Barrier. MOC. Gas detection. Operating Window. Barrier ESD. Barrier Emergency Response. Degradation Loss of containment Scenario. Consequence Small fire. 6. Page 3.
(4) Topic or Session or Module Name. Link to Manufacturing Work Processes Proactive Processes. Execution Processes. ESP Bow-Tie. ME RCM. Barriers needed. IPF RBI. RRM* RRM Critical Activities needed to maintain barriers. TA EI ESP. Critical activities needed to maintain barriers Emergency Response, MOC, Competency Mgt., Permit to Work, Document Management, HSE Compliance, Contractor Mgt., PPE 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. Page 4.
(5) Topic or Session or Module Name. S-RBI requires regular updating (evergreening) Asset Integrity Database. Corrosion Loop Assessment Including IOW*. Initiate Corrective Actions Remnant Life Calculation. Analyse results & Document. Task Execution. Criticality (Risk) Assessment. Confidence Rating Inspection Interval & Tasks. 9. *IOW: Integrity Operating Window. Assessment of the Criticality (RAM). CONSEQUENCE CATEGORY. PROBABILITY C CLASS. Susceptibility to Failure Very susceptible to H degradation. Criticality L. MH. H. E. E. M. Susceptible to degradation under normal conditions. L. M. MH. H. E. L. Susceptible to degradation under upset conditions. N. L. M. MH. H. N. Not susceptible under any forseen conditions. N. N. L. M. MH. ECONOMICS (US$). no/slight damage. minor damage. local damage. major damage. extensive damage. 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. NEGLIGIBLE. LOW. MEDIUM. HIGH. EXTREME. CONSEQUENCE CLASS. RAM = Risk Assessment Matrix N = Negligible L = Low MH = Medium High H = High. M = Medium E = Extreme 10. Page 5.
(6) Topic or Session or Module Name. S-RBI is documented & managed Methodology gy. Process. people p p. RRM = process : people : tools = 40 : 40 : 20. Tool. 11. Deliverables S-RBI 9 Corrosion Control Document per Unit — Corrosion loops (systems) – potential degradation mechanism – integrity operating parameters – RBI study validity window. 9 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. 9 Shared knowledge and buy-in by stakeholders 9 Auditable process (transparency). 12. Page 6.
(7) Topic or Session or Module Name. 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 experience i ffrom the h industry i d (standards ( d d and d procedures) d ). 13. Implementation experience. [2/2]. Actions and recommendations •. 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. Page 7.
(8) Topic or Session or Module Name. 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. Copyright: Shell Brands International AG 2008. THANK YOU Discover more at www.shell.com or contact: [email protected]. Sub-Brand zone. Page 8.
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